A leading manufacturer of high-performance cutting tools in Zhuzhou approached Epic Powder. They were looking for a Jet Mill to produce Tungsten Carbide. The challenge was daunting, the Tungsten Carbide is a material with extreme hardness and density. Most traditional milling methods either failed to reach this uniformity or suffered from extreme wear-and-tear, leading to frequent downtime and metallic contamination.
The Challenge
Tungsten Carbide is very difficult to grind without introducing impurities. Our client’s previous mechanical mills were struggling with: Eliminating large particles entirely (D100) is significantly harder than hitting a median (D50). The abrasive nature of WC was “eating” through standard steel components. Maintaining structural integrity meant avoiding the high temperatures often generated by mechanical friction.
The Solution
After conducting a series of pilot tests at our R&D center, we recommended a customized Fluidized Bed Jet Mill for tungsten carbide production. Unlike mechanical grinding, jet milling uses high-velocity compressed air to make particles collide with each other, virtually eliminating tool wear and heat buildup.
To meet the client’s strict purity and fineness requirements, we implemented:
Ceramic Lining
To prevent iron contamination, all internal contact parts were lined with high-strength technical ceramics.
High-Precision Classification
A specialized high-speed turbine classifier was integrated to ensure that not a single particle over 3.8 μm escaped the chamber.
Optimized Airflow
Given the high density of Tungsten Carbide, we tuned the nozzle geometry to maximize kinetic energy for effective particle breakage.
The Result: Consistent Quality, High Throughput
The transition was seamless. Not only did the client hit their almost impossible particle size distribution, but they also achieved a stable production rate that exceeded their previous benchmarks. The resulting powder showed superior flowability and sintering characteristics, directly improving the strength of their final cutting tool products.
Technical Parameters
Material: Tungsten Carbide (WC)
Particle Size: D 100 < 3.8μm
| Output: 90kg/h |
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