Rising carbide prices: exploring alternatives

Must a carbide component or a carbide-based coating remain the first choice? When are technical ceramics a viable alternative? And when is a ceramic coating or a carbide-free coating the more sensible option?
The answer depends on the application. The key factors are which surface is critical, what stresses are involved, and what service life is required. This is precisely where the technical evaluation begins.

Carbide component or carbide coating?
When carrying out the assessment, it is first worth making a clear distinction. In some applications, the focus is on solid carbide components. In many other cases, the focus is on carbide-based coatings on functional surfaces.
Typical examples include shafts, bearing seats, guides, sealing surfaces, or sliding surfaces. In these cases, the entire component is usually not made of carbide. What matters are the surface properties, wear behaviour, friction, and corrosion resistance. 
Alternative materials or coating systems may be of interest for these functional surfaces. The question is not simply which material is harder. The decisive factor is the function of the surface or the material in the specific application. 

Two approaches: advanced ceramics and coatings
Alternatives to carbide can take different forms.
In some applications, advanced ceramics can be a suitable solution for the component itself. In these cases, the material concept is reconsidered from the ground up. This can be particularly beneficial when a component is being redesigned or optimised from a design perspective.
In other cases, a coating is the more suitable approach. The base component remains unchanged, while the functional surface is selectively enhanced and protected.
Both approaches have their merits. The right choice depends on the application.
Advanced ceramics can offer excellent wear resistance, low friction, and strong corrosion resistance. Depending on the material selected, additional properties such as thermal stability or electrical conductivity may also be achieved.
Modern components are often required to meet multiple performance criteria simultaneously. In these situations, hardness alone is not the determining factor. What matters is the interaction between material properties, component function, operating environment, and expected service life.
Coatings are particularly attractive when the existing geometry must be retained. They also allow established components to be optimised without redesigning the entire part. The substrate continues to provide the required mechanical strength, while the surface is tailored to deliver the properties needed in service.
Carbide-free coating solutions may also be worth considering. They can be a viable option where conventional carbide coatings are being reassessed due to material availability or rising costs.

Guidance for material selection
Not every ceramic material is suitable for every application. Aluminium oxide, zirconium oxide, silicon nitride and silicon carbide each offer a distinct combination of properties and performance characteristics.

Further material datasheets can assist with the selection process. However, they should not be considered in isolation. What counts is, how the material behaves in the specific application.

The right solution starts with the application
Not all ceramics are the same. And not all coatings are the same.
Ceramic coatings must be suited to the load and the component. That is why a good solution does not start with a standard material. It starts with questions.
Where does wear occur?
What forces are at work?
What temperatures are involved?
Which media are in contact?
What friction is the part exposed to?
Which function must be maintained over the long term?
Only then can a decision be made as to whether a ceramic component, a ceramic coating, or a carbide-free coating solution is appropriate.

Real solutions for real challenges
A practical example is a tried-and-tested solution for a glass shear. Glass shears operate while maintaining optimised performance parameters. The components must function reliably. Wear can affect service life, cutting quality, and process reliability. The glass shears we have developed demonstrate significantly extended service life under optimal performance parameters.
In such applications, it becomes clear that the solution arises from an understanding of the application, the right material, and the collaboration between partners who are focused on finding a joint solution.

Technical assessment of the actual component
Rauschert supports projects as a development partner. Together, we examine the component’s function, the loads acting on it, and the possible material or coating options. This includes material selection, prototyping, sampling, and application-specific testing. The aim is not to find a one-size-fits-all alternative. The aim is to find a solution that makes technical sense and is economically viable.
Sometimes, advanced ceramics are the right choice. Sometimes a coating is the better option. And occasionally, testing shows that the existing solution remains the best option. This, too, is part of a proper evaluation.

Key takeaway: It pays to test early on
Carbide remains a tried-and-tested choice in many applications. However, rising carbide prices are changing the basis for decision-making. That is why it can make sense to explore alternatives at an early stage.
Whether the solution involves technical ceramics, ceramic coatings, or metallic coating systems, the specific application is always what determines the right approach. 
 

Would you like to know which approach suits your component? Talk to us about your application. Together, we will assess the component, the load, and possible solutions.