Fracture resistance of binderless tungsten carbide consolidated by spark plasma sintering and flash sintering

Binderless tungsten carbide (WC) consolidated by spark plasma sintering (SPS) and electrical resistance flash sintering (ERFS) has emerged as a promising alternative to materials obtained by traditional sintering methods. In this study, we investigated the influence of SPS and ERFS techniques on the mechanical properties of binderless WC. Hardness, indentation fracture resistance and elastic modulus were compared and analysed with respect to the microstructure of the resulting material. The results show that SPS tungsten carbide is harder, stiffer and denser when compared to the material produced by ERFS. Nevertheless, the fracture resistance of SPS ceramics was limited due to the lack of macroscopic toughening mechanisms. Conversely, flash-sintered tungsten carbide, consolidated by ERFS, possesses unique biphasic WC/W2C microstructures that promote crack deflection and bridging toughening mechanisms. Additionally, flash-sintered materials exhibit a more ductile character and are characterised by a lower effect of the strain gradient on the material plasticity upon indentation. This study provides valuable insights into the mechanical properties of ultra-hard monolithic ceramics, such as WC, influenced by ultrafast/flash sintering techniques.