If you work with tungsten carbide industrial products—whether it’s wear-resistant liners, seal rings, or cutting tools—you’ve probably wondered: “Does tungsten carbide break easily?” The answer isn’t a simple yes or no. Tungsten carbide’s tendency to break depends on a mix of factors, including its composition, how it’s used, and the conditions it’s exposed to. It can fracture unexpectedly under poor handling or mismatched conditions, but it can also withstand tough industrial environments when selected and used correctly. In this article, we’ll break down what makes tungsten carbide prone to breaking, common scenarios where it’s likely to fail, and practical steps to prevent fractures. All explanations are grounded in real-world industrial experience, keeping things straightforward and easy to apply.
Understanding Tungsten Carbide: Hardness vs. Toughness
To grasp why tungsten carbide might break, it helps to start with its basic structure. Tungsten carbide is a composite material, and its resistance to breaking comes from a balance between two key components:
- Tungsten carbide crystals: These are extremely hard (Mohs hardness 8.5–9), but they’re also inherently brittle on their own. Without support, they’d crack easily under even small amounts of force.
- Binder metals: Usually cobalt, nickel, or a mix, these act as a “binder” that holds the hard crystals together. They add toughness, allowing the material to absorb some stress or impact without shattering.
The key takeaway: The type and amount of binder directly affect how likely tungsten carbide is to break. More binder (within a reasonable range) generally means better toughness and lower risk of fracture, while less binder prioritizes hardness but makes the material more brittle.
Example: A tungsten carbide part with 12% cobalt binder can often survive a light drop onto a concrete floor with only minor scratches. In contrast, a part with 3% cobalt binder might crack or shatter under the same conditions—all because of the difference in how much the binder can absorb impact.
3 Common Scenarios Where Tungsten Carbide Breaks
In industrial settings, tungsten carbide rarely breaks “just because.” Most fractures are linked to specific issues with material selection, handling, or environmental conditions. Here are the most frequent causes:
1. Insufficient or mismatched binder content
The binder is critical for preventing breakage, so using the wrong type or amount is a major risk:
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Low binder content: When manufacturers prioritize extreme hardness by reducing binder (e.g., cobalt content below 5%), the material loses its ability to absorb stress. This makes it prone to cracking under impacts, even small ones like tool vibration or contact with hard debris.
Industrial case: A mining operation used tungsten carbide drill bits with 4% cobalt to tackle hard rock. While the bits were very hard, they cracked within hours when hitting gravel in the rock. Switching to bits with 10% cobalt solved the problem, with bits lasting 2+ weeks in the same conditions. -
Wrong binder type for the environment: Cobalt binder works well in most cases, but it becomes brittle in extremely low temperatures (-40°C or lower). In acidic environments, standard cobalt can corrode, weakening its ability to hold crystals together—eventually leading to breakage.
2. Sudden impact or improper installation
Tungsten carbide handles steady, predictable forces (like the constant friction of a seal ring or the gradual wear of a liner) well. It’s sudden, intense forces that cause problems:
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Drops or collisions: Accidentally dropping a tungsten carbide part (e.g., a wear block or cutter) onto a hard surface (concrete, metal) can create enough impact to crack it. Similarly, equipment jams or unexpected contact with foreign objects (like a rock hitting a crusher liner) often lead to fractures.
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Forced installation: If a tungsten carbide part (such as a seal ring) is slightly too large for its housing, forcing it into place or hitting it with a hammer to “adjust” can create internal stress. Even if it doesn’t break immediately, this stress weakens the material, making it more likely to crack during use.
Common mistake: Workers sometimes assume tungsten carbide’s hardness means it can withstand rough handling. One factory reported frequent seal ring fractures until they stopped using metal tools to tap rings into place—switching to rubber mallets and precise fitting reduced breakages by 70%.
3. Extreme or rapid temperature changes
Temperature fluctuations affect tungsten carbide more than many realize, as heat and cold can create internal stress:
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Rapid heating or cooling: Exposing tungsten carbide to sudden temperature shifts—like moving a hot part from a furnace directly into cold water, or introducing high-temperature fluid into a cold valve with tungsten carbide components—causes uneven expansion and contraction. This stress can split the material.
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Prolonged high heat: Temperatures above 1,200°C cause cobalt binders to soften or even melt, weakening their grip on the tungsten carbide crystals. In this state, the material loses structural integrity and may break under normal operating forces.
Real example: A chemical plant’s tungsten carbide heat exchanger suffered cracks after a coolant system failure caused the core to overheat suddenly, then cool rapidly when the system restarted. The temperature swing created stress that split the material.
4 Practical Tips to Reduce Tungsten Carbide Breakage
Most fractures are preventable with careful selection and handling. Here’s how to keep your tungsten carbide parts intact:
1. Choose the right grade for your
Matching the tungsten carbide grade to your environment is the first line of defense:
- For high-impact settings (mining crushers, construction tools): Opt for grades with 8–15% cobalt or nickel-cobalt binders, which offer better toughness.
- For low-temperature environments (freezing equipment, Arctic operations): Use nickel-based binders, which stay tough in cold conditions (unlike cobalt, which becomes brittle).
- For acidic/caustic environments (chemical reactors, plating tanks): Select grades with corrosion-resistant binders (e.g., nickel-molybdenum alloys) to avoid binder breakdown.
2. Handle and install with care
- Transport gently: Use padded trays or foam to separate tungsten carbide parts during storage and transport, preventing collisions.
- Avoid forced fitting: Always check part dimensions against housings before installation. If a part is too tight, sand or grind it to fit—never hammer or press it into place.
- Use proper tools: When positioning parts, use rubber mallets or wooden blocks to avoid direct metal-on-tungsten carbide impacts.
3. Control temperature exposure
- Avoid rapid shifts: Let hot tungsten carbide parts cool to room temperature naturally (don’t quench them). For cold-weather equipment, preheat parts gradually before use.
- Limit high-heat exposure: If your process involves temperatures above 1,000°C, ask your supplier for high-temperature grades (with heat-stabilized binders) designed to withstand these conditions.
Small cracks can grow into fractures over time. Make it a habit to:
- Visually check parts monthly, using a bright light to spot tiny cracks (pay extra attention to edges and areas that take impact).
- For critical components (e.g., seal rings, precision tools), use ultrasonic testing annually to detect internal cracks that aren’t visible to the naked eye.
Common Myths About Tungsten Carbide Breakage
Let’s clear up some misconceptions that lead to avoidable fractures:
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Myth 1: “The harder the tungsten carbide, the more likely it is to break.”
Not true. Modern manufacturing allows for grades that balance high hardness (HRA 90+) with good toughness, thanks to fine-grained crystals and optimized binders. These grades resist both wear and breakage. -
Myth 2: “All tungsten carbide is the same—if it breaks, it’s poor quality.”
Fractures often stem from using the wrong grade for the job, not poor quality. A grade designed for low-impact polishing won’t hold up in a high-vibration crusher, no matter how well it’s made. -
Myth 3: “Broken tungsten carbide is useless and must be discarded.”
Small cracks in non-critical areas (e.g., a corner of a large wear plate) can sometimes be repaired with laser welding. However, severely cracked or shattered parts should be replaced to avoid safety risks.
Final Thoughts: Tungsten Carbide Breaks When Misused—Not by Nature
Tungsten carbide isn’t inherently “prone to breaking.” Its durability depends on choosing the right grade for your specific conditions (impact, temperature, chemicals) and handling it with care. By matching the material to the job, avoiding rough treatment, and controlling temperature shifts, you can minimize fractures and get the most out of your tungsten carbide parts.
If you’re struggling with frequent breakages or aren’t sure which grade fits your equipment (whether it’s a mining tool or a chemical processing component), feel free to reach out. We can help assess your and recommend a grade that balances hardness and toughness—keeping your operations running smoothly.