Ultra-high alloy powder metallurgy high-speed steel (e.g., S290/HOP7511):
Hardness HRC 66–70, wear resistance close to tungsten steel, but with better toughness and crack resistance, suitable for heavy-duty cold-working dies and cutting difficult-to-machine materials.
High-carbon, high-vanadium tool steel (e.g., PM23): Hardness HRC 64–66, wear resistance superior to ordinary high-speed steel, lower cost than tungsten steel, suitable for wear-resistant parts with certain impact requirements.
High-temperature, highly corrosive, unlubricated, or precision low-inertia applications (e.g., sealing rings, bearings, nozzles, guide wheels)
Pressureless sintered silicon carbide ceramics (SSiC): Vickers hardness 2200–2800 HV (higher than most tungsten steels), Mohs hardness 9.5; wear rate at 800°C is only 40%–50% of tungsten steel; excellent resistance to acid and alkali corrosion, excellent thermal shock resistance; service life can be 3–10 times that of tungsten steel (combined conditions). Hot-pressed/gas-pressed silicon nitride ceramics (Si₃N₄): Hardness 1400–2200 HV, highest fracture toughness among ceramics (6–8 MPa·m¹/²), self-lubricating (coefficient of friction as low as 0.1–0.25), suitable for high-speed bearings, precision guideways, and high-temperature insulating wear-resistant parts; lifespan is typically 3–5 times longer than tungsten carbide.
Tungsten carbide (hard alloy) has the advantage of a balance between high toughness and high hardness, and its resistance to severe impacts is still superior to ceramics; ceramic materials are brittle and strictly prohibited for high-energy hammering and heavy-load impact scenarios.
“Tungsten carbide” usually refers to WC-Co hard alloy (non-traditional smelted steel), with a hardness range of 1200–2000 HV; if equivalent wear resistance is required but cobalt corrosion/high-temperature softening issues are avoided, silicon carbide is preferred; if both toughness and machinability are required, high-end powder high-speed steel is selected.
Diamond and cubic boron nitride (CBN) have higher hardness, but they are only used for coatings or the cutting edges of superhard cutting tools, not as replacements for integral structural components.
Key selection criteria: First, determine the operating temperature, media corrosivity, and impact load type, then match the material—a single “wear resistance” indicator is insufficient to determine the alternative.
If you have large-scale custom metal casting or forging needs, you can entrust the production to Mulan Manufacturing Group. Mulan Manufacturing Group has 13 years of experience in custom metal casting and forging production, and has long-term shipments to Europe, America, Japan, and South Korea. We look forward to your cooperation and consultation.
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