TiC-Based Metal Matrix Composites via SPS and PTAW as Alternatives to Tungsten Carbide in Mining Applications

Surface mining equipment in Alberta, Canada, operates under extreme conditions where severe material wear leads to high maintenance costs, unexpected failures, and operational bottlenecks, with wear-related costs in the Canadian mining sector estimated at $15 billion annually. Tungsten carbide (WC)-based metal matrix composites (MMCs) are widely used to mitigate wear, typically deposited as overlays via plasma transferred arc welding (PTAW) or gas metal arc welding (GMAW), consisting of 60–65 wt% WC in a Ni-based self-fluxing matrix. However, tungsten is classified as a critical material by Canada, the US, and the EU, with 85% of global production controlled by China and demand projected to double by 2031, posing significant supply risks to industries such as mining.

Titanium carbide (TiC)-based MMCs offer a promising alternative given titanium's wider availability and Canadian sourcing potential. Previous attempts at PTAW deposition of TiC/Ni-based MMCs were hindered by severe TiC degradation and porosity, motivating the exploration of alternative processing routes. This study investigates TiC-based MMCs produced by both Spark Plasma Sintering (SPS) and PTAW, comparing their microstructure and wear performance against conventional WC-based MMCs. Results will inform the viability of TiC-based MMCs as a domestically sourced, supply-secure alternative for wear protection in mining applications.