Whisker reinforced composites for cutting tools with improved performance

Abstract: The properties of silicon carbide whisker reinforced aluminium oxide, at present used for cutting tools when machining nickel based alloys, are in a very complex way related to processing and microstructure. important parameters that have been recognized include whisker/platelet distribution, diameter, aspect ratio, surface chemistry and surface morphology. One parameter that has not been discussed is the crystal structure of the silicon carbide phase. Silicon carbide exsist in a mumber of different polytypes, the most common with cubic or hexagonal structure. Available commercial silicon carbide contains mixed hexagonal and cubic silicon carbide-phases or single phase cubic. During sintering it is possible to transform cubic to hexagonal phase by special processing. It is shown that the hexagonal to cubic ratio strongly affects the performance in metal cutting operations and especially toughness behaviour is related to a high hexagonal to cubic ratio.

Description: The present invention relates in general to ceramic cutting tool materials and, in particular, to such materials in which monocrystalline silicon carbide whiskers are homogenously distributed in an oxide based matrix and, more particularly to such composites wherein the crystal structure of the silicon carbide whiskers are modified during sintering from a low to a high hexagonal to cubic ratio. Ceramic cutting tools have now been availble for several decades. It is not until the last decade they have got a more substantial importance for use in chip forming machining. The main reason for the limited acceptance of ceramic cutting tools has been sudden and unexpected tool insert failures because of inadequate strength, toughness and thermal shock resistance. During the last ten years the properties of ceramic cutting materials have been improved in many respects why they have especially increased their relative share in cutting of cast iron and heat resistant alloys. Aluminium oxide based cutting tools are very sensitive to thermal cracking as aluminium oxide in itself has a relatively low thermal conductivity. This fact leads to very short tool lives under conditions leading to thermal shock i.e. high cutting edge temperatures, short engagement times and varying cutting depths. To a certain extent the thermal properties have been improved by addition of titanium carbide and/or titanium nitride which improves the thermal conductivity of the composite material. The addition also increases the hardness of the composite. In comparison with pure aluminium oxide materials an increased tool life is therefore obtained in cutting of hard workpiece materials and in operations demanding high resistance to thermal shocks. This type of material has, however, too poor a toughness behaviour for a more general use and is therefore mainly used at relatively low feeds. Another, later step of development includes addition of homogenously dispersed fine-grained zirconium oxide particles in a matrix of aluminium oxide. This type of material is described in the U.S. Patent No 4,218,253. Transformation of the "metastable" zirconium oxide particles during use increases both strength and toughness and thus will lead to a more predictable tool life. The thermal properties of said material are, however, insignificantly better than those of pure aluminium oxide materials why initiation and growth of thermally induced cracks still create problems in practical cutting operations generating high cutting edge temperatures. It has more recently been shown that addition of silicon carbide whiskers, monocrystalline hair crystals, to an aluminium oxide matrix leads to a greatly improved fracture toughness and strength. This type of material is described in U.S. Patent No. 4,543,345. Ceramic materials based upon this concept have proved a very good performance in cutting of heat resistant alloys, especially Inconel 718. Zirconium oxide and silicon carbide whiskers can also be combined as described in the U.S. Patent No. 4,657,877. Both the mentioned additions have led to substantial improvements of the toughness behaviour in certain metal cutting operations. However, the search for greater improvements of the properties of cutting tools is continuously ongoing. The properties of silicon carbide whisker reinforced ceramic composites are to a great extent dependent on the processing, since the chemistry of the whisker surface will determine the strength of the bond between the whisker and the matrix. A strong chemical bond is to be avoided since the desired bridging and deflecting properties of the whiskers then is lost. This is further described in the U.S. Patent No. 4,916,092. Silicon carbide exists in a number of different polytypes (Ramsdell LS, Amer. Miner. 32, p. 64-82, 1947). These different polytypes have different stability areas (Zangvil and Ruh, J.Am.Cer.Soc. 71,10, p 884-90, 1980). Possible mechanisms for transformation from cubic to hexagonal silicon carbide includes deformation and diffusion (Kravets VA, Izvestiya Akademii Nauk SSSR, Neorganicheskie Materialy, 20, n 4, pp 694-696, 1984). Commercially available silicon carbide whiskers have a cubic or a mixed cubic to hexagonal crystal structure having a low amount of the hexagonal crystal structure, typically about 20%. During sintering of a silicon carbide whisker reinforced aluminium oxide it is possible to alter the original crystal structure of the whisker and to partially transform the cubic crystal structure to a hexagonal crystal structure. The transformation is favoured by a high sintering temperature but may also be influenced by the chemical composition of the whisker. Fig 1 shows an X-ray diffraction pattern using CuKα-radiation from a material according to the invention; and Fig 2 shows an X-ray diffraction pattern using CuKα-radiation from a prior art material. α-SiC refers to hexagonal silicon carbide and β to cubic in both figs. It has now surprisingly been found that also the crystal structure of the silicon carbide whiskers affects the properties especially in metal cutting operations. The ceramic cutting material according to the present invention comprises an oxide based, preferably aluminium oxide based, matrix with, 10-40 %, especially 20-30 %, by volume homogenously dispersed whiskers and/or platelets of silicon carbide with a high hexagonal to cubic ratio (measured as the ratio between the peak heights in an X-ray diffraction pattern from the rake face of the cutting insert of the {10 1 0}-peak for hexagonal silicon carbide and the {111}-peak for cubic, said ratio being > 0.70, preferably > 0.75, most preferably > 0.775. Said whiskers consist of mono-crystals with a diameter of 0.2-10 µm and a length of 2.5-100 µm with a length to diameter ratio of 5-30. Said platelets consist of monocrystals with a diameter of < 20 µm and a thickness < 5 µm. The grain size of the oxide matrix shall be less then 10 µm, preferably less then 4 µm. The oxide matrix consists essentially of ceramic oxides or of ceramic oxides mixed with hard carbides and/or nitrides and/or borides. Preferably, the ceramic matrix shall contain < 20% by volume zirconium oxide. The cutting material according to the invention is made by wet milling and mixing of oxide based powder and whisker and/or platelets. After drying the mixture is pressed to desired geometrical form and sintered to near theoretical density, and after the sintering the possible remaining porosity can be further reduced using hot isostatic pressing. If it is not possible to obtain a closed porosity by pressureless sintering the material can be pressure sintered with a suitable graphite tool or after encapsulation be hot isostically pressed to desired density. The sintering conditions depend upon the whisker/platelet raw-material and is choosen so that the material reaches a density which exceeds 98%, preferably > 99.5 % of theoretical density, a maximum pore size of 10 µm and a hexagonal to cubic ratio as defined above. This ratio increases with sintering temperature and possibly holding time. Example 1 100 g of silicon carbide whiskers with a hexagonal to cubic ratio of 0.20 (SC9 silicon carbide whiskers from Advanced Composite Materials Corporation) were mixed with 300 g a aluminium oxide (Alcoa A16 SG) and 30 g magnesium oxide and 30 g yttrium oxide. After drying the mixture was hot pressed with varying sintering conditions. The sintered materials were characterized with respect to hardness, density, fracture toughness and X-ray diffraction to reveal the hexagonal to cubic ratio. Sintering Relative density, % Hardness, HV10 Fracture toughness Hexagonal/Cubic ratio A. 1800°C, 40 min 99.2 1978 5.26 0.086 Prior art B. 1800°C, 120 min 99.0 2019 5.08 0.091 C. 1810°C, 45 min 99.4 2022 5.34 0.613 D. 1825°C, 100 min 99.6 2014 5.25 0.773 Invention E. 1875°C, 130 min 99.9 2043 5.27 0.808 Example 2 The sintered materials from example 1 were cut into blanks and ground to cutting tool inserts SNGN 120416 with a reinforcement land of 25° and width 0.2 mm. Cutting tool tests were performed with respect to toughness and wear resistance. Toughness test was performed in steel SS 2242. Longitudinal turning with gradually increasing feed and interrupted cuts. 25 edges per variant were tested under the following conditions: Cutting speed 100 m/min Feed 0.17 mm/rev (start value) Depth of cut (DOC) 1.5 mm Percentage victories compared to material C and statistical difference expressed as t-values (Student's t-test) were % victories relative C t-value A 3 -3.8 Prior art B 10 -3.1 C - - D 83 2.8 Invention E 97 7.1 From the statistical analysis it is obvious that A and B have a significantly lower toughness behaviour than C (> 99.999% and > 99.995 % probability) and that D and E have a statistically better toughness behaviour than C (> 99.995% and > 99.999% probability) Wear resistance tests were performed in Inconel 718 (aged) with the following conditions: Cutting speed 200 m/min Feed 0.10 mm/rev Depth of cut 2.0 mm Tool life criterion was notch wear at the depth of cut point. Tool lives at DOC-notch wear >2.5 mm are given Tool life, min A. 4 Prior art B. 4.5 C. 4 D. 6 Acc to the invention E. 6 The notch wear resistance seems also to be improved by a high hexagonal to cubic ratio.

Claims: An oxide based ceramic cutting insert for chip forming machining comprising a ceramic oxide based matrix and 10 - 40 % by volume of homogeneously dispersed whiskers and/or platelets of silicon carbide at which said whiskers consist of monocrystals with a diameter of 0.2 - 10 µm and a length of 2.5 - 100 µm, the length to diameter ratio being 5 - 30, and said platelets consist of monocrystals with a diameter of < 20 µm and a thickness of < 5 µm, the intensity of the {10 1 0}-peak from the hexagonal modification of silicon carbide being > 0.7 of the intensity from the {111}-peak from the cubic modification of silicon carbide in the X-ray diffraction pattern from the rake face when using CuKα-radiation. Method of producing an oxide based ceramic cutting insert for chipforming machining comprising a ceramic oxide based matrix and 10 - 40 % by volume of homogeneously dispersed whiskers and/or platelets of silicon carbide at which said whiskers consist of monocrystals with a diameter of 0.2 - 10 µm and a length of 2.5 - 100 µm, the length to diameter ratio being 5 - 30, and said platelets consist of monocrystals with a diameter of < 20 µm and a thickness of < 5 µm by powder metallurgical methods characterized in that the sintering conditions are chosen such that the material of said insert reaches a relative density of > 98 % and that the intensity of the {10 1 0}-peak from the hexagonal modification of silicon carbide is > 0.7 of the intensity from the {111}-peak from the cubic modification of silicon carbide in the X-ray diffraction pattern from the rake face when using CuKα-radiation.

Inventors: BRANDT NILS GUNNAR, JOHANSSON PER GUSTAV, BRANDT, NILS GUNNAR, JOHANSSON, PER GUSTAV
Applicants: SANDVIK AB, SANDVIK AKTIEBOLAG
Application year: 1992
Main classification: C04B35
IPC codes: B23B27, C04B35