METHOD OF MAKING A CERAMIC BODY

Abstract: According to the invention there is now available a method of making a ceramic body where the body is sintered together from compacted parts to a body with desired shape. The compacted parts are made of powder with less than 6 weight-% lubricant and the sintering is done by isostatic pressing at elevated temperature at which the body is surrounded by a glass melt.

Description: Method of making a ceramic body The present invention relates to a method of making a ceramic body for machining tools, rock drilling tools, wear parts, corrosion resistant articles, heat resistant parts and bodies for construction purposes. The method is particularly useful for making of ceramic bodies which for some reason, e.g., outer shape, cannot directly be compacted to final shape by uniaxial tool pressing. Ceramic bodies can be produced by injection molding or slip casting followed by sintering. It is also pos¬ sible to produce ceramic bodies by tool pressing and sintering. As for ceramics as well as for other hard and wear resistant materials the ultimately desired shape must as far as possible be obtained before the sintering since it is very expensive and in some cases not possible to grind to final shape. Grinding must be performed with diamond tools. In certain cases it is not even possible to grind all faces. For ceramic bo¬ dies the shaping is preferably made directly to final shape. If shaping of the ceramic body must be perform¬ ed, it is preferred to do this directly after the form¬ ing, e.g., tool pressing or after a pre-sintering which has to take place at a temperature at which the ceramic body has got a certain strength but has not sintered so much that the strength becomes too high and the shaping that much more difficult. Another method being used for the making of ceramic bodies is cold isostatic pressing followed by sintering. A shaping operation may possibly be applied before the final sintering in order to ad¬ just the dimensions. The method is relatively expen¬ sive, however, and not suitable for small parts made in large volumes. If small parts are to be made in large volumes, tool pressing is often a good method. Many parts then carry the relatively high cost for the pressing tool. Tool pressing of such parts, however, have some limita¬ tions. Shapes which are too complex cannot be made ac¬ cording to this method. It is in addition difficult to compact parts with large height/width-ratios and at the same time obtain even density in the whole part. During sintering, the part may shrink unevenly or porosity may be formed in some sections of the body. Porosity and/or * cracks may appear if the geometric shape is complex. In certain cases, bodies with complex geometry can be pro¬ duced using a collapsible tool in which the die after the pressing is divided in order to expose the com¬ pacted body. Such tools are, however, very expensive and sensitive to the high compacting pressures used when producing ceramics and other hard alloys. It is known through Swedish patent applications 8803769-2 and 9001409-3 how to manufacture a cemented carbide body with complex geometry by sintering toge¬ ther the body from simpler parts to a body with desired complex geometry. The sintering, is performed usually at atmospheric pressure or lower and a joint is in ge¬ neral not visible and therefore the strength is comple¬ tely comparable with that of a directly compacted body. Ceramic materials are often difficult to sinter dense due to the fact that many ceramic systems do not contain any liquid phase during sintering. It is more difficult using solid state sintering to obtain fully dense materials due to the covalent nature of the cera¬ mic bonds in, e.g., Si3N4. In many cases, additions are made to the ceramic mixture (matrix) which facilitate the sintering, inhibit grain growth, increase the strength and/or performance, e.g., MgO to AI2O3- ceramics. Addition of needle shaped single crystals (whiskers) gives particularly good properties to cera¬ mic composites based usually on AI2O3 or i N^ These crystals are preferably carbides, nitrides, carbonitri- des, carbooxinitrides and/or oxides of metals with re¬ fractory character such as the metals of group 4b (the Ti-group) , 5b (the V-group) and 6b (the Cr-group) of the periodic system and the metals B and Si. The length to diameter ratio should be more than 5. Also plate- shaped crystals with a length-width/thickness ratio greater than 5 have been shown to give good properties. Particularly good properties have been obtained with mixtures of needle shaped and plate shaped crystals. It has also turned out that materials with particularly good properties can be obtained by mixing in large and small particles, plate and/or needle shaped crystals of the above mentioned type in the ceramics. It is difficult to sinter composites with additions of needle or plate shaped crystals to high relative density, more than 98 %. This is due to that it is dif¬ ficult to compact powder bodies with such additions in a homogeneous way. At additions of more than about 10 % by volume special sintering methods have to be applied in order to obtain a good result. Uniaxial pressure sintering (hot pressing) is such a method where the ceramic can be compacted to high re¬ lative density. The method presupposes subsequent ma- chining (cutting, grinding) after the sintering which is expensive and in some cases gives bodies with poor performance. Ceramic bodies can also be made with so called glass encapsulated HIPing (HIP means Hot Isostatic Pressing) where the bodies are embedded in molten glass acting as pressure transmitting medium during sintering as disclosed in, e.g., US 4,446,100. This method is particularly suited for the above mentioned ceramic composites with larger additions of needle shaped and/or plate shaped single crystals. During sintering the temperature is increased such that the glass begins to soften and forms a tight layer around the bodies. After that, the pressure in the furnace is increased to 50 MPa (Ar, N2 etc gases are possible to use) or more and the temperature is increased to sintering tempera- ture. Silicon nitride based ceramics or ceramic compo¬ sites can advantageously be made in this way. Alumina based ceramics or ceramic composites must be protected from influence from the glass and this can be done with the aid of one or more protective layers. In certain cases, an innermost layer is used which serves as a release agent (herein referred to as relief layer) . This layer may comprise finegrained BN. US Patent No. 4,579,703 discloses the manufacture of a ceramic body, a turbine wheel of Si3N4 , where first is formed at least two parts of which at least one is a shaped powder body formed from powder of a ce¬ ramic material mixed with a plasticizer. The individual parts are assembled together into a body of desired shape, the assembled parts are surrounded with a gas- impermeable layer of, e.g., glass. Finally the assembled parts are HIPed to form a dense, homogeneous body. It has now surprisingly been found that compacted ceramic parts effectively can be joined during sinte- ring by using the features of the above mentioned glass-HIP-method. By doing so, bodies with complex geo¬ metry and/or different composition can be obtained. The joint is in general not visible and the strength is completely comparable with that of a directly compacted body. In some cases, the joint may be seen in the structure, e.g., in that the crystals get different orientation or somewhat increased porosity. The strength of the joint does not become reduced due to this, however. It is suitable that the joint or joints, if possib¬ le, are located in such a way that symmetrical parts are obtained. Moreover, it is suitable that the surface of one or more of the parts to be joined is provided with one or more recesses and nobs or grooves which secure the relative positions of the parts during sin- tering and/or that the parts are placed in a suitable fixture. Another possibility is to apply between the bodies some type of 'glue', which disappears during the presintering, or alternatively remains and facilitates the sintering. Desirable is, of course, that the parts are given their final shape already during the pres¬ sing, but it is also possible to a certain extent to shape the parts after compaction or presintering. The idea behind the glass-HIP-method according to the invention is to take two or more compacted (and in certain cases presintered parts) and assemble them. Some of the parts can be completely or partly sintered before assembly. After that, depending on the ceramic system, the assembled parts are surrounded by a relief layer and one or more protective layers in such a way that no layer is present between the contact surfaces of the parts. This can, e.g., be made by painting, spraying or dipping. After that the body is placed on a glass powder bed in a graphite crucible and the crucib¬ le is filled with glass powder. Organic additions to the powders are evaporated. The crucible is then placed in a HIP-furnace and HIPped. The invention is applicable for all ceramic systems which do not react with the glass which transmits the pressure (when protective coating is not used), e.g., Si3N4~based ceramics or for ceramics where protective layers should be used, e.g., ceramics based on AI2O3, TiB2, Zrθ2, SiC etc. In both cases a relief layer is suitable. The invention is preferably applicable for ceramics containing needle- and/or plate-shaped single crystals as described above, most particularly I2O3- based ceramics. It is also applicable to ceramic com- posites containing mono- or polycrystalline particles. The fraction of single crystals or particles is 5-95 volume-%, preferably 5-60 volume-%, and most preferably 10-50 volume-%. The ceramic powder used to compact the parts is ty¬ pically standard powder with lubricants suitable for tool pressing of cutting tools, i.e. no plasticizer is needed. Such an addition is generally present when in¬ jection moulding is used. The amount of lubricant in the powder according to the invention is less than 6 weight-%, preferably 2,5 - 5 weight-%. The lubricant is evaporated from the parts before the embedding in glass powder or at least before the glass has melted forming a tight enclosure. The invention is furthermore applicable for the ma¬ nufacture of ceramic compound bodies, preferably of a sandwich-structure, whose various parts consist of ma¬ terial with different composition and/or structure, e.g., ceramics with a tough core and wear resistant surface. In doing so, ' the core is compacted separately and the surface part(s) separately. In addition, it is possible to adjust the composition of the parts and in that way get a ceramic body which, e.g., partly is under compressive stress, which counteracts crack for- mation, and partly under tensile stress. If the difference in shrinkage during the sintering of the compound material is too great one or more cracks may be formed after the glass-HIPing but gene¬ rally not in the joint. This is in most cases comple- tely pore free and contains no other defects. An example of a suitable ceramic compound material is a material with a tough core of whisker reinforced (25 to 60 volume-%) alumina ceramics and an outer part of pure alumina with small additions of zirconia (1 to 10 volume-%) can be mentioned. Other examples are wear parts made of a tough ceramics such as whisker rein- forced alumina composite or zirconium oxide with a wear resistant part of, e.g., alumina. The invention is also applicable for other types of ceramic compound mate¬ rial, e.g., systems where for geometric reasons it is necessary to make compacts which are assembled and sin¬ tered. Also parts which for technical compaction rea¬ sons (cracks, porosity) are difficult or not possible to make are suitable to produce according to the inven¬ tion. The compound material can be shaped as a sandwich structure but since it by glass-HIP is possible to con¬ trol the shrinkage also the outer parts can be shaped, e.g., as a 'hat' which partly or completely covers the clearance faces. The thickness of the outer parts can be from some ten micrometers up to several millimeters and by a subsequent grinding the thickness of the layer can be further reduced. The method according to the invention gives possi¬ bility for the manufacture of bodies with layers (compound materials) which can not easily be made with conventional CVD- or PVD-methods. The invention gives also the possibility for the manufacture of ceramic inserts with chip breakers form¬ ed during the compaction and/or central holes for the clamping and ceramic bodies with inner cavities or channels. A further application of the invention is the manu¬ facture of parts designed to maintain or release heat during a longer period of time. This can be acco plish- ed by making compacted bodies comprising an upper part and a lower part with cavities. These cavities contain crystalline or glassy materials which when heated are subject to a phase transformation which is strongly en- dothermic. The phase transformation is reversible. Du- ring temperature decrease the reaction is strongly ex¬ othermic and releases heat to the surrounding body which in this way can maintain its heat for a long time. The compacted parts and the material which is subject to phase transformation are sintered together to one unit. Conversely, the invention gives possibi- lity to make cooling bodies. In certain cases, partial sintering of the ceramic parts can take place so that the surfaces of the parts are sintered dense (gas-impermeable) followed by an in¬ crease in sintering gas pressure to obtain a body with an effective joint. Sintering pressures of <200 bar may be used in some of these cases. This sintering as well as the gas HIPing is conducted using conventional techniques. What has been said above about ceramics also app- lies to other systems of type titanium based carbonit- ride alloys often referred to as cermets, ceramic-metal and other systems difficult to densely sinter in a con¬ ventional way. Below some examples are given to illustrate the in- vention: Example 1 Powder of Si3N4 with a mean grain size of 2 um was milled together with 1 weight-% 2O3 and 0.5 weight-% I2O3 and 3 weight-% polyvinylalcohol dissolved in pro- panol. After 10 hours milling in a vibrator mill, the slurry was dried on trays in a drying chamber and disintegrated through a 400 μm sieve. The powder was compacted into blanks of type SPGN 120312 (according to ISO) . A graphite crucible was painted on the inside with BN mixed in propanol. In the bottom of the cruci¬ ble a glass powder was filled (consisting of 40 weight-% Siθ2, 2 weight-% AI2O3 and 58 weight-% B2O3) . The blanks were placed in the crucible two to two with the smallest square surfaces against each other. The crucible was subsequently filled with glass powder. The crucible with its content was heated to 500°C, 1 h in hydrogen in order to evaporate the lubricant and then the temperature was raised to 1000 - 1200°C in argon at atmospheric pressure after which the pressure was rai- sed to 200 MPa and the temperature to 1750°C which was maintained for one hour. When the furnace had cooled down to about 50°C it was opened and the crucible with glass and blanks was taken out. The glass was removed by blasting. In such a way an insert was obtained with eight positive edges, which after a slight edge round¬ ing can be used for turning purposes. The obtained body had a joint with a structure not distinguishable from the structure of the other parts of the material. Example 2 A powder mixture consisting of 70 weight-% AI2O3 and 30 weight-% Sic whiskers was prepared in the same way as described in Example 1. Round plates with diame¬ ter of 13 mm and a clearance angle of 7° were compacted of this mixture. The plates were heat-treated in a com¬ bined evaporation and pre-sintering cycle up to a sin¬ tering temperature of 1300°C in a presintering furnace with protective gas. The plates were put together two to two with the smallest circular surfaces against each other. Then a 0.5 mm thick relief layer was sprayed on to the assembled plates after which an equally thick protective layer was painted on. The relief layer was made of BN mixed with propanol and 5 % Plexigum P26. The protective layer consisted of a mixture of mullite in ethylmethylketon with 5 % Plexigum P26. The obtained body was put in a crucible with glass powder. The cru¬ cible was filled with glass powder. The composition of the glass was 80 weight-% Siθ2, 12 weight-% B2O3, 3 weight-% AI2O3, 4 weight-% Na2θ and 1 weight-% K2O + CaO. The crucible with its content was put in a high pressure furnace, binders in the layers were evaporated in vacuum at temperatures between room temperature and 600°C and the temperature was raised to 1000 - 1200°C at atmospheric pressure in order to melt the glass pow¬ der and make it impermeable to the pressure medium (argon) . After that the pressure was raised to 160 MPa and the temperature to 1550°C and was maintained at these values for one hour. After cooling, the glass and protective layers were removed. The obtained body, a double positive, round insert, had an invisible joint. Example 3 Two tubes were made of I2O3 powder by cold isosta- tic compaction having outer diameter 25 mm, inner dia¬ meter 20 mm and length 100 mm. Two plates with diameter 25 mm and height 3 mm were compacted by tool pressing. In order to make a bottomed tube one of the plates was put on top of one of the compacted tubes and was sin¬ tered conventionally in air at 1500°C for one hour. Tube and lid obtained full density but the lid could rather easily be loosened from the tube. In the second case the lid was put onto the tube and a relief layer and a protective layer was applied. The assembled body was placed in a graphite crucible with glass powder all according to Example 2. After HIPing at 1500°C for one hour in argon with the pressure 160 MPa a bottomed tube was obtained with perfect joint between lid and tube. Example 4 A ceramic compound body was made by compacting two round plates of I2O3 powder with diameter 13 mm and height 1 mm. In the same compacting tool a 10 mm high body of Zr©2 powder was compacted. The compacting pres¬ sures were adjusted so that the plates had the same sintering shrinkage. The compacted I2O -plates were put on the compacted Zrθ2 body in such a way that the two AI2O3-plates faced the two circular surfaces of the Zrθ2 body. A relief layer and a protective layer were painted on the compound body which was HIPed according to the same procedure as disclosed in Example 2. The final sintering temperature was 1480°C. The obtained compound body had a defect free joint without cracks. Example 5 A compound body was made in the same was as in Example 4 but with the difference that the compacting pressures were adjusted so that the ZrC>2 material shrank about 1 % more that the AI2O3 material during the sintering. Also in this case a defect free joint was obtained. Example 6 A powder mixture consisting of 80 weight-% Si3N4, 8 weight-% 2O3, 6 weight-% AI2O3 and 6 weight-% AlN was made as in Example 1. Plates were compacted with the dimension 13x13x4 mm. After pre-sintering at 600°C for one hour in hydrogen the plates were put together two to two in a graphite crucible on a powder bed of a mix¬ ture of BN and Si3N4 with weight ratio 4:1. In such a way an active powder bed was obtained giving an in¬ creased pressure of SiO-gas around the plates which is important to obtain dense sintering and joining. On top of each pair of plates a piece of sintered Sialon was placed acting as a weight after which the crucible was filled with the powder mixture. The plates were sin¬ tered at 1800°C for one hour in nitrogen of atmospheric pressure. In the obtained bodies, a faintly visible joint could be observed (increased porosity) . The Sia¬ lon weight could easily be removed from the joined parts.

Claims: Claims 1. Method of making a ceramic body wherein com¬ pacted parts are assembled to a body with desired shape and sintered c h a r a c t e r i z e d in that said compacted parts are made of powder with <6 weight-% lubricant and that the sintering is done by isostatic pressing at elevated temperature at which the body is surrounded by a glass melt. 2. Method according to claim 1 c h a r a c t e r i z e d in that said parts have been compacted by tool pressing. 3. Method according to any of the preceding claims c h a r a c t e r i z e d in that said parts have dif¬ ferent composition and/or structure. 4. Method according to any of the preceding claims c h a r a c t e r i z e d in that some of said parts is at least partly sintered prior to assembly. 5. Method according to any of the preceding claims c h a r a c t e r i z e d in that a relief layer and/or one or more protective layers are applied on the assembled parts prior to sintering. 6. Method according to any of the preceding claims c h a r a c t e r i z e d in that at least one of said parts comprises 5 - 95 volume-% needle shaped and/or plate shaped single crystals in a ceramic matrix. 7. Method according to any of the preceding claims c h a r a c t e r i z e d in that said matrix is based on alumina. 8. Method according to any of the preceding claims c h a r a c t e r i z e d in that said body has such a geometry that it cannot be compacted to final shape by uni-axial compaction. 9. Method according to any of the preceding claims c h a r a c t e r i z e d in that said body is a cut- ting tool for metal cutting machining. 10. Method according to the preceding claim c h a r a c t e r i z e d in that said cutting tool is provided with chip-breakers and/or central hole for clamping.

Inventors: INGELSTROEM NILS ANDERS, INGELSTROEM, NILS, ANDERS
Applicants: SANDVIK AB
Application year: 1992
Main classification: C04B37
IPC codes: C04B35, C04B37