Si3N4 ceramic cutting tool sintered with CeO2 and Al2O3 additives with AlCrN coating

Souza, José Vitor C.; Silva, Olivério Moreira de Macedo; Nono, Maria do Carmo de Andrade; Machado, João Paulo Barros; Pimenta, Marcelo Dornelles; Ribeiro, Marcos Valério

doi:10.1590/s1516-14392011005000077

Cited by 10 publications

(5 citation statements)

References 9 publications

(9 reference statements)

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“…The cast iron microstructure alternated with the graphite layer would typically contribute to good surface roughness. Similar evidence of changes in surface roughness is reported in the works of Souza, et al (2009) and Souza, et al (2011) [23,27].…”

Section: Surface Roughnesssupporting

confidence: 87%

Dry machining of nodular cast iron using a YAG-reinforced alumina ceramic cutting tool

Sousa¹,

Simba²,

Souza

et al. 2022

Preprint

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In this work an alumina-yttrium aluminum garnet (Al2O3-YAG) cutting tool was developed and characterized aiming application in dry machining of nodular (spheroidal) cast iron. Ceramic powders containing 85 wt.% Al2O3 and 15 wt.% Y3Al5O12(YAG) were homogenized, compacted, and sintered at 1600 ºC for 2h at a heating rate of 5 °C/min. The sintered ceramic presented relative density of 98.3 ±0.2%. X-ray diffraction (XRD) and Scanning Electron Microscopy (SEM) revealed α-Al2O3 and YAG as crystal phases, both with equiaxed grains with average sizes of 1-4 𝜇m (Al2O3 phase) and 0.7-1 𝜇m (YAG phase). In addition, this ceramic composite presented Vickers hardness and fracture toughness of 15.2 ±0.2 GPa and 4.6 ±0.3 MPa.m1/2, respectively. The dry machining performance of the Al2O3-YAG cutting tool was compared with that of a commercial cemented carbide cutting tool using cutting speed (VC) of 200 and 500 m/min, feed rate (f) of 0.25 and 0.10 mm/rev, and axial depth of cut (ap) of 0.60 mm. The results showed that the best setting for the cemented carbide cutting tool was obtained at VC=200 m/min and f=0.25 mm/rev, which produced the best machinability with average surface roughness (Ra) of 3.516 μm, cutting length (LC) of 6000 m, and maximum flank wear (VBmax) of 0.58 mm. For the Al2O3-YAG cutting tool, the best setting was achieved at VC=500 m/min and f=0.10 mm/rev, which produced Ra=0.848 μm, LC=12,293 m, and VBmax=0.54 mm.

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Section: Surface Roughnesssupporting

confidence: 87%

Dry machining of nodular cast iron using a YAG-reinforced alumina ceramic cutting tool

Sousa¹,

Simba²,

Souza

et al. 2022

Preprint

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“…The use of widespread instrumental vacuum-plasma coatings, such as TiN, (TiAl)N and (TiZr)N, does not provide significant "healing" of surface layer defects formed during diamond grinding of ceramic inserts but is only able to minimize the depth of the defective layer [20,23,25]. The morphological pattern of the formed coatings largely copies the characteristic defects present on the surface layer of the tool [32][33][34].…”

Section: Discussionmentioning

confidence: 99%

“…The increased defectiveness of the surface layer of the ceramic substrate contributes to the formation of defective coatings (porous and discontinuous), characterized by reduced adhesive bond strength, which significantly reduces their effectiveness when applied to CCT [22,23,33]. Despite the negative impact of the defective surface layer of the ceramic substrate on the quality of the formed coatings, their deposition on the CCT changes the conditions of the contact interaction between the working surfaces of the tool and the material to be processed.…”

Section: Discussionmentioning

confidence: 99%

“…[22] increased the average tool resistance of ceramic cutting inserts based on Al 2 O 3 +TiC by 1.8 times compared to an uncoated tool when milling hardened bearing steel by applying (TiZr)N coating. At the same time, the analysis of the results of previous studies shows that coatings with a thickness of up to 4.0 µm are not able to "heal" numerous defects in the form of deep grooves and torn grains, which are visible already on the surface of coatings when studying their microstructure, but only reduce the depth of the defective layer [32][33][34].…”

Section: Introductionmentioning

confidence: 99%

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Influence of Surface Layer Condition of Al2O3+TiC Ceramic Inserts on Quality of Deposited Coatings and Reliability during Hardened Steel Milling

et al. 2022

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The specific features of the destruction of tool ceramics, associated with structural heterogeneity and defects formed during diamond grinding, largely determine their reduced reliability (dispersion of resistance). This is most pronounced at increased heat and power loads on the contact surfaces and limits the industrial application of ceramic cutting tools. The surface layer of industrially produced Al2O3+TiC cutting inserts contains numerous defects, such as deep grooves and torn grains. During the milling of hardened steels of the 100CrMn type with increased cutting parameters, the “wear–cutting time” curves have a fan-shaped character with different wear rates. The resistance of the tool that was taken from one batch before reaching the accepted failure criterion has a significant variation in values (VarT is 30%). The study is aimed to evaluate the influence of the condition of the surface layer of Al2O3+TiC inserts processed by various types of abrasive treatments, such as diamond grinding, lapping and polishing, on the quality of the (TiAl)N and (TiZr)N coatings and the reliability of prefabricated end mills. The obtained “wear–cutting time” curves are characterized as closely intertwined bundles. The coefficient of resistance variation (the tool’s reliability) decreases by more than two times (14%). This can be used further in coating development to improve the performance of CCT.

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“…[29][30][31][32][33][34][35]. However, data obtained by various researchers show that increased defectiveness of the surface layer contributes to the formation of defective coatings with an increased content of pores and discontinuities, characterized by a reduced strength of the adhesive bond with the ceramic base, which significantly limits their effectiveness during operation [36][37][38][39][40]. A more detailed overview of the problem and the kind of defects is presented shortly in the previous work of the authors [28], where Section 2.1 is devoted to the detailed overview of the problem.…”

Section: Introductionmentioning

confidence: 99%

Technological Principles of Complex Plasma-Beam Surface Treatment of Al2O3/TiC and SiAlON Ceramics

Grigoriev,

Volosova,

Lyakhovetsky

et al. 2023

JMMP

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Thermomechanical action during high-performance diamond grinding of sintered cutting Al2O3/TiC and SiAlON ceramics leads to increased defectiveness of the surface layer of the deposited TiZrN and CrAlSiN/DLC coatings. It predetermines the discontinuous and porous coatings and reduces its effectiveness under abrasive exposure and fretting wear. The developed technological approach is based on “dry” etching with beams of accelerated argon atoms with an energy of 5 keV for high-performance removal of defects. It ensures the removal of the defective layer on ceramics and reduces the index of defectiveness (the product of defects’ density per unit surface area) by several orders of magnitude, compared with diamond grinding. There are no pronounced discontinuities and pores in the microstructure of coatings. Under mechanical loads, the coatings ensure a stable boundary anti-friction film between the ceramics and counter body that significantly increases the wear resistance of samples. The treatment reduces the volumetric wear under 20 min of abrasive action by 2 and 6 times for TiZrN and CrAlSiN/DLC coatings for Al2O3/TiC and by 5 and 23 times for SiAlON. The volumetric wear under fretting wear at 105 friction cycles is reduced by 2–3 times for both coatings for Al2O3/TiC and by 3–4 times for SiAlON.

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Si3N4 ceramic cutting tool sintered with CeO2 and Al2O3 additives with AlCrN coating

Cited by 10 publications

References 9 publications

Dry machining of nodular cast iron using a YAG-reinforced alumina ceramic cutting tool

Dry machining of nodular cast iron using a YAG-reinforced alumina ceramic cutting tool

Influence of Surface Layer Condition of Al2O3+TiC Ceramic Inserts on Quality of Deposited Coatings and Reliability during Hardened Steel Milling

Technological Principles of Complex Plasma-Beam Surface Treatment of Al2O3/TiC and SiAlON Ceramics

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