Development of DLC-Coated Solid SiAlON/TiN Ceramic End Mills for Nickel Alloy Machining: Problems and Prospects

Abstract

The study is devoted to the development and testing of technological principles for the manufacture of solid end mills from ceramics based on a powder composition of α-SiAlON, β-SiAlON, and TiN additives, including spark plasma sintering powder composition, diamond sharpening of sintered ceramic blanks for shaping the cutting part of mills and deposition of anti-friction Si-containing diamond-like carbon (DLC) coatings in the final stage. A rational relationship between the components of the powder composition at spark plasma sintering was established. The influence of optimum temperature, which is the most critical sintering parameter, on ceramic samples’ basic physical and mechanical properties was investigated. DLC coatings’ role in changing the surface properties of ceramics based on SiAlON, such as microrelief, friction coefficient, et cetera, was studied. A comparative analysis of the efficiency of two tool options, such as developed samples of experimental mills made of SiAlON/TiN and commercial samples ceramic mills based on SiAlON, doped with stabilizing additives containing Yb when processing nickel alloys (NiCr20TiAl alloy was used as an example). DLC coatings’ contribution to the quantitative indicators of the durability of ceramic mills and the surface quality of machined products made of nickel alloy is shown.

Investigation of MAO Coatings Characteristics on Titanium Products Obtained by EBM Method Using Additive Manufacturing

“…The chemical composition, hydrophilicity, morphology, and surface roughness in this case are key factors for the active interaction of the implant with bone tissue and subsequent osseointegration [9,10]. Surface modification methods such as plasma spraying [11][12][13][14][15], alkali treatment [16][17][18][19][20], acid etching [21][22][23][24], laser treatment [25][26][27][28], and anodizing [29][30][31] are used, as well as the increasingly widely used plasma-electrolytic method of microarc oxidation (MAO) [32][33][34][35][36]. MAO is commonly used to produce useful coatings with various oxide layers on the surface of various metals, such as Ti, Al, Mg and Zr and their alloys, to improve corrosion resistance, tribological properties, biocompatibility and thermal properties [37][38][39][40][41][42][43].…”

Granulation of Silicon Nitride Powders by Spray Drying: A Review

“…Si 3 N 4 finds application both in the form of porous and dense ceramics [6]. Due to their high densification, high-temperature stability, good corrosive resistance, and relatively high elastic modulus, dense Si 3 N 4 ceramics are widely used for the production of gas turbine engines, high-speed cutting tools [7,8], extrusion heads [9], rocket fairings, satellite antennas, aerospace devices, as well as bearing and sealing [10,11]. On the other hand, the combination of lightweight and mechanical properties makes porous Si 3 N 4 highly demanded separation membranes, radomes, catalyst supports, gas filters, and other engineering applications.…”

New image processing algorithm to control the accuracy of sharpening drills

“…The cutting mechanisms of the drill blade are distinguished by a continuous point of contact with a characteristic abrasive contact when removing material [29][30][31][32] and wear of the blade, which changes the conditions of the cutting kinematics, forming an intensification of the load on the cutting part [33][34][35][36][37]. To analyze the effectiveness of using a blade for, the effectiveness of using new monitoring tools was established under various conditions of contact between the cutting edge and the product [38][39][40][41][42][43].…”