Preparation of WC-TiC-Ni3Al-CaF2 functionally graded self-lubricating tool material by microwave sintering and its cutting performance

Abstract

<jats:title>Abstract</jats:title><jats:p>With the concern of the environment, green dry cutting technology is getting more and more attention and self-lubricating tool technology plays an important role in dry cutting. Due to the demand for high temperature performance of tools during dry cutting process, cemented carbide with Ni<jats:sub>3</jats:sub>Al as the binder phase has received extensive attention due to its excellent high temperature strength and high temperature oxidation resistance. In this paper, WC-TiC-Ni<jats:sub>3</jats:sub>Al-CaF<jats:sub>2</jats:sub> graded self-lubricating material and tools were prepared by microwave heating method, and its microstructure, mechanical properties and cutting performance were studied. Results show that gradient self-lubricating material can be quickly prepared by microwave heating technology, and the strength is equivalent to that of conventional heating technology. CaF<jats:sub>2</jats:sub> not only plays a role in self-lubrication, but also refines the grain of the material. A reasonable gradient design can improve the mechanical properties of the material. When the gradient distribution exponent is n<jats:sub>1</jats:sub> = 2, the material has high mechanical properties. Cutting experiments show that the WC-TiC-Ni<jats:sub>3</jats:sub>Al-CaF<jats:sub>2</jats:sub> functional gradient self-lubricating tool has better cutting performance than the homogeneous WC-TiC-Ni<jats:sub>3</jats:sub>Al hard alloys.</jats:p>

Analysis of mechanical properties of Al2O3‐cBN‐hBN composites and identification of main influencing factors

“…Accordingly, particle surface coating modification and material gradient design have been studied to reduce the gap in mechanical properties between self-lubricating ceramics and conventional ceramics. [3][4][5] The high-pressure synthesis method provides an effective solution for fabricating self-lubricating ceramics with excellent mechanical properties. In a previous study, Al 2 O 3 -cBN-hBN composites with excellent mechanical properties were synthesized using a highpressure sintering method.…”

“…Thus, ceramic's mechanical and self‐lubricating properties are constrained by the self‐lubricating component. Accordingly, particle surface coating modification and material gradient design have been studied to reduce the gap in mechanical properties between self‐lubricating ceramics and conventional ceramics 3–5 . The high‐pressure synthesis method provides an effective solution for fabricating self‐lubricating ceramics with excellent mechanical properties.…”

Review on developments of bulk functionally graded composite materials

“…The sample was sintered at 1250°C for 20 min, and it had a relative density >97%. Tang et al [162] prepared WC–TiC–Ni 3 Al–CaF 2 functionally graded self-lubricating tool materials by microwave sintering. To design the FGCM, CaF 2 was first considered as the second phase and WC–TiC–Ni 3 Al was considered as the matrix.…”

“…FGCM was fabricated by infiltration of the porous body with copper (photograph shown on the left). The numbers (1–5) on the SEM images correspond to the numbers marked in blue in the left photograph (cited images have been reproduced with due permission from the publisher).

Figure 21. SEM backscattered electron micrographs of the WC–TiC–Ni 3 Al–CaF 2 FGCMs fabricated using different values of the gradient distribution exponent n 1 : (a) n 1 = 1, (b) n 1 = 2 and (c) n 1 = 4 [162] (cited image has been reproduced with due permission from the publisher).

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Vat Photopolymerization Additive Manufacturing of Functionally Graded Materials: A Review

“…Short and Ballinger [23] designed a lead-bismuth-cooled reactor composed of a functionally graded composite, that offers corrosion resistance provided by Fe-12Cr-2Si alloy layer and high strength provided by F91 alloy layer. For the cutting tools, high wear resistance is required at the outer surface and high toughness is expected in the inner sides and it was reported in literature that cutting tools developed from FGMs were superior to that of commercially used cutting tools [24,25].…”