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EP4496782A1 - Ceramic sintered body made of a sialon material, raw material mixture thereof, and manufacture thereof - Google Patents

Ceramic sintered body made of a sialon material, raw material mixture thereof, and manufacture thereof

Info

Publication number
EP4496782A1
EP4496782A1 EP23709204.4A EP23709204A EP4496782A1 EP 4496782 A1 EP4496782 A1 EP 4496782A1 EP 23709204 A EP23709204 A EP 23709204A EP 4496782 A1 EP4496782 A1 EP 4496782A1
Authority
EP
European Patent Office
Prior art keywords
weight
sialon
sintered body
raw material
phase
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP23709204.4A
Other languages
German (de)
French (fr)
Inventor
Sandra Nemrava
Volker Dietrich
Moritz STAHL
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ceramtec GmbH
Original Assignee
Ceramtec GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ceramtec GmbH filed Critical Ceramtec GmbH
Publication of EP4496782A1 publication Critical patent/EP4496782A1/en
Pending legal-status Critical Current

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Definitions

  • Ceramic sintered body made of a Sialon material, its raw material mixture and production
  • the subject of the invention is a sialon material whose sialon phase comprises ß-sialon and 15R sialon polytypoid.
  • the Sialon material further comprises an amorphous or semi-crystalline grain boundary phase.
  • Sintered sialons are well-known, chemically stable materials with high mechanical strength over a wide temperature range. Sialons are therefore used as heat-resistant parts in machines. The high mechanical strength leads to low wear in abrasion-intensive processes. Sialones are therefore widely used as cutting agents in cutting tools.
  • Sintered moldings made of a/ß-Sialon, especially for use as a cutting tool, e.g. B. as cutting means are known from the prior art.
  • the mixtures of a-sialon and ß-sialon enable the production of sintered moldings which, on the one hand, have a high hardness due to the granular a-sialon and, on the other hand, also have good toughness due to the needle-shaped ß-sialon grains.
  • the object of the invention is to provide a sialon sintered body that has high chemical resistance, high hardness and good fracture toughness.
  • the sintered body is primarily intended for use in the machining of nickel-based alloys or Heat Resistant Super Alloys (HRSA).
  • HRSA Heat Resistant Super Alloys
  • a method for producing a Sialon sintered body and the underlying inorganic raw material mixture should be provided.
  • All components of the Sialon sintered body and also the inorganic raw material mixture can contain impurities.
  • the purity of the starting materials is at least > 97%, ie each starting material can contain up to 3% by weight of impurities (based on the total amount of the respective starting material).
  • the purity of the starting materials is preferably >99%, ie i Up to 1% by weight of impurities (based on the total amount of the respective starting material) is possible, particularly preferably the purity is > 99.7%, ie up to 0.3% by weight of impurities (based on the total amount of the respective starting material ) are possible.
  • the purity of the starting materials is > 99.9%, meaning there are almost no impurities (up to 0.1% by weight).
  • the impurities are preferably foreign metals in quantities of less than 1000 ppm.
  • Fe ions are contained in the range between 10 and 1000 ppm, preferably between 10 and 500 ppm, particularly preferably between 10 and 100 ppm.
  • a lower Fe content leads to disproportionately high raw material and manufacturing process costs.
  • a higher Fe content leads to the formation of iron silicide, which negatively affects the fracture toughness of the sintered body.
  • the levels of foreign metals are determined using X-ray fluorescence analysis.
  • the nitride components of the raw material mixtures can contain oxygen in amounts of less than 1.5% by weight, preferably less than 1% by weight, particularly preferably less than 0.7% by weight, based on the total amount of the respective starting material.
  • the grain sizes of the components of the sialon in the sintered sintered body are determined using SEM images.
  • the maximum needle length, i.e. the maximum expansion of the grains, should not exceed 100 pm.
  • the composition of the Sialon sintered body is determined using conventional X-ray analysis methods, for example XRD (DIN EN 13925-1 (2003-07) and DIN 13925-2 (2003-07)).
  • Chemical analyzes of the metallic components of the sintered body according to the invention are carried out by energy-dispersive X-ray analysis (ISO 15632; DIN EN 1071-4) and X-ray fluorescence analysis (XRF; DIN 51001 (2003-08), DIN 51418-1 (2010-05), DIN 51418-2 ( 2015-03)).
  • the oxygen content is determined using hot gas extraction (ASTM E 1409:2013).
  • Sialons are typically made by sintering a powdered mixture and consist primarily of silicon nitride, aluminum oxide and other inorganic starting materials such as: B. sintering aids.
  • the sintered body i.e. the material, the sintered body made from the starting materials, comprises a sialon phase and an amorphous or at least partially crystalline grain boundary phase.
  • the sialon phase includes ß (beta) - sialon (Sie-zAlzOzNs-z where 0 ⁇ Z ⁇ 4.2) and 15R-sialon polytypoid (SiAUOzN ⁇ .
  • the proportion of 15R-sialon polytypoid is 20 - 80% by weight , preferably 30 - 70% by weight, particularly preferably 40 - 60% by weight, based on the total weight of the sialon phase.
  • the proportion of ß-sialon is preferably at least 10% by weight, particularly preferably at least 35% by weight. %. Particularly preferred is a proportion of ß-sialon of 40% by weight.
  • the proportion of ß-sialon is a maximum of 80% by weight.
  • the proportion of 15R polytypoid leads to a sintered body that has a high level of chemical inertness, ie chemical reactions occur with or on the sintered body avoided by a high proportion of 15R polytypoid.
  • a high proportion of 15R polytypoid leads to high brittleness of the sintered body.
  • an optimal ratio of chemical inertness to fracture toughness of the sintered body can be obtained.
  • the detection limit in the X-ray analysis method for determining the composition of the sialon phase and for determining the individual sialons present in the sintered body is approximately 5% by weight. Up to 10, preferably up to 5% by weight, of further sialons, preferably selected from the list comprising a (alpha), 12H, 21R and/or 27R sialons, can be contained in the sialon phase.
  • the sintered shaped body consists of >80% by weight, preferably >85% by weight, of the sialon phase and up to 20% by weight, preferably up to 15% by weight of the amorphous or at least partially crystalline phase Grain boundary phase, based on the total weight of the sintered body.
  • the sintered shaped body consists of >90% by weight of the sialon phase.
  • the proportion of grain boundary phase in the total weight of the sintered body is preferably ⁇ 12% by weight, particularly preferably ⁇ 10% by weight.
  • the sintered shaped body consists of the sialon phase and the grain boundary phase, i.e. the sum of the proportions of the sialon phase and the grain boundary phase is 100% by weight.
  • sintering aids added as additives.
  • the amount of additives added influences the amount of grain boundary phase.
  • the proportion of grain boundary phase is at least 5% by weight.
  • the sintered shaped body according to the invention is created by heat treatment, sintering, of a starting material mixture.
  • This raw material mixture includes an inorganic raw material mixture and organic components.
  • An inorganic raw material mixture for the production of sialons includes the components SisN4, AIN, AI2O3 and sintering aids.
  • an inorganic raw material mixture is proposed, to which Yb2Ü3 is added as a sintering aid.
  • the use of Yb2Ü3 results in a sintered body that has high fracture toughness.
  • the high fracture toughness leads to increased stability of the cutting edge.
  • the sintered molding thus withstands the stresses during machining even at high cutting speeds, increased feed and/or greater cutting depths, even in interrupted cuts.
  • the sintered body according to the invention, the sialon, is obtained from an inorganic raw material mixture which comprises the following components:
  • the sum of the inorganic components is 100% by weight and the inorganic raw material mixture consists only of the components SisN4, AlN, Al2O3 and Yb2O3 as sintering aids.
  • the inorganic raw material mixture includes all inorganic components that are used to produce the sintered body according to the invention.
  • organic components such as: B. Dispersants, pressing aids and binders that are completely burned during heat treatment, debinding and sintering.
  • These organic components preferably do not contain any metallic components.
  • ammonium salts are used instead of sodium salts of the organic components.
  • the inorganic raw material mixture according to the invention comprises
  • the sum of the inorganic components is 100% by weight.
  • the inorganic raw material mixture according to the invention comprises
  • the sum of the inorganic components is 100% by weight.
  • the raw material mixture includes Yb2Ü3 as a sintering aid, which is used to produce high-density ceramics.
  • Yb2Ü3 as a sintering aid, which is used to produce high-density ceramics.
  • the proportion of Yb2Ü3 in relation to the inorganic raw material mixture according to the invention is 0.4 - 1.5 mol%, preferably 0.6 - 1.5 mol% and particularly preferably 0.6 - 1 mol%. %.
  • the sintered shaped body is produced from the inorganic raw material mixture according to the invention.
  • the inorganic raw material mixture is first provided.
  • One or more organic auxiliary substances are added.
  • the raw materials are first mixed and/or ground in a solvent.
  • the solvent is water.
  • the solvent is an organic solvent, a mixture of several organic solvents or a mixture of one or more organic solvents and water.
  • the solvent mixtures are preferably single-phase, i.e. the solvents dissolve completely into each other in the required amounts.
  • the powdery inorganic raw material mixture should comprise particles with an average particle size of 10 pm or less, preferably 5 pm or less, more preferably 3 pm or less.
  • the inorganic raw material mixture is preferably placed in a mixing and grinding machine, such as a ball mill or a SiaN pot mill, with SisN grinding balls, and a solvent is added to the material which does not, at least substantially, dissolve the powdery raw material.
  • a mixing and grinding machine such as a ball mill or a SiaN pot mill, with SisN grinding balls
  • a solvent is added to the material which does not, at least substantially, dissolve the powdery raw material.
  • the grain sizes of the raw material mixture are referred to as agglomerates or primary particles.
  • the D50 value of the primary particles, the ground raw materials is determined using centrifugal sedimentation using the Particle Distribution Analyzer (DIN EN 725-5:2007, ISO 13320:2020-01).
  • the mixture is then ground and mixed until a slurry is formed and the desired primary grain size, i.e. the grain size of the raw material after grinding and before shaping, has been set.
  • the mixing and grinding process usually takes at least 5 minutes, preferably 30 minutes, particularly preferably 1 hour to a maximum of 300 hours, preferably a maximum of 200 hours, particularly preferably a maximum of 100 hours.
  • the SiaN powder has a primary grain size D50 0.25 ⁇ x ⁇ 2.5 pm, preferably 0.25 ⁇ x ⁇ 2.0 pm, particularly preferably D50 0.35 ⁇ x ⁇ 1.0 pm.
  • the primary grain size influences the shaping and the sintering activity.
  • the Si3N4 has a primary grain size D50 of 1.5 ⁇ x ⁇ 2.0 pm.
  • the organic auxiliary substances to be added before or after grinding can be dispersants, binders, pressing aids and/or plasticizers.
  • the organic auxiliaries are used in an amount of 1 to 30% by weight the weight of the inorganic raw material mixture is added to the powdered raw material mixture or the slurry produced.
  • the mixture produced, the slurry, comprising the inorganic and organic raw materials in a solvent mixture are, in one embodiment, by a suitable process, such as. B. spray drying, subjected to granulation.
  • the mixture or granules are then shaped. All methods for bringing the state of the art into form can be used.
  • the granules are brought into shape by pressing, preferably axial pressing, at 50 to 200 MPa.
  • the shaping takes place using isostatic pressing.
  • Molding can also be done by using other methods such as injection molding, extrusion molding or slip casting.
  • the shaped mixture of starting materials is then debinded and sintered.
  • sintering takes place under protective gas, such as. B. nitrogen and/or argon.
  • Debinding and sintering usually takes place in a heating device.
  • the gas atmosphere during debinding and sintering is inert in one embodiment and comprises N 2 , argon or a mixture of N 2 and other inert gases, preferably Ar.
  • the debinding preferably takes place at 400 to 800 ° C and preferably lasts at least 5 minutes, preferably 30 minutes, particularly preferably 1 hour to a maximum of 100 hours, preferably a maximum of 50 hours, particularly preferably a maximum of 30 hours.
  • the exact contents of the individual sialon phase components and the proportion and composition of the amorphous or semi-crystalline grain boundary phase are set by the selected sintering parameters.
  • the sintering aid Yb 2 O3 is converted, among other things, into Yb-Al-garnet, Yb 3 AI 5 0i 2 , and accumulates in the amorphous or semi-crystalline grain boundary phase.
  • the smallest possible proportion of Yb-Al garnet in the grain boundary phase is preferred.
  • the lower the proportion of Yb-Al garnet in the grain boundary phase of the sintered body the higher the wear and abrasion resistance of the sintered body.
  • a maximum of 1.4% by weight of Yb-Al garnet can be detected in the grain boundary phase.
  • the Yb-Al garnet as a crystalline component stabilizes the grain boundary phase by increasing the softening temperature compared to a completely amorphous grain boundary phase.
  • at least 0.02% by weight of Yb-Al-garnet can be detected in the grain boundary phase.
  • the amount of Yb-Al garnet is determined by the sintering parameters, such as: B. influences the sintering temperature. At sintering temperatures up to 1950 ° C, lower proportions of Yb-Al garnet are obtained; at lower sintering temperatures, a higher proportion of Yb-Al garnet is obtained (see also Table 2).
  • the proportion of Yb-Al garnet in the sintered body is preferably between 0.01 and 5% by weight, particularly preferably between 0.015 and 3% by weight, particularly preferably between 0.02 and 1.4% by weight the amount of crystalline phases in the sintered body.
  • the proportion of crystalline grain boundary phase, and thus also the proportion of Yb-Al garnet in the grain boundary phase, is increased.
  • a sintering temperature that is too low leads to a less dense sintered body with increased porosity and, as a result, lower abrasion resistance.
  • the sintering temperature is therefore preferably more than 1600 ° C.
  • the cooling rate also affects the proportion of Yb-Al garnet in the amorphous and/or semi-crystalline grain boundary phase.
  • the slower the cooling the higher the proportion of Yb-Al garnet.
  • the cooling rate is therefore preferably higher than 1000 ° C in 14 h, particularly preferably higher than 1000 ° C in 12 h, particularly preferably higher than 1000 ° C in 10 h.
  • the cooling rate is slower than 1000 ° C in 4 hours, preferably the cooling rate is in the range of 1000 ° C in 4 - 8 hours.
  • the sintering temperature also affects the grain size of the crystallites. These can be refined as part of a Rietveld refinement based on an X-ray diffractogram of the sintered body. Table 2 shows the average grain size of the individual crystalline phases (crystallite size). This is the average length of the congruent scattering domains in the sintered body. For the ß-Sialon phase, the higher the sintering temperature, the larger the crystallite size of the ß-Sialon phase. In addition, the Crystallite Size of the Yb-Al-Garnet phase in the sintered body according to the invention is smaller than the average Crystallite Size of the Sialon phases.
  • the crystallite size of the Yb-Al-Grant phase is preferably at least 5 times smaller than the average crystallite size of the Sialon phases, particularly preferably the crystallite size of the Yb-Al-garnet phase is at least 10 times smaller than the average crystallite Size of the Sialon phases.
  • the shaped mixture of starting materials is sintered at a temperature between 1600 ° C and 1950 ° C, preferably between 1650 ° C and 1900 ° C, particularly preferably between 1750 ° C and 1875 ° C. At these sintering temperatures, the densest possible sintered body is obtained (> 99% of the theoretical density) and the proportion of Yb-Al garnet is in the preferred range.
  • the sintering takes place in a gas pressure sintering furnace under a pressure of at least 10 bar, preferably at least 50 bar, particularly preferably at least 75 bar and preferably at most 150 bar, particularly preferably at most 100 bar.
  • the sintering time is preferably at least 30 minutes and preferably a maximum of 3 hours, particularly preferably the sintering time is 45 minutes to 2.5 hours.
  • the final sintered Sialon sintered body can then be removed.
  • Final processing is carried out using methods known in the prior art.
  • the sintered molded body is further processed by grinding into indexable inserts or solid shank milling cutters.
  • the sintered molded body according to the invention can be processed into a cutting agent that has little contact with the workpiece material to be processed, e.g. B. nickel-based alloys or steels. Chemically resistant, hard cutting materials are required for machining Ni-based alloys. The alloys are highly heat-resistant and hard; very high temperatures arise during machining, which leads to reactions and rapid wear with conventional cutting materials.
  • the present invention relates to a sintered body based on ß-sialon and 15R-sialon, which, as a cutting material, has a high cutting performance compared to.
  • HRSA Heat Resistant Super Alloys
  • a ceramic sintered body which has a sialon phase and an amorphous or semi-crystalline grain boundary phase.
  • the sialon phase has a proportion of 20 - 80% by weight of 15R sialon polytypoid.
  • the amorphous or semi-crystalline grain boundary phase optionally comprises a Yb-Al garnet and accounts for up to 15% by weight of the entire sintered body.
  • the Yb2O3 from the raw material mixture serves, in addition to the Al-based additives and the SiO2 contained in the Si3N 4 raw material, as a sintering aid. While the Al-based additives and the SiÜ2 can also be incorporated into the crystal lattice of the described sialon phases during the sintering process, the Yb remains in the grain boundary phase of the sintered body. This, and the Yb content, influences the properties of the grain boundary phase such as the glass transformation point and the bonding of the sialon phases with the grain boundary phase. This bond determines the dominant mechanisms for crack propagation in the sintered body and is therefore crucial for the fracture toughness of the sintered body.
  • the grain boundary phase of the sintered molding according to the invention contains at least 1.5% by weight, preferably 2% by weight, particularly preferably 2.5% by weight and a maximum of 5% by weight of Yb, calculated in the form of the sequioxide Yb2Ü3 and in relation to the total weight of the Sintered body.
  • the sintered shaped body is made from an inorganic raw material mixture containing 40 to 57% by weight of SisN 4 ; 40 - 55% by weight of a mixture of AIN and AI2O3, the ratio of AI2O3 to AIN being in the range 1 - 1.5:1, and comprising 3 to 5% by weight of Yb2Ü3 as a sintering aid.
  • inorganic raw material mixture containing 40 to 57% by weight of SisN 4 ; 40 - 55% by weight of a mixture of AIN and AI2O3, the ratio of AI2O3 to AIN being in the range 1 - 1.5:1, and comprising 3 to 5% by weight of Yb2Ü3 as a sintering aid.
  • RM inorganic raw material mixtures
  • the starting materials see Table 1, were mixed. SisN4 with an a-Si3N4 content of > 95%, an average grain diameter > 0.45 pm and an oxygen content of 1.2 - 1.4% by weight and Yb2O3 with a purity > 99.9%, one average grain diameter of approx. 5 pm, AI2O3 with a purity > 99.9%, an average grain diameter of 0.3 pm and AIN with an oxygen content of 0.6 - 1% and average grain diameter 1.2 - 1.7 pm are weighed, mixed with water and ground for at least 30 minutes in an agitator ball mill. The organic components are then added. The resulting ceramic slip (slurry) is granulated using spray drying. Shaped bodies were axially pressed at a pressure of approx. 1000 bar and debinded at 500 °C for 2 hours. The subsequent sintering took place according to the parameters from Table 2.
  • the sintered moldings were ground into cutting plates.
  • the measured values were determined in accordance with the following standard specifications: XRF: DIN 51001 (2003-08), DIN 51418-1 (2010-05), DIN 51418-2 (2015-03); XRD: DIN EN 13925-1 (2003-07), DIN 13925-2 (2003-07); Density: DIN EN 623-2 (1993-11), ISO 18754 (2020-04); Hardness: DIN EN 843-3 (2005-08), ISO 14705 (2016-12), ASTM C 1327 (2015); Fracture toughness: ISO 14627 (2012-07)

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Abstract

The present invention relates to a sintered body which is based on β-sialon as well as 15R-sialon and which, as a cutting material, exhibits a high cutting performance compared to workpieces made of nickel-based alloy or Heat Resistant Super Alloys (HRSA). To this end, a ceramic sintered body is disclosed which has a sialon phase and an amorphous or semi-crystalline grain boundary phase. The sialon phase has a proportion of 20 - 80 wt.% 15R-sialon polytypoid. The amorphous or semi-crystalline grain boundary phase optionally comprises a Yb-Al garnet, and constitutes up to 15 wt.% of the total sintered body. The sintered body is manufactured from an inorganic raw material mixture which comprises 40 to 57 wt.% of Si3N4; 40 - 55 wt.% of a mixture of AlN and Al2O3, the ratio of Al2O3 to AlN being in the range of 1-1.5:1, and 3 to 5 wt.% of Yb2O3 as a sintering aid.

Description

Keramischer Sinterformkörper aus einem Sialon-Werkstoff, seine Rohstoffmischung und Herstellung Ceramic sintered body made of a Sialon material, its raw material mixture and production

Gegenstand der Erfindung ist ein Sialon-Werkstoff, dessen Sialonphase ß-Sialon und 15R- Sialon-Polytypoid umfasst. Der Sialon-Werkstoff umfasst weiterhin eine amorphe oder teilkristalline Korngrenzphase. The subject of the invention is a sialon material whose sialon phase comprises ß-sialon and 15R sialon polytypoid. The Sialon material further comprises an amorphous or semi-crystalline grain boundary phase.

Gesinterte Sialone sind bekannte, chemisch stabile Materialien mit einer hohen mechanischen Festigkeit über einen breiten Temperaturbereich. Sialone werden daher als hitzeresistente Teile in Maschinen eingesetzt. Die hohe mechanische Festigkeit führt zu einem geringen Verschleiß bei abriebsintensiven Prozessen. Einen breiten Einsatz finden Sialone daher als Schneidmittel in Schneidwerkzeugen. Sintered sialons are well-known, chemically stable materials with high mechanical strength over a wide temperature range. Sialons are therefore used as heat-resistant parts in machines. The high mechanical strength leads to low wear in abrasion-intensive processes. Sialones are therefore widely used as cutting agents in cutting tools.

Sinterformkörper aus a/ß-Sialon, insbesondere zur Verwendung als Schneidwerkzeug, z. B. als Schneidmittel, sind aus dem Stand der Technik bekannt. Die Mischungen aus a-Sialon und ß-Sialon ermöglichen die Herstellung von Sinterformkörpern, die einerseits eine hohe Härte aufgrund des körnigen a-Sialons aufweisen und andererseits auch über eine gute Zähigkeit aufgrund der nadelförmigen ß-Sialon-Körner verfügen. Sintered moldings made of a/ß-Sialon, especially for use as a cutting tool, e.g. B. as cutting means are known from the prior art. The mixtures of a-sialon and ß-sialon enable the production of sintered moldings which, on the one hand, have a high hardness due to the granular a-sialon and, on the other hand, also have good toughness due to the needle-shaped ß-sialon grains.

Die Aufgabe der Erfindung besteht darin, einen Sialon-Sinterformkörper bereitzustellen, der eine hohe chemische Beständigkeit, eine hohe Härte und eine gute Bruchzähigkeit aufweist. Hauptsächlich soll der Sinterformkörper Einsatz bei der spanenden Bearbeitung von Nickel- Basis-Legierungen oder Heat Resistant Super Alloys (HRSA) finden. Außerdem soll ein Verfahren zur Herstellung eines Sialon-Sinterformkörpers bereitgestellt werden und die zugrundeliegende anorganische Rohstoffmischung. The object of the invention is to provide a sialon sintered body that has high chemical resistance, high hardness and good fracture toughness. The sintered body is primarily intended for use in the machining of nickel-based alloys or Heat Resistant Super Alloys (HRSA). In addition, a method for producing a Sialon sintered body and the underlying inorganic raw material mixture should be provided.

Die Aufgabe wird durch eine anorganische Rohstoffmischung gemäß Anspruch 1 , einen Sialon-Sinterformkörper gemäß Anspruch 6, das Verfahren gemäß Anspruch 10 sowie die Verwendung gemäß Anspruch 14 gelöst. Die untergeordneten Ansprüche geben bevorzugte Ausgestaltungen wieder. Weitere bevorzugte Ausgestaltungen sind nachfolgend beschrieben. Ausgestaltungen können untereinander frei kombiniert werden. The object is achieved by an inorganic raw material mixture according to claim 1, a Sialon sintered body according to claim 6, the method according to claim 10 and the use according to claim 14. The subordinate claims reflect preferred embodiments. Further preferred embodiments are described below. Designs can be freely combined with one another.

Sämtliche Prozentangaben beziehen sich, wenn nicht anders angegeben, auf das Gewicht (Gew.-%). Unless otherwise stated, all percentages are based on weight (% by weight).

Sämtliche Angaben in mol-% beziehen sich, wenn nicht anders angegeben, auf die Gesamtmischung. Unless otherwise stated, all information in mol% refers to the total mixture.

Sämtliche Bestandteile des Sialon-Sinterformkörpers und auch der anorganischen Rohstoffmischung können Verunreinigungen aufweisen. Die Reinheit der Ausgangsmaterialien beträgt mindestens > 97%, d.h. jedes Ausgangsmaterial kann bis zu 3 Gew.-% Verunreinigungen aufweisen (bezogen auf die Gesamtmenge des jeweiligen Ausgangsmaterials). Bevorzugt beträgt die Reinheit der Ausgangsmaterialien > 99 %, d.h. i bis zu 1 Gew.-% Verunreinigungen (bezogen auf die Gesamtmenge des jeweiligen Ausgangsmaterials) sind möglich, besonders bevorzugt beträgt die Reinheit > 99,7 %, d.h. bis zu 0,3 Gew.-% Verunreinigungen (bezogen auf die Gesamtmenge des jeweiligen Ausgangsmaterials) sind möglich. Im Idealfall ist die Reinheit der Ausgangsmaterialien > 99,9 %, d.h. es liegen nahezu keine Verunreinigungen vor (bis zu 0,1 Gew.-%). All components of the Sialon sintered body and also the inorganic raw material mixture can contain impurities. The purity of the starting materials is at least > 97%, ie each starting material can contain up to 3% by weight of impurities (based on the total amount of the respective starting material). The purity of the starting materials is preferably >99%, ie i Up to 1% by weight of impurities (based on the total amount of the respective starting material) is possible, particularly preferably the purity is > 99.7%, ie up to 0.3% by weight of impurities (based on the total amount of the respective starting material ) are possible. Ideally, the purity of the starting materials is > 99.9%, meaning there are almost no impurities (up to 0.1% by weight).

Bevorzugt handelt es sich bei den Verunreinigungen um Fremdmetalle in Mengen von jeweils weniger als 1000 ppm. In einer bevorzugten Ausgestaltung sind Fe-Ionen im Bereich zwischen 10 und 1000 ppm, bevorzugt zwischen 10 und 500 ppm, besonders bevorzugt zwischen 10 und 100 ppm enthalten. Ein geringerer Fe-Gehalt führt zu unverhältnismäßig hohen Rohstoff- und Herstellprozesskosten. Ein höherer Fe-Anteil führt zur Bildung von Eisensilicid, was die Bruchzähigkeit des Sinterformkörpers negativ beeinträchtigt. Die Gehalte an Fremdmetallen werden mittels Röntgenfluoreszenzanalyse bestimmt. The impurities are preferably foreign metals in quantities of less than 1000 ppm. In a preferred embodiment, Fe ions are contained in the range between 10 and 1000 ppm, preferably between 10 and 500 ppm, particularly preferably between 10 and 100 ppm. A lower Fe content leads to disproportionately high raw material and manufacturing process costs. A higher Fe content leads to the formation of iron silicide, which negatively affects the fracture toughness of the sintered body. The levels of foreign metals are determined using X-ray fluorescence analysis.

Weiterhin können die nitridischen Bestandteile der Rohstoffmischungen Sauerstoff in Mengen von weniger als 1 ,5 Gew.-%, bevorzugt weniger als 1 Gew.-%, besonders bevorzugt weniger als 0,7 Gew.-% bezogen auf die Gesamtmenge des jeweiligen Ausgangsstoffs aufweisen. Furthermore, the nitride components of the raw material mixtures can contain oxygen in amounts of less than 1.5% by weight, preferably less than 1% by weight, particularly preferably less than 0.7% by weight, based on the total amount of the respective starting material.

Die Korngrößen der Bestandteile des Sialons im gesinterten Sinterformkörper werden mittels REM-Aufnahmen bestimmt. Die maximale Nadellänge, d.h. die maximale Ausdehnung der Körner sollte 100 pm nicht überschreiten. Die Bestimmung der Zusammensetzung des Sialon-Sinterformkörpers erfolgt mittels herkömmlichen röntgenographischen Analyseverfahren, beispielsweise XRD (DIN EN 13925-1 (2003-07) und DIN 13925-2 (2003- 07)). Chemische Analysen der metallischen Bestandteile des erfindungsgemäßen Sinterformkörpers erfolgen durch energiedispersive Röntgenanalyse (ISO 15632; DIN EN 1071-4) und Röntgenfluoreszenzanalyse (RFA; DIN 51001 (2003-08), DIN 51418-1 (2010- 05), DIN 51418-2 (2015-03)). Der Sauerstoffgehalt wird mittels Heißgasextraktion bestimmt (ASTM E 1409:2013). The grain sizes of the components of the sialon in the sintered sintered body are determined using SEM images. The maximum needle length, i.e. the maximum expansion of the grains, should not exceed 100 pm. The composition of the Sialon sintered body is determined using conventional X-ray analysis methods, for example XRD (DIN EN 13925-1 (2003-07) and DIN 13925-2 (2003-07)). Chemical analyzes of the metallic components of the sintered body according to the invention are carried out by energy-dispersive X-ray analysis (ISO 15632; DIN EN 1071-4) and X-ray fluorescence analysis (XRF; DIN 51001 (2003-08), DIN 51418-1 (2010-05), DIN 51418-2 ( 2015-03)). The oxygen content is determined using hot gas extraction (ASTM E 1409:2013).

Sialone werden typischerweise durch Sintern einer pulverförmigen Mischung hergestellt und bestehen hauptsächlich aus Siliziumnitrid, Aluminiumoxid und weiteren anorganischen Ausgangsmaterialien, wie z. B. Sinterhilfsmitteln. Der Sinterformkörper, d.h. der Werkstoff, der gesinterte Körper aus den Ausgangsmaterialien, umfasst eine Sialon-Phase und eine amorphe oder zumindest teilkristalline Korngrenzphase. Die Sialon-Phase umfasst ß (beta) - Sialon (Sie-zAlzOzNs-z wobei 0 < Z < 4.2) und 15R-Sialon-Polytypoid (SiAUOzN^. Der Anteil an 15R-Sialon-Polytypoid beträgt 20 - 80 Gew.-%, bevorzugt 30 - 70 Gew.-%, besonders bevorzugt 40 - 60 Gew.-% bezogen auf das Gesamtgewicht der Sialon-Phase. Der Anteil an ß-Sialon beträgt bevorzugt mindestens 10 Gew.-%, besonders bevorzugt mindestens 35 Gew.-%. Insbesondere bevorzugt ist ein Anteil an ß-Sialon von 40 Gew.-%. Der Anteil an ß-Sialon beträgt maximal 80 Gew.-%. Sialons are typically made by sintering a powdered mixture and consist primarily of silicon nitride, aluminum oxide and other inorganic starting materials such as: B. sintering aids. The sintered body, i.e. the material, the sintered body made from the starting materials, comprises a sialon phase and an amorphous or at least partially crystalline grain boundary phase. The sialon phase includes ß (beta) - sialon (Sie-zAlzOzNs-z where 0 < Z < 4.2) and 15R-sialon polytypoid (SiAUOzN^. The proportion of 15R-sialon polytypoid is 20 - 80% by weight , preferably 30 - 70% by weight, particularly preferably 40 - 60% by weight, based on the total weight of the sialon phase. The proportion of ß-sialon is preferably at least 10% by weight, particularly preferably at least 35% by weight. %. Particularly preferred is a proportion of ß-sialon of 40% by weight. The proportion of ß-sialon is a maximum of 80% by weight.

Der Anteil an 15R-Polytypoid führt zu einem Sinterformkörper, der eine hohe chemische Inertheit aufweist, d.h. chemische Reaktionen mit dem bzw. am Sinterformkörper werden durch einen hohen Anteil an 15R-Polytypoid vermieden. Allerdings führt ein hoher Anteil an 15R-Polytypoid zu einer hohen Sprödigkeit des Sinterformkörpers. Im Bereich von 40 bis 60 Gew.-% 15R kann ein optimales Verhältnis von chemischer Inertheit zu Bruchzähigkeit des Sinterformkörpers erhalten werden. The proportion of 15R polytypoid leads to a sintered body that has a high level of chemical inertness, ie chemical reactions occur with or on the sintered body avoided by a high proportion of 15R polytypoid. However, a high proportion of 15R polytypoid leads to high brittleness of the sintered body. In the range of 40 to 60% by weight 15R, an optimal ratio of chemical inertness to fracture toughness of the sintered body can be obtained.

Die Nachweisgrenze beim röntgenographischen Analyseverfahren zur Bestimmung der Zusammensetzung der Sialon-Phase und zur Ermittlung der im Sinterformkörper vorliegenden einzelnen Sialone liegt bei ca. 5 Gew.-%. Es können bis zu 10, bevorzugt bis zu 5 Gew.-% weitere Sialone, bevorzugt ausgewählt aus der Liste umfassend a (alpha) -, 12H-, 21 R- und/oder 27R-Sialon in der Sialon-Phase enthalten sein. The detection limit in the X-ray analysis method for determining the composition of the sialon phase and for determining the individual sialons present in the sintered body is approximately 5% by weight. Up to 10, preferably up to 5% by weight, of further sialons, preferably selected from the list comprising a (alpha), 12H, 21R and/or 27R sialons, can be contained in the sialon phase.

Der Sinterformkörper besteht dabei zu > 80 Gew.-%, bevorzugt zu > 85 Gew.-% aus der Sialon-Phase und zu bis zu 20 Gew.-%, bevorzugt zu bis zu 15 Gew.-% aus der amorphen oder zumindest teilkristallinen Korngrenzphase, bezogen auf das Gesamtgewicht des Sinterformkörpers. Besonders bevorzugt besteht der Sinterformkörper zu > 90 Gew.-% aus der Sialon-Phase. The sintered shaped body consists of >80% by weight, preferably >85% by weight, of the sialon phase and up to 20% by weight, preferably up to 15% by weight of the amorphous or at least partially crystalline phase Grain boundary phase, based on the total weight of the sintered body. Particularly preferably, the sintered shaped body consists of >90% by weight of the sialon phase.

Bevorzugt ist der Anteil an Korngrenzphase am Gesamtgewicht des Sinterformkörpers < 12 Gew.-%, besonders bevorzugt < 10 Gew.-%. In einer bevorzugten Ausgestaltung besteht der Sinterformkörper aus der Sialon-Phase und der Korngrenzphase, d.h. die Summe der Anteile der Sialon-Phase und der Korngrenzphase ergibt 100 Gew.-%. Um einen möglichst dichten Sinterformkörper herstellen zu können, werden z. B. Sinterhilfsmittel als Additive zugegeben. Die Menge der zugesetzten Additive beeinflusst die Menge an Korngrenzphase. In einer bevorzugten Ausgestaltung beträgt der Anteil an Korngrenzphase mindestens 5 Gew.-%.The proportion of grain boundary phase in the total weight of the sintered body is preferably <12% by weight, particularly preferably <10% by weight. In a preferred embodiment, the sintered shaped body consists of the sialon phase and the grain boundary phase, i.e. the sum of the proportions of the sialon phase and the grain boundary phase is 100% by weight. In order to be able to produce the densest possible sintered body, e.g. B. sintering aids added as additives. The amount of additives added influences the amount of grain boundary phase. In a preferred embodiment, the proportion of grain boundary phase is at least 5% by weight.

Der erfindungsgemäße Sinterformkörper entsteht durch Wärmebehandlung, dem Sintern, einer Ausgangsstoffmischung. Diese Ausgangsstoffmischung umfasst eine anorganische Rohstoffmischung und organische Bestandteile. Eine anorganische Rohstoffmischung zur Herstellung von Sialonen umfasst die Bestandteile SisN4, AIN, AI2O3 sowie Sinterhilfsmittel.The sintered shaped body according to the invention is created by heat treatment, sintering, of a starting material mixture. This raw material mixture includes an inorganic raw material mixture and organic components. An inorganic raw material mixture for the production of sialons includes the components SisN4, AIN, AI2O3 and sintering aids.

Zur Herstellung des erfindungsgemäßen Sinterformkörpers wird eine anorganische Rohstoffmischung vorgeschlagen, der Yb2Ü3 als Sinterhilfsmittel zugesetzt wird. To produce the sintered shaped body according to the invention, an inorganic raw material mixture is proposed, to which Yb2Ü3 is added as a sintering aid.

Die Verwendung von Yb2Ü3 resultiert in einem Sinterformkörper der eine hohe Bruchzähigkeit aufweist. Dadurch eignet sich der erfindungsgemäße Sinterformkörper sehr gut als Schneidmittel zur spanenden Bearbeitung von metallischen Werkstückstoffen. Die hohe Bruchzähigkeit führt zu einer erhöhten Stabilität der Schneidkante. Somit hält der Sinterformkörper den Belastungen bei der Zerspanung auch bei hohen Schnittgeschwindigkeiten, erhöhtem Vorschub und/oder größerer Schnitttiefe, auch im unterbrochenen Schnitt, stand. The use of Yb2Ü3 results in a sintered body that has high fracture toughness. This makes the sintered molded body according to the invention very suitable as a cutting agent for the machining of metallic workpiece materials. The high fracture toughness leads to increased stability of the cutting edge. The sintered molding thus withstands the stresses during machining even at high cutting speeds, increased feed and/or greater cutting depths, even in interrupted cuts.

Der erfindungsgemäße Sinterformkörper, das Sialon, wird aus einer anorganischen Rohstoffmischung erhalten, welche folgende Bestandteile umfasst: The sintered body according to the invention, the sialon, is obtained from an inorganic raw material mixture which comprises the following components:

40 - 57 Gew.-% SisN4 40 - 55 Gew.-% eines Gemischs aus AIN und AI2O3, wobei das Verhältnis von AI2O3 zu AIN im Bereich 1 - 1 ,5:1 , bevorzugt 1 - 1 ,25:1 , besonders bevorzugt 1 - 1 ,2:1 liegt, 40 - 57% by weight SisN4 40 - 55% by weight of a mixture of AIN and AI2O3, the ratio of AI2O3 to AIN being in the range 1 - 1.5:1, preferably 1 - 1.25:1, particularly preferably 1 - 1.2:1 ,

3 - 5 Gew.-% Yb2O3 als Sinterhilfsmittel. 3 - 5% by weight of Yb2O3 as a sintering aid.

In einer bevorzugten Ausgestaltung beträgt die Summe der anorganischen Bestandteile 100 Gew.-% und die anorganische Rohstoffmischung besteht lediglich aus den Bestandteilen SisN4, AIN, AI2O3 sowie Yb2O3 als Sinterhilfsmittel. In a preferred embodiment, the sum of the inorganic components is 100% by weight and the inorganic raw material mixture consists only of the components SisN4, AlN, Al2O3 and Yb2O3 as sintering aids.

Die anorganische Rohstoffmischung umfasst alle anorganischen Bestandteile, die zur Herstellung des erfindungsgemäßen Sinterformkörpers eingesetzt werden. Um den Sinterformkörper herzustellen, werden weitere organische Bestandteile hinzugefügt, wie z. B. Dispergatoren, Presshilfsmittel und Binder, die während der Wärmebehandlung, dem Entbindern und Sintern vollständig verbrannt werden. Diese organischen Bestandteile enthalten bevorzugt keine metallischen Komponenten. So werden in einer bevorzugten Ausgestaltung Ammoniumsalze anstelle von Natriumsalzen der organischen Bestandteile verwendet. The inorganic raw material mixture includes all inorganic components that are used to produce the sintered body according to the invention. In order to produce the sintered body, further organic components are added, such as: B. Dispersants, pressing aids and binders that are completely burned during heat treatment, debinding and sintering. These organic components preferably do not contain any metallic components. In a preferred embodiment, ammonium salts are used instead of sodium salts of the organic components.

In einer bevorzugten Ausgestaltung umfasst die erfindungsgemäße anorganische Rohstoffmischung In a preferred embodiment, the inorganic raw material mixture according to the invention comprises

45 - 54,5 Gew.-% Si3N4, 45 - 54.5% by weight Si3N4,

42 - 50 Gew.-% eines Gemischs aus AIN und AI2O3, wobei das Verhältnis von AI2O3 zu AIN im Bereich 1 - 1 ,5:1 , bevorzugt 1 - 1 ,25:1 , besonders bevorzugt 1 - 1 ,15:1 liegt. 42 - 50% by weight of a mixture of AIN and AI2O3, the ratio of AI2O3 to AIN being in the range 1 - 1.5:1, preferably 1 - 1.25:1, particularly preferably 1 - 1.15:1 .

- 3,5 - 5 Gew.-% Yb2O3. - 3.5 - 5% by weight of Yb 2 O 3 .

In einer bevorzugten Ausgestaltung beträgt die Summe der anorganischen Bestandteile 100 Gew.-%. In a preferred embodiment, the sum of the inorganic components is 100% by weight.

In einer besonders bevorzugten Ausgestaltung umfasst die erfindungsgemäße anorganische Rohstoffmischung In a particularly preferred embodiment, the inorganic raw material mixture according to the invention comprises

- 47,5 - 51 ,5 Gew.-% Si3N4, - 47.5 - 51.5% by weight Si 3 N 4 ,

45 - 48 Gew.-% eines Gemischs aus AIN und AI2O3, wobei das Verhältnis von AI2O3 zu AIN im Bereich 1 - 1 ,5:1 , bevorzugt 1 - 1 ,25:1 , besonders bevorzugt 1 - 1 ,2:1 liegt. 45 - 48% by weight of a mixture of AIN and AI2O3, the ratio of AI2O3 to AIN being in the range 1 - 1.5:1, preferably 1 - 1.25:1, particularly preferably 1 - 1.2:1 .

- 3,5 - 4,5 Gew.-% Yb2O3. - 3.5 - 4.5% by weight of Yb 2 O 3 .

In einer bevorzugten Ausgestaltung beträgt die Summe der anorganischen Bestandteile 100 Gew.-%. In a preferred embodiment, the sum of the inorganic components is 100% by weight.

Die Rohstoffmischung umfasst Yb2Ü3 als Sinterhilfsmittel, welches dazu dient, hochdichte Keramiken zu erzeugen. Bei der Verwendung von mehr als 5 Gew.-% Yb2Ü3 bezogen auf den gesamten Sinterformkörper verringert sich die Wärmebeständigkeit, die Zähigkeit und die Härte des Sialon-Sinterkörpers. In einer Ausgestaltung beträgt der Anteil an Yb2Ü3 in Bezug auf die erfindungsgemäße anorganische Rohstoffmischung 0,4 - 1 ,5 mol.-%, bevorzugt 0,6-1 , 5 mol.-% und besonders bevorzugt 0,6 - 1 mol.-%. The raw material mixture includes Yb2Ü3 as a sintering aid, which is used to produce high-density ceramics. When using more than 5% by weight of Yb2Ü3 based on the entire sintered body, the heat resistance, toughness and the hardness of the Sialon sintered body. In one embodiment, the proportion of Yb2Ü3 in relation to the inorganic raw material mixture according to the invention is 0.4 - 1.5 mol%, preferably 0.6 - 1.5 mol% and particularly preferably 0.6 - 1 mol%. %.

Der Sinterformkörper wird aus der erfindungsgemäßen anorganischen Rohstoffmischung hergestellt. Dazu wird zunächst die anorganische Rohstoffmischung bereitgestellt. Es werden ein oder mehrere organische Hilfsstoffe hinzugegeben. The sintered shaped body is produced from the inorganic raw material mixture according to the invention. For this purpose, the inorganic raw material mixture is first provided. One or more organic auxiliary substances are added.

Die Rohstoffe werden zunächst in einem Lösungsmittel gemischt und/oder gemahlen. Das Lösungsmittel ist in einer Ausgestaltung Wasser. In einer weiteren Ausgestaltung ist das Lösungsmittel ein organisches Lösungsmittel, ein Gemisch mehrerer organischer Lösungsmittel oder ein Gemisch aus einem oder mehreren organischen Lösungsmitteln und Wasser. Bevorzugt sind die Lösungsmittelgemische einphasig, d.h. die Lösungsmittel lösen sich in den benötigten Mengen vollständig ineinander. The raw materials are first mixed and/or ground in a solvent. In one embodiment, the solvent is water. In a further embodiment, the solvent is an organic solvent, a mixture of several organic solvents or a mixture of one or more organic solvents and water. The solvent mixtures are preferably single-phase, i.e. the solvents dissolve completely into each other in the required amounts.

Die pulverförmige anorganische Rohstoffmischung sollte Partikel mit einer durchschnittlichen Partikelgröße von 10 pm oder weniger, vorzugsweise 5 pm oder weniger, bevorzugter 3 pm oder weniger umfassen. Die anorganische Rohstoffmischung wird bevorzugt in eine Misch- und Mahlmaschine, wie eine Kugelmühle oder eine SiaN^Topfmühle, mit SisN^Mahlkugeln gegeben und dem Material wird ein Lösungsmittel zugesetzt, welches das pulverförmige Rohmaterial nicht, zumindest im Wesentlichen nicht, löst. Die Korngrößen der Rohstoffmischung werden je nach Bearbeitungsschritt als Agglomerate oder Primärpartikel bezeichnet. Die Bestimmung des D50- Werts der Primärpartikel, der gemahlenen Rohstoffe, erfolgt mittels Centrifugal Sedimentation mittels Particle Distribution Analyzer (DIN EN 725- 5:2007, ISO 13320:2020-01). The powdery inorganic raw material mixture should comprise particles with an average particle size of 10 pm or less, preferably 5 pm or less, more preferably 3 pm or less. The inorganic raw material mixture is preferably placed in a mixing and grinding machine, such as a ball mill or a SiaN pot mill, with SisN grinding balls, and a solvent is added to the material which does not, at least substantially, dissolve the powdery raw material. Depending on the processing step, the grain sizes of the raw material mixture are referred to as agglomerates or primary particles. The D50 value of the primary particles, the ground raw materials, is determined using centrifugal sedimentation using the Particle Distribution Analyzer (DIN EN 725-5:2007, ISO 13320:2020-01).

Dann wird die Mischung gemahlen und so lang gemischt, dass eine Aufschlämmung entsteht und die angestrebte Primärkorngröße, d.h. die Korngröße des Rohstoffs nach der Mahlung und vor der Formgebung, eingestellt wurde. Der Misch- und Mahlprozess dauert üblicherweise mindestens 5 min, bevorzugt 30 min, besonders bevorzugt 1 h bis maximal 300 h, bevorzugt maximal 200 h, besonders bevorzugt maximal 100 h. The mixture is then ground and mixed until a slurry is formed and the desired primary grain size, i.e. the grain size of the raw material after grinding and before shaping, has been set. The mixing and grinding process usually takes at least 5 minutes, preferably 30 minutes, particularly preferably 1 hour to a maximum of 300 hours, preferably a maximum of 200 hours, particularly preferably a maximum of 100 hours.

Das SiaN^Pulver weist in einer Ausgestaltung eine Primärkorngröße D50 0,25 < x < 2,5 pm, bevorzugt 0,25 < x < 2,0 pm besonders bevorzugt D50 0,35 < x < 1 ,0 pm, auf. Die Primärkorngröße beeinflusst die Formgebung und die Sinteraktivität. In one embodiment, the SiaN powder has a primary grain size D50 0.25 <x <2.5 pm, preferably 0.25 <x <2.0 pm, particularly preferably D50 0.35 <x <1.0 pm. The primary grain size influences the shaping and the sintering activity.

In einerweiteren Ausgestaltung weist das Si3N4 eine Primärkörngröße D50 von 1 ,5 < x < 2,0 pm auf. In a further embodiment, the Si3N4 has a primary grain size D50 of 1.5 <x <2.0 pm.

Nach dem Mahlen können auch weitere organische Hilfsstoffe zugegeben werden, die mit den genannten Bestandteilen gemischt werden. After grinding, other organic auxiliary substances can also be added, which are mixed with the components mentioned.

Die vor bzw. nach dem Mahlen hinzuzufügenden organischen Hilfsstoffe können Dispergatoren, Binder, Presshilfsmittel und/oder Plastifizierer sein. Die organischen Hilfsstoffe werden in einer Ausgestaltung in einer Menge von 1 bis 30 Gew.-% bezogen auf das Gewicht der anorganischen Rohstoffmischung zur pulverförmigen Rohstoffmischung oder der hergestellten Aufschlämmung gegeben. The organic auxiliary substances to be added before or after grinding can be dispersants, binders, pressing aids and/or plasticizers. In one embodiment, the organic auxiliaries are used in an amount of 1 to 30% by weight the weight of the inorganic raw material mixture is added to the powdered raw material mixture or the slurry produced.

Die hergestellte Mischung, die Aufschlämmung, umfassend die anorganischen und organischen Rohstoffe in einem LösungsmittelAgemisch werden in einer Ausgestaltung durch ein geeignetes Verfahren, wie z. B. Sprühtrocknen, einer Granulierung unterzogen.The mixture produced, the slurry, comprising the inorganic and organic raw materials in a solvent mixture are, in one embodiment, by a suitable process, such as. B. spray drying, subjected to granulation.

Anschließend wird das Gemisch bzw. das Granulat in Form gebracht. Dabei sind alle Methoden zum in-Form-Bringen des Standes der Technik anwendbar. In einer bevorzugten Ausgestaltung wird das Granulat mittels Pressen, bevorzugt axialem Pressen, bei 50 bis 200 MPa in Form gebracht. In einer weiteren Ausgestaltung erfolgt die Formgebung mittels isostatischem Pressen. The mixture or granules are then shaped. All methods for bringing the state of the art into form can be used. In a preferred embodiment, the granules are brought into shape by pressing, preferably axial pressing, at 50 to 200 MPa. In a further embodiment, the shaping takes place using isostatic pressing.

Das Formen kann auch durch die Anwendung anderer Verfahren wie Spritzgießen, Extrusionsformen oder Schlickergießen erfolgen. Molding can also be done by using other methods such as injection molding, extrusion molding or slip casting.

Das in Form gebrachte Gemisch der Ausgangsmaterialien wird anschließend entbindert und gesintert. In einer bevorzugten Ausgestaltung erfolgt das Sintern unter Schutzgas, wie z. B. Stickstoff und/oder Argon. The shaped mixture of starting materials is then debinded and sintered. In a preferred embodiment, sintering takes place under protective gas, such as. B. nitrogen and/or argon.

Üblicherweise erfolgt das Entbindern und Sintern in einer Heizvorrichtung. Die Gasatmosphäre beim Entbindern und Sintern ist in einer Ausgestaltung inert und umfasst N2, Argon oder eine Mischung aus N2 und anderen inerten Gasen, bevorzugt Ar. Debinding and sintering usually takes place in a heating device. The gas atmosphere during debinding and sintering is inert in one embodiment and comprises N 2 , argon or a mixture of N 2 and other inert gases, preferably Ar.

Das Entbindern erfolgt bevorzugt bei 400 bis 800°C und dauert bevorzugt mindestens 5 min, bevorzugt 30 min, besonders bevorzugt 1 h bis maximal 100 h, bevorzugt maximal 50 h, besonders bevorzugt maximal 30 h. The debinding preferably takes place at 400 to 800 ° C and preferably lasts at least 5 minutes, preferably 30 minutes, particularly preferably 1 hour to a maximum of 100 hours, preferably a maximum of 50 hours, particularly preferably a maximum of 30 hours.

Die genauen Gehalte der einzelnen Sialon-Phasenbestandteile und der Anteil sowie die Zusammensetzung der amorphen bzw. teilkristallinen Korngrenzphase werden durch die gewählten Sinterparameter eingestellt. Bei der Herstellung des Sinterformkörpers, beim Sintern der anorganischen Rohstoffmischung wird das Sinterhilfsmittel Yb2O3 u. a. zu Yb-Al- Granat, Yb3AI50i2, umgewandelt und reichert sich in der amorphen oder teilkristallinen Korngrenzphase an. Dabei wird ein möglichst geringer Anteil an Yb-Al-Granat in der Korngrenzphase bevorzugt. Je niedriger der Anteil an Yb-Al-Granat in der Korngrenzphase des Sinterformkörpers, desto höher ist die Verschleiß- und Abriebsresistenz des Sinterformkörpers. In einer bevorzugten Ausgestaltung ist in der Korngrenzphase maximal 1 ,4 Gew. % Yb-Al-Granat nachweisbar. The exact contents of the individual sialon phase components and the proportion and composition of the amorphous or semi-crystalline grain boundary phase are set by the selected sintering parameters. During the production of the sintered body, during the sintering of the inorganic raw material mixture, the sintering aid Yb 2 O3 is converted, among other things, into Yb-Al-garnet, Yb 3 AI 5 0i 2 , and accumulates in the amorphous or semi-crystalline grain boundary phase. The smallest possible proportion of Yb-Al garnet in the grain boundary phase is preferred. The lower the proportion of Yb-Al garnet in the grain boundary phase of the sintered body, the higher the wear and abrasion resistance of the sintered body. In a preferred embodiment, a maximum of 1.4% by weight of Yb-Al garnet can be detected in the grain boundary phase.

Der Yb-Al-Granat als kristalliner Anteil stabilisiert die Korngrenzphase, indem er die Erweichungstemperatur gegenüber einer komplett amorphen Korngrenzphase erhöht. In einer bevorzugten Ausgestaltung ist in der Korngrenzphase mindestens 0,02 Gew. % Yb-Al- Granat nachweisbar. Die Menge an Yb-Al-Granat wird über die Sinterparameter, wie z. B. die Sintertemperatur beeinflusst. Bei Sintertemperaturen bis zu 1950 °C werden geringere Anteile an Yb-Al-Granat erhalten, bei niedrigeren Sintertemperaturen wird ein höherer Anteil an Yb-Al-Granat erhalten (siehe auch Tabelle 2). Bevorzugt beträgt der Anteil an Yb-Al-Granat im Sinterformkörper zwischen 0,01 und 5 Gew.- %, besonders bevorzugt zwischen 0,015 und 3 Gew.-%, insbesondere bevorzugt zwischen 0,02 und 1 ,4 Gew.-% bezogen auf die Menge der kristallinen Phasen im Sinterformkörper.The Yb-Al garnet as a crystalline component stabilizes the grain boundary phase by increasing the softening temperature compared to a completely amorphous grain boundary phase. In a preferred embodiment, at least 0.02% by weight of Yb-Al-garnet can be detected in the grain boundary phase. The amount of Yb-Al garnet is determined by the sintering parameters, such as: B. influences the sintering temperature. At sintering temperatures up to 1950 ° C, lower proportions of Yb-Al garnet are obtained; at lower sintering temperatures, a higher proportion of Yb-Al garnet is obtained (see also Table 2). The proportion of Yb-Al garnet in the sintered body is preferably between 0.01 and 5% by weight, particularly preferably between 0.015 and 3% by weight, particularly preferably between 0.02 and 1.4% by weight the amount of crystalline phases in the sintered body.

Mit einer niedrigeren Sintertemperatur wird der Anteil an kristalliner Korngrenzphase, und damit auch der Anteil an Yb-Al-Granat in der Korngrenzphase erhöht. Zusätzlich führt eine zu niedrige Sintertemperatur zu einem weniger dichten Sinterformkörper mit erhöhter Porosität und daraus folgend auch geringerer Abriebsresistenz. Bevorzugt beträgt die Sintertemperatur daher mehr als 1600 °C. With a lower sintering temperature, the proportion of crystalline grain boundary phase, and thus also the proportion of Yb-Al garnet in the grain boundary phase, is increased. In addition, a sintering temperature that is too low leads to a less dense sintered body with increased porosity and, as a result, lower abrasion resistance. The sintering temperature is therefore preferably more than 1600 ° C.

Neben der Sintertemperatur wirkt sich auch die Abkühlgeschwindigkeit auf den Anteil an Yb- Al-Granat in der amorphen und/oder teilkristallinen Korngrenzphase aus. Je langsamer die Abkühlung erfolgt, desto höher ist der Anteil an Yb-Al-Granat. Bevorzugt ist die Abkühlgeschwindigkeit daher höher als 1000 °C in 14 h, besonders bevorzugt höher als 1000 °C in 12 h, insbesondere bevorzugt höher als 1000 ° in 10 h. Die Abkühlgeschwindigkeit ist in einer Ausgestaltung langsamer als 1000 °C in 4 h, bevorzugt liegt die Abkühlgeschwindigkeit im Bereich von 1000 °C in 4 - 8 h. In addition to the sintering temperature, the cooling rate also affects the proportion of Yb-Al garnet in the amorphous and/or semi-crystalline grain boundary phase. The slower the cooling, the higher the proportion of Yb-Al garnet. The cooling rate is therefore preferably higher than 1000 ° C in 14 h, particularly preferably higher than 1000 ° C in 12 h, particularly preferably higher than 1000 ° C in 10 h. In one embodiment, the cooling rate is slower than 1000 ° C in 4 hours, preferably the cooling rate is in the range of 1000 ° C in 4 - 8 hours.

Die Sintertemperatur wirkt sich neben den Anteilen der kristallinen Phasen auch auf die Korngröße der Kristallite aus. Diese können im Rahmen einer Rietveld-Verfeinerung, basierend auf einem Röntgendiffraktogramm des Sinterformkörpers, verfeinert werden. Tabelle 2 zeigt die mittlere Korngröße der einzelnen kristallinen Phasen (Crystallite Size). Dabei handelt es sich um die mittlere Länge der kongruent streuenden Domänen im Sinterformkörper. Für die ß-Sialon-Phase gilt, je höher die Sintertemperatur, desto größer die Crystallite Size der ß-Sialon-Phase. Zudem ist die Crystallite Size der Yb-Al-Granat-Phase im erfindungsgemäßen Sinterformkörper kleiner als die mittlere Crystallite Size der Sialon- Phasen. Bevorzugt ist die Crystallite Size der Yb-Al-Grant-Phase mindestens 5-mal kleiner als die mittlere Crystallite Size der Sialon-Phasen, besonders bevorzugt ist die Crystallite Size der Yb-Al-Granat-Phase mindestens 10 Mal kleiner als die mittlere Crystallite Size der Sialon-Phasen. In addition to the proportions of crystalline phases, the sintering temperature also affects the grain size of the crystallites. These can be refined as part of a Rietveld refinement based on an X-ray diffractogram of the sintered body. Table 2 shows the average grain size of the individual crystalline phases (crystallite size). This is the average length of the congruent scattering domains in the sintered body. For the ß-Sialon phase, the higher the sintering temperature, the larger the crystallite size of the ß-Sialon phase. In addition, the Crystallite Size of the Yb-Al-Garnet phase in the sintered body according to the invention is smaller than the average Crystallite Size of the Sialon phases. The crystallite size of the Yb-Al-Grant phase is preferably at least 5 times smaller than the average crystallite size of the Sialon phases, particularly preferably the crystallite size of the Yb-Al-garnet phase is at least 10 times smaller than the average crystallite Size of the Sialon phases.

Das in Form gebrachte Gemisch der Ausgangsmaterialien wird bei einer Temperatur zwischen 1600 °C und 1950 °C, bevorzugt zwischen 1650 °C und 1900 °C, besonders bevorzugt zwischen 1750 °C und 1875 °C gesintert. Bei diesen Sintertemperaturen wird ein möglichst dichter Sinterformkörper erhalten (> 99 % der theoretischen Dichte) und der Anteil an Yb-Al-Granat ist im bevorzugten Bereich. The shaped mixture of starting materials is sintered at a temperature between 1600 ° C and 1950 ° C, preferably between 1650 ° C and 1900 ° C, particularly preferably between 1750 ° C and 1875 ° C. At these sintering temperatures, the densest possible sintered body is obtained (> 99% of the theoretical density) and the proportion of Yb-Al garnet is in the preferred range.

Das Sintern erfolgt in einer bevorzugten Ausgestaltung in einem Gasdruck-Sinterofen unter einem Druck von mindestens 10 bar, bevorzugt mindestens 50 bar, besonders bevorzugt mindestens 75 bar und bevorzugt maximal 150 bar, besonders bevorzugt maximal 100 bar.In a preferred embodiment, the sintering takes place in a gas pressure sintering furnace under a pressure of at least 10 bar, preferably at least 50 bar, particularly preferably at least 75 bar and preferably at most 150 bar, particularly preferably at most 100 bar.

Die Sinterdauer beträgt bevorzugt mindestens 30 min und bevorzugt maximal 3 h, besonders bevorzugt beträgt die Sinterdauer 45 min bis 2,5 h. The sintering time is preferably at least 30 minutes and preferably a maximum of 3 hours, particularly preferably the sintering time is 45 minutes to 2.5 hours.

Der final gesinterte Sialon-Sinterformkörper kann anschließend entnommen werden. Eine Endbearbeitung erfolgt nach den im Stand der Technik bekannten Methoden. In einer Ausgestaltung wird der Sinterformkörper durch Schleifen zu Wendeschneidplatten oder Vollschaftfräsern weiterverarbeitet. Der erfindungsgemäße Sinterformkörper lässt sich zu einem Schneidmittel verarbeiten, das nur wenig mit dem zu bearbeitenden Werkstückstoff, z. B. Nickel-Basis-Legierungen oder Stählen, reagiert. Für die spanende Bearbeitung von Ni- Basis-Legierungen werden chemisch beständige, harte Schneidstoffe benötigt. Die Legierungen sind hoch-hitzeresistent und hart, es entstehen sehr hohe Temperaturen beim Zerspanen, was bei konventionellen Schneidstoffen zu Reaktionen und schnellem Verschleiß führt. Bei der spanenden Bearbeitung von Nickel-Basis-Legierungen oder Heat Resistant Super Alloys (HRSA) entsteht keine Aufbauschneide, d.h. der Werkstoff des zu bearbeitenden Werkstücks haftet kaum bis gar nicht am Schneidmittel an. Zusätzlich führt der hohe Anteil an 15R-Sialon-Polytypoid zu einem chemisch sehr beständigen Sinterformkörper. The final sintered Sialon sintered body can then be removed. Final processing is carried out using methods known in the prior art. In one In this embodiment, the sintered molded body is further processed by grinding into indexable inserts or solid shank milling cutters. The sintered molded body according to the invention can be processed into a cutting agent that has little contact with the workpiece material to be processed, e.g. B. nickel-based alloys or steels. Chemically resistant, hard cutting materials are required for machining Ni-based alloys. The alloys are highly heat-resistant and hard; very high temperatures arise during machining, which leads to reactions and rapid wear with conventional cutting materials. When machining nickel-based alloys or Heat Resistant Super Alloys (HRSA), no built-up edge is created, meaning that the material of the workpiece to be machined hardly or does not adhere to the cutting medium. In addition, the high proportion of 15R sialon polytypoid leads to a chemically very stable sintered body.

Die vorliegende Erfindung betrifft einen Sinterformkörper auf Basis von ß-Sialon sowie 15R- Sialon, der als Schneidwerkstoff eine hohe Schneidperformance ggü. Werkstücken aus Nickel-Basis-Legierung oder Heat Resistant Super Alloys (HRSA) aufweist. Dazu wird ein keramischer Sinterformkörper gezeigt, der eine Sialon-Phase und eine amorphe oder teilkristalline Korngrenzphase aufweist. Die Sialon-Phase weist einen Anteil von 20 - 80 Gew.-% 15R-Sialon-Polytypoid auf. Die amorphe oderteilkristalline Korngrenzphase umfasst ggf. einen Yb-Al-Granat, und macht bis zu 15 Gew.-% des gesamten Sinterformkörpers aus.The present invention relates to a sintered body based on ß-sialon and 15R-sialon, which, as a cutting material, has a high cutting performance compared to. Workpieces made of nickel-based alloys or Heat Resistant Super Alloys (HRSA). For this purpose, a ceramic sintered body is shown which has a sialon phase and an amorphous or semi-crystalline grain boundary phase. The sialon phase has a proportion of 20 - 80% by weight of 15R sialon polytypoid. The amorphous or semi-crystalline grain boundary phase optionally comprises a Yb-Al garnet and accounts for up to 15% by weight of the entire sintered body.

Das Yb2O3 aus der Rohstoffmischung dient, neben den Al-basierten Additiven und dem im Si3N4- Rohstoff enthaltenen SiO2, als Sinterhilfsmittel. Während die Al-basierten Additive und das SiÜ2 während des Sinterprozesses auch in das Kristallgitter der beschriebenen Sialon- Phasen eingebaut werden können, verbleibt das Yb in der Korngrenzphase des Sinterformkörpers. Dadurch, und durch den Gehalt an Yb, werden die Eigenschaften der Korngrenzphase wie der Glas-Transformationspunkt und die Bindung der Sialon-Phasen mit der Korngrenzphase beeinflusst. Diese Bindung bestimmt die dominierenden Mechanismen bei der Rissausbreitung im Sinterformkörper und ist dadurch entscheidend für die Bruchzähigkeit des Sinterformkörpers. Deshalb enthält die Korngrenzphase des erfindungsgemäßen Sinterformkörpers mindestens 1 ,5 Gew. %, bevorzugt 2 Gew. %, besonders bevorzugt 2,5 Gew. % und maximal 5 Gew. % Yb, berechnet in Form des Sequioxides Yb2Ü3 und in Bezug auf das Gesamtgewicht des Sinterformkörpers. The Yb2O3 from the raw material mixture serves, in addition to the Al-based additives and the SiO2 contained in the Si3N 4 raw material, as a sintering aid. While the Al-based additives and the SiÜ2 can also be incorporated into the crystal lattice of the described sialon phases during the sintering process, the Yb remains in the grain boundary phase of the sintered body. This, and the Yb content, influences the properties of the grain boundary phase such as the glass transformation point and the bonding of the sialon phases with the grain boundary phase. This bond determines the dominant mechanisms for crack propagation in the sintered body and is therefore crucial for the fracture toughness of the sintered body. Therefore, the grain boundary phase of the sintered molding according to the invention contains at least 1.5% by weight, preferably 2% by weight, particularly preferably 2.5% by weight and a maximum of 5% by weight of Yb, calculated in the form of the sequioxide Yb2Ü3 and in relation to the total weight of the Sintered body.

Der Sinterformkörper wird aus einer anorganischen Rohstoffmischung hergestellt, die 40 bis 57 Gew.-% SisN4; 40 - 55 Gew.-% eines Gemischs aus AIN und AI2O3, wobei das Verhältnis von AI2O3 zu AIN im Bereich 1 - 1 ,5:1 liegt, und 3 bis 5 Gew.-% Yb2Ü3 als Sinterhilfsmittel umfasst. Ausführungsbeispiele: The sintered shaped body is made from an inorganic raw material mixture containing 40 to 57% by weight of SisN 4 ; 40 - 55% by weight of a mixture of AIN and AI2O3, the ratio of AI2O3 to AIN being in the range 1 - 1.5:1, and comprising 3 to 5% by weight of Yb2Ü3 as a sintering aid. Examples:

Folgende anorganische Rohstoffmischungen (RM) wurden für die Synthese von Sinterformkörpern bereitgestellt. The following inorganic raw material mixtures (RM) were provided for the synthesis of sintered moldings.

Tab. 1 Zusammensetzung der anorganischen Rohstoffmischung Table 1 Composition of the inorganic raw material mixture

Die Ausgangsmaterialien, siehe Tab. 1 , wurden vermischt. SisN4 mit einem a-Si3N4-Gehalt von > 95 %, einem mittleren Korndurchmesser > 0,45 pm und einem Sauerstoff-Gehalt von 1 ,2 - 1 ,4 Gew.-% sowie Yb2O3 mit einer Reinheit > 99,9 %, einem mittleren Korndurchmesser von ca. 5 pm, AI2O3 mit einer Reinheit > 99,9 %, einem mittleren Korndurchmesser von 0,3 pm und AIN mit einem Sauerstoff-Gehalt von 0,6 - 1 % und durchschnittlichem Korndurchmesser 1 ,2 - 1 ,7 pm werden abgewogen, mit Wasser versetzt und für min. 30 min in einer Rührwerkskugelmühle gemahlen. Anschließend erfolgt die Zugabe der organischen Komponenten. Der so erhaltene keramische Schlicker (Aufschlämmung) wird mittels Sprühtrocknung granuliert. Formkörper wurden bei einem Pressdruck von ca. 1000 bar axial gepresst und bei 500 °C für 2 h entbindert. Die anschließende Sinterung erfolgte nach den Parametern aus Tabelle 2. The starting materials, see Table 1, were mixed. SisN4 with an a-Si3N4 content of > 95%, an average grain diameter > 0.45 pm and an oxygen content of 1.2 - 1.4% by weight and Yb2O3 with a purity > 99.9%, one average grain diameter of approx. 5 pm, AI2O3 with a purity > 99.9%, an average grain diameter of 0.3 pm and AIN with an oxygen content of 0.6 - 1% and average grain diameter 1.2 - 1.7 pm are weighed, mixed with water and ground for at least 30 minutes in an agitator ball mill. The organic components are then added. The resulting ceramic slip (slurry) is granulated using spray drying. Shaped bodies were axially pressed at a pressure of approx. 1000 bar and debinded at 500 °C for 2 hours. The subsequent sintering took place according to the parameters from Table 2.

Die gesinterten Formkörper wurden zu Schneidplatten geschliffen. The sintered moldings were ground into cutting plates.

5 Tab. 2 Zusammensetzung und Eigenschaften der Sinterformkörper 5 Table 2 Composition and properties of the sintered moldings

* die Angabe bezieht sich auf den Anteil an den kristallinen Phasen und wurde bestimmt mittels Rietveld-Verfeinerung, Topas Vers. 4.2, cif-files 00-048-1616, 00-042-0160, 00 023-1476 * the information refers to the proportion of the crystalline phases and was determined using Rietveld refinement, Topas Vers. 4.2, cif-files 00-048-1616, 00-042-0160, 00 023-1476

** die Angabe bezieht sich auf das Ergebnis der zur Ermittlung der kristallinen Phasen durchgeführten Rietveld-Verfeinerung (siehe *), die Crystallite Size wurde nach Gaus verfeinert ** the information refers to the result of the Rietveld refinement carried out to determine the crystalline phases (see *), the Crystallite Size was refined according to Gaus

10 ‘“Resultate aus Experimenten zum Zerspanen von Nickel-Basis-Legierungen (Inconel 718) 10 “Results from experiments on machining nickel-based alloys (Inconel 718)

Die Bestimmung der Messwerte erfolgte gemäß den folgenden Normvorgaben: RFA: DIN 51001 (2003-08), DIN 51418-1 (2010-05), DIN 51418-2 (2015-03); XRD: DIN EN 13925-1 (2003-07), DIN 13925-2 (2003-07); Dichte: DIN EN 623-2 (1993-11), ISO 18754 (2020-04); Härte: DIN EN 843-3 (2005-08), ISO 14705 (2016-12), ASTM C 1327 (2015); Bruchzähigkeit: ISO 14627 (2012-07) The measured values were determined in accordance with the following standard specifications: XRF: DIN 51001 (2003-08), DIN 51418-1 (2010-05), DIN 51418-2 (2015-03); XRD: DIN EN 13925-1 (2003-07), DIN 13925-2 (2003-07); Density: DIN EN 623-2 (1993-11), ISO 18754 (2020-04); Hardness: DIN EN 843-3 (2005-08), ISO 14705 (2016-12), ASTM C 1327 (2015); Fracture toughness: ISO 14627 (2012-07)

Claims

Patentansprüche Patent claims 1. Anorganische Rohstoffmischung umfassend: 1. Inorganic raw material mixture comprising: 40 - 57 Gew.-% Si3N4 40 - 57% by weight Si3N 4 40 - 55 Gew.-% eines Gemischs aus AIN und AI2O3, wobei das Verhältnis von AI2O3 zu AIN im Bereich 1 - 1 ,5:1 liegt, und 40 - 55% by weight of a mixture of AIN and AI2O3, the ratio of AI2O3 to AIN being in the range 1 - 1.5:1, and 3 - 5 Gew.-% Yb2O3, wobei die Summe der anorganischen Bestandteile 100 Gew.- % ergibt. 3 - 5% by weight of Yb2O3, with the sum of the inorganic components being 100% by weight. 2. Rohstoffmischung nach Anspruch 1 , wobei das Verhältnis von AI2O3 zu AIN 1 - 1 ,25:1 , bevorzugt 1 - 1 ,12:1 beträgt. 2. Raw material mixture according to claim 1, wherein the ratio of AI2O3 to AIN is 1 - 1.25:1, preferably 1 - 1.12:1. 3. Rohstoffmischung nach einem der vorstehenden Ansprüche, umfassend 3. Raw material mixture according to one of the preceding claims, comprising 45 - 54,5 Gew.-% Si3N4, 45 - 54.5% by weight Si3N4, 42 - 50 Gew.-% eines Gemischs aus AIN und AI2O3, 42 - 50% by weight of a mixture of AIN and AI2O3, - 3,5 - 5 Gew.-% Yb2O3 - 3.5 - 5% by weight of Yb 2 O 3 4. Rohstoffmischung nach einem der vorstehenden Ansprüche, umfassend 4. Raw material mixture according to one of the preceding claims, comprising - 47,5 - 51 ,5 Gew.-% Si3N4, - 47.5 - 51.5% by weight Si 3 N 4 , 45 - 48 Gew.-% eines Gemischs aus AIN und AI2O3, 45 - 48% by weight of a mixture of AIN and AI2O3, - 3,5 - 4,5 Gew.-% Yb2O3 - 3.5 - 4.5% by weight of Yb 2 O 3 5. Rohstoffmischung nach einem der vorstehenden Ansprüche, wobei das Si3N4-Pulver eine Primärkorngröße D50 0,25 < x < 2,5 pm, bevorzugt D50 0,25 < x < 2,0 pm, besonders bevorzugt D50 0,35 < x < 1 ,0 pm oder 1 ,5 < x < 2,0 pm aufweist. 5. Raw material mixture according to one of the preceding claims, wherein the Si 3 N 4 powder has a primary grain size D50 0.25 <x <2.5 pm, preferably D50 0.25 <x <2.0 pm, particularly preferably D50 0.35 <x <1.0 pm or 1.5 <x <2.0 pm. 6. Keramischer Sinterformkörper umfassend eine Sialon-Phase umfassend ß-Sialon und 15R-Sialon, wobei der Anteil an 15-R- Sialon-Polytypoid 20 - 80 Gew.-% der Sialon-Phase beträgt, sowie eine amorphe oder teilkristalline Korngrenzphase, wobei die Korngrenzphase bis zu 15 Gew.-% des gesamten Sinterformkörpers ausmacht, wobei die Korngrenzphase maximal 5 Gew. % Yb, berechnet in Form des Sequioxides Yb2Ü3 und in Bezug auf das Gesamtgewicht des Sinterformkörpers, aufweist. 6. Ceramic sintered body comprising a sialon phase comprising ß-sialon and 15R-sialon, the proportion of 15-R-sialon polytypoid being 20 - 80% by weight of the sialon phase, and an amorphous or semi-crystalline grain boundary phase, where the grain boundary phase accounts for up to 15% by weight of the entire sintered body, the grain boundary phase having a maximum of 5% by weight of Yb, calculated in the form of the sequioxide Yb2Ü3 and in relation to the total weight of the sintered body. 7. Keramischer Sinterformkörper nach Anspruch 6, wobei die Korngrenzphase mindestens 1 ,5 Gew. %, bevorzugt 2 Gew. %, besonders bevorzugt 2,5 Gew. % Yb, berechnet in Form des Sequioxides Yb2O3 und in Bezug auf das Gesamtgewicht des Sinterformkörpers, aufweist. 7. Ceramic sintered shaped body according to claim 6, wherein the grain boundary phase contains at least 1.5% by weight, preferably 2% by weight, particularly preferably 2.5% by weight of Yb, calculated in the form of the sequioxide Yb2O3 and in relation to the total weight of the sintered shaped body, having. 8. Keramischer Sinterformkörper nach Anspruch 6 oder 7, wobei der Anteil an 15R- Sialon-Polytypoid 30 - 70 Gew.-%, bevorzugt 40 - 60 Gew.-% bezogen auf das Gesamtgewicht der Sialon-Phase beträgt. 8. Ceramic sintered shaped body according to claim 6 or 7, wherein the proportion of 15R sialon polytypoid is 30 - 70% by weight, preferably 40 - 60% by weight, based on the total weight of the sialon phase. 9. Keramischer Sinterformkörper nach Anspruch 8, wobei die Sialon-Phase zusätzlich bis zu 10 Gew.-% 12H-, 21 R-, 27R- oder a-Sialon, bevorzugt bis zu 5 Gew.-% 12H-, 21 R- , 27R- oder a-Sialon enthält. 9. Ceramic sintered body according to claim 8, wherein the sialon phase additionally contains up to 10% by weight of 12H-, 21R-, 27R- or a-sialon, preferably up to 5% by weight of 12H-, 21R-, 27R or a-Sialon contains. 10. Keramischer Sinterformkörper nach einem der Ansprüche 6 bis 9, wobei der Anteil an Yb-Al-Granat im Sinterformkörper zwischen 0,01 und 5 Gew.-%, besonders bevorzugt zwischen 0,015 und 3 Gew.-%, insbesondere bevorzugt zwischen 0,02 und 1 ,4 Gew.- %, bezogen auf die Menge der kristallinen Phasen im Sinterformkörper, beträgt. 10. Ceramic sintered body according to one of claims 6 to 9, wherein the proportion of Yb-Al garnet in the sintered body is between 0.01 and 5% by weight, particularly preferably between 0.015 and 3% by weight, particularly preferably between 0. 02 and 1.4% by weight, based on the amount of crystalline phases in the sintered body. 11. Keramischer Sinterformkörper nach einem der Ansprüche 6 bis 10, wobei die Crystallite Size der Yb-Al-Granat-Phase kleiner als die mittlere Crystallite Size der Sialon-Phasen, bevorzugt mindestens 5 Mal kleiner, besonders bevorzugt mindestens 10 Mal kleiner ist. 11. Ceramic sintered body according to one of claims 6 to 10, wherein the crystallite size of the Yb-Al-garnet phase is smaller than the average crystallite size of the sialon phases, preferably at least 5 times smaller, particularly preferably at least 10 times smaller. 12. Verfahren zur Herstellung des gesinterten Sinterformkörpers gemäß einem der Ansprüche 6 bis 11 , mit den Verfahrensschritten: 12. A method for producing the sintered sintered shaped body according to one of claims 6 to 11, with the method steps: (a) Bereitstellen einer Rohstoffmischung gemäß einem der Ansprüche 1 bis 5(a) Providing a raw material mixture according to one of claims 1 to 5 (b) Zugabe eines oder mehrerer organischer Hilfsstoffe (b) Addition of one or more organic auxiliaries (c) Mischen und Mahlen der Rohstoffe, bevorzugt in mindestens einer Flüssigkeit ausgewählt unter Wasser und/oder mindestens einem organischen Lösungsmittel und ggf. Zugabe eines oder mehrerer weiterer organischer Hilfsstoffe(c) mixing and grinding the raw materials, preferably in at least one liquid selected from water and/or at least one organic solvent and, if necessary, adding one or more further organic auxiliaries (d) In-Form-Bringen des Gemischs (d) shaping the mixture (e) Entbindern und Sintern (e) Debinding and sintering (f) Entnahme des gesinterten Sinterformkörpers (f) Removal of the sintered sintered body 13. Verfahren gemäß Anspruch 12, wobei das Sintern in Verfahrensschritt (e) bei 1600 °C bis 1950 °C, bevorzugt zwischen 1650 °C und 1900 °C, besonders bevorzugt bei 1750 °C bis 1875 °C durchgeführt wird. 13. The method according to claim 12, wherein the sintering in process step (e) is carried out at 1600 °C to 1950 °C, preferably between 1650 °C and 1900 °C, particularly preferably at 1750 °C to 1875 °C. 14. Verfahren nach Anspruch 12 oder 13, wobei die Gasatmosphäre ausgewählt ist unter N2 und/oder einem Schutzgas, bevorzugt ausgewählt unter N2 oder einem Gemisch aus14. The method according to claim 12 or 13, wherein the gas atmosphere is selected from N2 and/or a protective gas, preferably selected from N2 or a mixture of N2 und Ar und/oder wobei das Sintern bei einem Druck zwischen 10 und 100 bar stattfinden. N2 and Ar and/or where the sintering takes place at a pressure between 10 and 100 bar. 15. Verwendung des keramischen Sinterformkörpers nach einem der Ansprüche 6 bis 11 als Schneidmittel, bevorzugt als Wendeschneidplatte oder Vollschaftfräser. 15. Use of the ceramic sintered body according to one of claims 6 to 11 as a cutting means, preferably as an indexable insert or solid end mill.
EP23709204.4A 2022-03-21 2023-03-07 Ceramic sintered body made of a sialon material, raw material mixture thereof, and manufacture thereof Pending EP4496782A1 (en)

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KR102328799B1 (en) * 2014-11-13 2021-11-18 대구텍 유한책임회사 Ceramic material and cutting tools made thereof
KR102086570B1 (en) * 2017-12-29 2020-03-09 한국세라믹기술원 Method for manufacturing sialon-based ceramic materials having controlled hardness and toughness for cutting tools and materials manufactured thereby

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US20250206674A1 (en) 2025-06-26
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