WO1991008992A1 - Composites ceramiques renforces par barbes de carbure de silicium, et leur procede de fabrication - Google Patents
Composites ceramiques renforces par barbes de carbure de silicium, et leur procede de fabrication Download PDFInfo
- Publication number
- WO1991008992A1 WO1991008992A1 PCT/US1990/007276 US9007276W WO9108992A1 WO 1991008992 A1 WO1991008992 A1 WO 1991008992A1 US 9007276 W US9007276 W US 9007276W WO 9108992 A1 WO9108992 A1 WO 9108992A1
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- Prior art keywords
- whiskers
- coarse
- fine
- whisker
- silicon carbide
- Prior art date
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- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 title claims abstract description 36
- 239000002131 composite material Substances 0.000 title claims abstract description 32
- 239000011226 reinforced ceramic Substances 0.000 title claims abstract description 7
- 229910010271 silicon carbide Inorganic materials 0.000 title claims description 13
- 238000000034 method Methods 0.000 title description 16
- 238000005520 cutting process Methods 0.000 claims abstract description 60
- 238000009826 distribution Methods 0.000 claims abstract description 29
- 230000002902 bimodal effect Effects 0.000 claims abstract description 23
- 229910010293 ceramic material Inorganic materials 0.000 claims abstract description 15
- 239000013078 crystal Substances 0.000 claims abstract description 11
- 239000000203 mixture Substances 0.000 claims description 20
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 13
- 239000000919 ceramic Substances 0.000 claims description 13
- 239000011159 matrix material Substances 0.000 claims description 13
- 229910021421 monocrystalline silicon Inorganic materials 0.000 claims description 8
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 6
- 229910052581 Si3N4 Inorganic materials 0.000 claims description 6
- 238000000280 densification Methods 0.000 claims description 6
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 claims description 6
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims description 5
- 229910052863 mullite Inorganic materials 0.000 claims description 5
- QYEXBYZXHDUPRC-UHFFFAOYSA-N B#[Ti]#B Chemical compound B#[Ti]#B QYEXBYZXHDUPRC-UHFFFAOYSA-N 0.000 claims description 3
- 229910052582 BN Inorganic materials 0.000 claims description 3
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 3
- 229910033181 TiB2 Inorganic materials 0.000 claims description 3
- 239000000395 magnesium oxide Substances 0.000 claims description 3
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 claims description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims 2
- ATUUNJCZCOMUKD-OKILXGFUSA-N MLI-2 Chemical compound C1[C@@H](C)O[C@@H](C)CN1C1=CC(C=2C3=CC(OC4(C)CC4)=CC=C3NN=2)=NC=N1 ATUUNJCZCOMUKD-OKILXGFUSA-N 0.000 claims 1
- 239000000377 silicon dioxide Substances 0.000 claims 1
- 239000000463 material Substances 0.000 abstract description 24
- 238000007731 hot pressing Methods 0.000 description 10
- 238000012360 testing method Methods 0.000 description 7
- 229910052751 metal Inorganic materials 0.000 description 6
- 238000002156 mixing Methods 0.000 description 6
- 239000000843 powder Substances 0.000 description 6
- 239000002184 metal Substances 0.000 description 5
- 238000003801 milling Methods 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 238000003754 machining Methods 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 230000002411 adverse Effects 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 239000006185 dispersion Substances 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
- 238000011068 loading method Methods 0.000 description 3
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- 239000000908 ammonium hydroxide Substances 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 239000002173 cutting fluid Substances 0.000 description 2
- 230000006378 damage Effects 0.000 description 2
- 239000008367 deionised water Substances 0.000 description 2
- 229910021641 deionized water Inorganic materials 0.000 description 2
- 229910003460 diamond Inorganic materials 0.000 description 2
- 239000010432 diamond Substances 0.000 description 2
- 238000009792 diffusion process Methods 0.000 description 2
- 239000002270 dispersing agent Substances 0.000 description 2
- 229910002804 graphite Inorganic materials 0.000 description 2
- 239000010439 graphite Substances 0.000 description 2
- 238000001513 hot isostatic pressing Methods 0.000 description 2
- 238000001878 scanning electron micrograph Methods 0.000 description 2
- 238000004626 scanning electron microscopy Methods 0.000 description 2
- 239000002002 slurry Substances 0.000 description 2
- GZPBVLUEICLBOA-UHFFFAOYSA-N 4-(dimethylamino)-3,5-dimethylphenol Chemical compound CN(C)C1=C(C)C=C(O)C=C1C GZPBVLUEICLBOA-UHFFFAOYSA-N 0.000 description 1
- 229910052580 B4C Inorganic materials 0.000 description 1
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- 229910001060 Gray iron Inorganic materials 0.000 description 1
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 238000005054 agglomeration Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 238000010420 art technique Methods 0.000 description 1
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 1
- 238000007657 chevron notch test Methods 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000010494 dissociation reaction Methods 0.000 description 1
- 230000005593 dissociations Effects 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 239000007970 homogeneous dispersion Substances 0.000 description 1
- 239000008240 homogeneous mixture Substances 0.000 description 1
- 229910001026 inconel Inorganic materials 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 210000003127 knee Anatomy 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 229910017604 nitric acid Inorganic materials 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 238000004227 thermal cracking Methods 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
- RUDFQVOCFDJEEF-UHFFFAOYSA-N yttrium(III) oxide Inorganic materials [O-2].[O-2].[O-2].[Y+3].[Y+3] RUDFQVOCFDJEEF-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/58—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
- C04B35/584—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicon nitride
- C04B35/593—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicon nitride obtained by pressure sintering
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/71—Ceramic products containing macroscopic reinforcing agents
- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
- C04B35/80—Fibres, filaments, whiskers, platelets, or the like
Definitions
- the present invention generally concerns ceramic composites reinforced by silicon carbide, whiskers.
- the composites have utility in applications requiring high temperature physical and chemical stability, abrasion wear resistance and resistance to brittle failure.
- One such application is the cutting or machining of metals.
- Metal cutting or machining finds extensive application in manufacturing processes. Typical machining operations include shaping, planing, milling, facing, broaching, grinding, sawing, turning, boring, drilling and reaming. Some of these operations, e.g., sawing, act on both internal and external surfaces, whereas others act only on internal surfaces (reaming) or external surfaces (milling).
- a common productivity measure for machining operations is stated in terms of total amount of metal removed from a work material per unit of time.
- Parameters specific to cutting tool performance include the material being cut, cutting speed, depth of cut, feed rate and tool life.
- Tipnis, in "Cutting Tool Wear", Wear Control Handbook, pages 891-893 ? notes that wear is the preferred failure mode for cutting tools. Other failure modes such as fracture, chipping, softening or thermal cracking lead to catastrophic and erratic failures. Although wear is the preferred mode, Tipnis cautions that no predictive tool wear theories are available. As such, the practical approach involves generation and application of tool wear data to balance work material removal rates and economical tool life.
- Tipnis summarizes basic requirements for a cutting tool as follows: "(a) it must be harder than the material being cut so as to resist forces generated during cutting; (b) it must be tough so as not to fracture under such forces; (c) it must withstand high temperatures generated at the tool-chip interface without deforming; and (d) it must not wear too rapidly.”
- hot hardness i.e., resistance to softening under temperatures generated at the cutting edge of the tool
- toughness i.e., resistance to fracture under impacts
- chemical stability and reactivity i.e., the resistance to dissociation and transformation under temperatures and pressures generated at the cutting edge
- tendency towards diffusion of elements i.e., resistance to cratering at high cutting temperatures.
- toughness refers to resistance to premature failure, particularly during initiation of cutting, of a silicon carbide whisker reinforced, ceramic cutting tool. It does not necessarily equate to Kic measured at room temperature according to fracture mechanics definitions of toughness. Cutting performance does not correlate well with data supporting these definitions.
- M. C. Shaw in Metal Cutting Principles, page 334, (Oxford, 1984), highlights three criteria used in selecting materials for cutting tool applications.
- the criteria are (a) physical and chemical stability at use temperatures, (b) abrasion wear resistance and (c) resistance to brittle failure. Chemical instability at use temperatures can, for example, destroy tool materials quite rapidly through mechanisms such as melting, excessive diffusion, or a combination of welding and chipping. Shaw suggests, at pages 353-357, that three key physical properties be considered in selecting materials for use as cutting tools.
- One criterion is strength as measured in four-point- bend testing (Military Standard 1942b).
- the second criterion is hardness as measured by a Vickers indentor.
- the third criterion is resistance to fracture.
- Fracture toughness a commonly used indication of resistance to brittle failure, is measured by the Single Notch Beam Technique or the Chevron Notch Technique. Resistance to crack propagation, or Palmqvist Toughness is determined in conjunction with the hardness test.
- Satisfactory cutting tool materials must also possess sufficient toughness and strength to withstand mechanical shocks and the like which occur during cutting operations.
- the composites comprise a matrix of ceramic material having homogeneously dispersed therein 5 to 60 volume percent of silicon carbide whiskers.
- the whiskers have a monocrystalline structure, a diameter of about 0.6 micrometers and a length of 10 to 80 micrometers.
- the ceramic material may be alumina, mullite or boron carbide.
- the present invention is a densified, whisker- -reinforced ceramic composite material comprising a matrix of ceramic material having homogeneously dispersed therein 5 to 40 percent by volume of a bimodal distribution of chemically compatible single crystal whiskers, the whiskers being silicon carbide, silicon nitride, titanium carbide, mullite, titanium diboride, alumina, magnesia or boron nitride, provided, however, that the whiskers are not the same as the ceramic matrix material, the bimodal distribution being based upon relative whisker volume versus whisker width and comprising a volumetric ratio of coarse single crystal whiskers to fine single crystal whiskers of 0.1 to 1, the coarse whiskers having, prior to densification, a number average diameter of greater than or equal to 0.5 but less than 1.0 micrometer and a diameter range of from about 0.1 to 3 micrometers, the fine whiskers having, prior to densification, a number average diameter of greater than or equal to 0.1 but less than 0.5 micrometer and a diameter range of 0.
- the whiskers are desirably single crystal silicon carbide whiskers.
- the silicon carbide whiskers used in the present invention are single crystals containing beta and mixed alpha and beta phases of silicon carbide.
- the whiskers are selected from two distinct average whisker diameter ranges to provide a volume-based, bimodal size j - distribution. Whiskers designated as “coarse whiskers” have a number average whisker diameter within a range of from 0.5 to less than 1.0 micrometer. This represents a diameter range distribution of 0.1 to 3 micrometers. Whiskers designated as "fine whiskers” have an average
- the graphic portrayal is plotted using a five-point t - smoothing program (0.1 and 0.2 micrometer channel width).
- polished cross-sections of densified composite material prepared using standard metallographic procedures, are subjected to scanning electron microscopy (SEM) at a
- a small number of coarse whiskers may, because of the size of such whiskers, occupy a volume equal to that occupied by a much larger number of fine whiskers.
- a scanning electron micrograph _ of a polished cross-section of a densified composite material prepared from a mixture of alumina and 34 volume percent of SiC whiskers shows that, of 2356 counted, only 77 have a width greater than about 1.4 micrometers.
- the 77 whiskers account for only 3 percent of the number of whiskers but occupy about 68 percent of whisker volume.
- the relative volume occupied by coarse whiskers versus that occupied by fine whiskers provides a more accurate picture of whisker distribution than the mere number of such whiskers.
- bimodal distribution of submicrometer, single crystal silicon carbide whiskers provides an increase in cutting performance over that attainable with the same amount of whiskers selected only from one mode of the distribution.
- a ten percent, by volume, bimodal distribution provides a- cutting .performance at least as good as a 25 percent, by volume, content of either coarse or fine single crystal silicon carbide whiskers.
- the single crystal silicon carbide whiskers which provide the bimodal distribution are suitably present in a concentration within a range of 5 to 40 percent by volume, based upon total composite volume.
- the concentration is desirably 10 to 34 percent by volume.
- a whisker content of less than five volume percent provides insufficient toughness.
- a whisker content in excess of forty volume percent leads to processing difficulties, particularly in hot pressing. A solution to such processing difficulties should, however, allow one to use more than forty volume percent.
- the bimodal distribution suitably has a ratio of coarse whiskers to fine whiskers of 0.3 to 1.0.
- the ratio is desirably 0.4 to 0.8.
- the silicon carbide whiskers suitably have an aspect ratio of ten or less.
- the aspect ratio is desirably 10.
- Aspect ratios of less than 2.5 provide no advantage and may, in fact, have a considerable disadvantage in that they tend to increase brittleness of the resultant composite.
- Single crystal silicon carbide whiskers are typically available as mixtures of whiskers with a small amount of particulate silicon carbide. Separation of particles from the whiskers without excessive, loss of whiskers is physically quite difficult. Fortunately, the presence of a small portion of silicon carbide particles does not adversely influence performance of the resultant composite. Care must be taken, however, to avoid an excess of particulate silicon carbide as brittleness, and concurrent likelihood of fracture, increases with an increase in particle loading.
- Silicon carbide whiskers are believed to be particularly suitable for purposes of the present invention. Satisfactory results may, however, be attained with other whiskers such as those formed from a material selected from the group consisting of silicon nitride, titanium carbide, mullite, titanium diboride, alumina, magnesia or boron nitride.
- the whiskers should be selected from a chemically compatible material other than that of the matrix. As used herein, "chemically compatible" means that the whiskers and the matrix material do not react to form new phases.
- the ceramic composites of the present invention are suitably prepared by hot pressing a homogeneous mixture of particulate ceramic material and the two different sizes of silicon carbide whiskers at a pressure and temperature sufficient to provide the composite with a density of greater than about 99 percent of the theoretical density of the ceramic material.
- the ceramic composites may, if desired, be prepared by hot isostatic pressing or sintering.
- the bimodal distribution of silicon carbide whiskers and the ceramic powder are desirably in the form of a homogeneous admixture prior to hot pressing.
- the admixture may be produced by any suitable mixing technique which provides a homogeneous dispersion of the whiskers in the powder and minimizes agglomeration of the ceramic powder, whisker clumping, and whisker breakage.
- a particularly suitable mixing procedure, especially when the ceramic material is alumina involves the use of an attritor mixer with alumina balls having a size of 3/16 inch (0.48 centimeter) or smaller. Care should be taken during mixing to minimize, if not eliminate, damage or destruction of whiskers.
- a solution of water, a dispersant and enough ammonium hydroxide to provide a solution pH of about 10.5 is admixed with alumina powder for about 30 minutes at 330 revolutions per minute (rpm) to form a uniform dispersion.
- Large silicon carbide whiskers wetted with water, a dispersant and a very small amount of ammonium hydroxide are added to the uniform dispersion while mixing continues.
- Ten minutes after completing addition of the large silicon carbide whiskers, small silicon carbide whiskers wetted with water are added to the dispersion while mixing continues.
- Two minutes after completing addition of the small whiskers the attritor is stopped and its contents are dumped onto a 30 mesh (550 micrometer) screen to separate the attritor balls.
- the contents After rinsing the attritor balls and equipment with deionized water, the contents are converted to a dilute slurry with additional deionized water.
- the dilute slurry is flocculated at a pH of 7.2 with 50 percent nitric acid.
- the flocculated material is dried in a 100°C. air circulating oven. The dried material is screened with a 60 mesh (250 micrometer) screen to provide a powdered admixture with a maximum agglomerate size of about 100 micrometers.
- the powdered admixture is formed into a suitable configuration and hot-pressed to a density of greater than about 99 percent of the theoretical density of the ceramic material.
- Hot pressing may be accomplished in a suitable induction or resistance heated furnace with punches or pressing components formed of graphite or any other suitable material which is capable of withstanding the required pressures and temperatures without adversely reacting with composite constituents.
- the powdered admixture is poured into a ' graphite die in a shape measuring three inches (7.6 cm) in length by 2.5 inches (6.4 cm) in width by 0.5 inch (1.3 cm) in depth.
- An initial pressure of 1000 psig (about 70 kg/cm 2 ) is 10 applied to the die while the temperature is raised from ambient to about 1200°C over a period of about 30 minutes. The pressure is then increased to 5000 psig. (about 350 kg/cm 2 ) and maintained at that level while the temperature is increased to 1725°C. over a period of
- the die is maintained at that temperature and pressure for an additional 45 minutes.
- the die is then cooled over a two hour period to a temperature of 100°C. with a gradual pressure release at
- ⁇ r- provide composites in which the whiskers are preferentially aligned and randomly distributed in a plane or axis perpendicular to the hot pressing axis. Satisfactory results are, however, expected with other processes such as hot isostatic pressing and, perhaps,
- a series of hot-pressed materials are prepared from mixtures of 66 volume percent of alumina (AI2O3) powder (0.8 ⁇ m in size) and 34 volume percent silicon carbide (SiC) whiskers.
- the mixtures are prepared and hot-pressed using the mixing and hot-pressing procedures set forth hereinabove.
- the AI2O3 powder is grade RC-HP commercially available from Reynolds Metals Co.
- the SiC whiskers are nominally coarse, fine or mixtures thereof.
- the coarse whiskers have an average diameter of 0.94 ⁇ m, an average aspect ratio of about 10.7 (ranging from 1.1 to 77) and are commercially available from American Matrix.
- the fine whiskers have an average diameter of 0.22 to 0.26 ⁇ m, an average aspect ratio of about 10.6 and are commercially available from Tateho Chemical Industries Co., Ltd.
- the volume percentages of whiskers and the ratio of large to small whiskers, where both sizes are present, are set forth in Table I together with cutting performance of the resultant compositions.
- the coarse and fine whiskers are denominated in Table I respectively by letters "C” and "F".
- the hot-pressed materials are diamond ground into cutting tool inserts- meeting A. .S.I, standards in the RNG 45 style.
- the cutting edge is chamfered at a 20° angle by 0.003 inch (0.008 cm) width.
- the insert is tested in a single point turning using a 30 Horsepower Le Blond 1610 Heavy Duty Lathe equipped with a variable speed (DC) drive.
- the cutting tool is held in place with a Kennametal holder.
- the cutting tools are tested on an Inconel ® 718 workpiece measuring four inches (10.2 cm) in diameter and twelve inches (30-5 cm) in length and having a hardness of 241 BHN.
- the workpiece is center drilled with a number 5 combined drill and countersink.
- the workpiece is held in the lathe by a twelve inch (30.5 cm), three-jaw, self-centering chuck, gripped on 3 inches (7.6cm) of length supported with number 4 Morse taper Nirol live center.
- the tool holder and quill of the tailstock containing the live center - are all adjusted for minimum overhang to insure maximum rigidity.
- the machine is run at a cutting speed of 750 feet per minute, a feed rate of 0.007 inches per revolution and a depth of cut of 0.100 inches. No cutting fluid is used. Successive passes are taken and the cutting edge is examined for flank wear and chipping. Testing is terminated after one minute of cutting and cutting performance in terms of uniform wear is measured. The cutting performance is also shown in
- Example 2 The procedure of Example 1 is duplicated with a different coarse whisker.
- the coarse whisker has a number average diameter of 0.67 micrometer and an average aspect ratio of 11.0. It is available from American Matrix. Cutting performance of cutting tool inserts prepared as in Example 1 are summarized in Table II.
- Example 1 The procedure of Example 1 is duplicated with the composition of Sample Number 1-3 to provide a hot- pressed material.
- the resultant material is examined via SEM in conjunction with the Zeiss-Kontron Image Processing System according to procedure described hereinabove.
- 2356 whiskers are counted in eleven fields (areas).
- An additional value for silicon carbide whiskers, denominated as relative volume percent, is determined by the following equation wherein X is DMIN (fiber width) :
- the relative volume percent represents a given volume percent normalized based upon total volume of whiskers.
- 15 corresponding to maxima in distribution are 1.0 ⁇ m and 2.4 ⁇ m respectively for fine and coarse whiskers.
- the volume ratio of coarse to fine whiskers is 0.8.
- composition of Sample Number 1-3 comprises
- Example 1 The procedure of Example 1 is replicated except for variations in the volume percentage of silicon -17-
- Example 1 The hot-pressing procedure of Example 1 is replicated with a different ceramic material.
- the ceramic material is a mixture of 92 percent silicon nitride, commercially available from UBE Industries under the trade designation UBE-SN-10, 6 percent yttria and two percent of the alumina used in Example 1. All percentages are based upon mixture weight. The amount of whiskers, if any, are shown in Table IV.
- the resultant hot-pressed materials are diamond ground into cutting tool inserts for comparison with a commercial cutting tool.
- the inserts are made according to A. .S.I, standards in the SNG 434 style with cutting
- inserts are tested in a center face milling application using a 40 horsepower Cincinnati #5 single spindle, knee and saddle, vertical milling machine with a 5 horsepower variable speed table.
- the 0 work material is Class 30 gray cast iron measuring 4 inches (10.2 cm) wide by 12 inches (30.5_ cm) long with a measured hardness of 170 BHN.
- a one-tooth milling cutter having a 12 inch (30.5 cm) diameter is used with a 5° axial rake, a -5° radial rake and a 15° lead angle.
- the machine is run at a cutting speed of 3000 surface feet per minute (metric), a 0.60 inch (0.152 cm) depth of cut, and a feed rate of 0.013 inch (0.033 cm) per revolution (or tooth).
- the center line of the cutter 0 and the center line of the workpiece are coaxial. No cutting fluid is used.
- Comparative Example C is an unreinforced silicon nitride cutting tool commercially available from Boride Products, Inc. under the trade designation U.S.-20.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Cutting Tools, Boring Holders, And Turrets (AREA)
- Ceramic Products (AREA)
Abstract
L'utilisation d'une distribution bimodale de barbes de carbure de silicium ''grossières'' et ''fines'', à cristal unique et ayant des dimensions inférieures au micromètre pour renforcer les matériaux céramiques permet d'accroître l'efficacité de coupe par rapport au cas où on utilise une quantité équivalente soit de barbes fines, soit de barbes grossières. Les barbes grossières ont un diamètre moyen numérique compris dans une plage allant de 0,5 micromètre à moins de 1,0 micromètre, tandis que les barbes fines ont un diamètre moyen numérique compris dans une plage allant de 0,1 micromètres à 0,5 micromètre. La distribution bimodale des barbes représente de 5 à 40 pour cent en volume du matériau céramique composite résultant renforcé par barbes. Les matériaux ainsi obtenus sont utiles en tant qu'outils de coupe.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US45014789A | 1989-12-13 | 1989-12-13 | |
| US450,147 | 1989-12-13 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO1991008992A1 true WO1991008992A1 (fr) | 1991-06-27 |
Family
ID=23786958
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US1990/007276 WO1991008992A1 (fr) | 1989-12-13 | 1990-12-10 | Composites ceramiques renforces par barbes de carbure de silicium, et leur procede de fabrication |
Country Status (4)
| Country | Link |
|---|---|
| CN (1) | CN1053603A (fr) |
| AU (1) | AU7169791A (fr) |
| IL (1) | IL96661A0 (fr) |
| WO (1) | WO1991008992A1 (fr) |
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0592871A1 (fr) * | 1992-10-12 | 1994-04-20 | Sumitomo Electric Industries, Limited | Matériau composite céramique et son procédé de fabrication |
| CN100417618C (zh) * | 2006-04-17 | 2008-09-10 | 山东大学 | 原位生长碳化钛晶须增韧氧化铝基陶瓷刀具材料粉末及其制备工艺 |
| CN100417617C (zh) * | 2006-04-14 | 2008-09-10 | 山东大学 | 原位生长碳氮化钛晶须增韧氧化铝基陶瓷刀具材料粉末及其制备工艺 |
| CN100448798C (zh) * | 2007-04-29 | 2009-01-07 | 北京科技大学 | 一种制备碳化硅晶须增强碳化硅复合材料零件的方法 |
| EP2002694A4 (fr) * | 2006-03-30 | 2009-09-02 | Advanced Composite Materials L | Matériaux composites et dispositif comprenant un carbure de silicium monocristallin chauffé par rayonnement magnétique |
| WO2010032137A1 (fr) * | 2008-09-17 | 2010-03-25 | Diamond Innovations, Inc. | Composites de céramique de nitrure de bore cubique et procédés de fabrication de ceux-ci |
| US20110169396A1 (en) * | 2008-08-08 | 2011-07-14 | Drazenovic Beatrice | Semiconductor ceramic |
| CN111943706A (zh) * | 2020-08-21 | 2020-11-17 | 齐鲁工业大学 | 一种添加SiC晶须的自润滑陶瓷刀具及制备方法和应用 |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7731776B2 (en) * | 2005-12-02 | 2010-06-08 | Exxonmobil Research And Engineering Company | Bimodal and multimodal dense boride cermets with superior erosion performance |
| CN101348869B (zh) * | 2007-07-16 | 2010-06-02 | 南京理工大学 | 晶粒尺寸可控双峰分布的块体超细/纳米晶合金制备方法 |
| CN111170755B (zh) * | 2019-12-19 | 2021-11-19 | 西安交通大学 | 一种二硼化钛基纳米复合刀具材料及制备方法 |
| CN116789458B (zh) * | 2023-07-06 | 2024-08-09 | 肇庆市高要区金祥精细陶瓷有限公司 | 一种晶须增强的耐火材料及其制备方法 |
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| US4543345A (en) * | 1984-02-09 | 1985-09-24 | The United States Of America As Represented By The Department Of Energy | Silicon carbide whisker reinforced ceramic composites and method for making same |
| WO1986005480A1 (fr) * | 1985-03-14 | 1986-09-25 | Atlantic Richfield Company | Corps ceramiques renforces a densite elevee et leur procede de fabrication |
| US4652413A (en) * | 1985-10-16 | 1987-03-24 | The United States Of America As Represented By The United States Department Of Energy | Method for preparing configured silicon carbide whisker-reinforced alumina ceramic articles |
| US4657877A (en) * | 1986-05-21 | 1987-04-14 | The United States Of America As Represented By The United States Department Of Energy | Silicon carbide whisker-zirconia reinforced mullite and alumina ceramics |
| US4749667A (en) * | 1987-02-03 | 1988-06-07 | Carboloy Inc. | Alumina - zirconia ceramics reinforced with silicon carbide whiskers and methods of making the same |
| US4789277A (en) * | 1986-02-18 | 1988-12-06 | Advanced Composite Materials Corporation | Method of cutting using silicon carbide whisker reinforced ceramic cutting tools |
| US4867761A (en) * | 1987-03-20 | 1989-09-19 | Sandvik Ab | Ceramic cutting tool reinforced by whiskers |
-
1990
- 1990-12-10 WO PCT/US1990/007276 patent/WO1991008992A1/fr unknown
- 1990-12-10 AU AU71697/91A patent/AU7169791A/en not_active Abandoned
- 1990-12-12 CN CN90110427.2A patent/CN1053603A/zh active Pending
- 1990-12-13 IL IL96661A patent/IL96661A0/xx unknown
Patent Citations (8)
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| US4543345A (en) * | 1984-02-09 | 1985-09-24 | The United States Of America As Represented By The Department Of Energy | Silicon carbide whisker reinforced ceramic composites and method for making same |
| WO1986005480A1 (fr) * | 1985-03-14 | 1986-09-25 | Atlantic Richfield Company | Corps ceramiques renforces a densite elevee et leur procede de fabrication |
| US4652413A (en) * | 1985-10-16 | 1987-03-24 | The United States Of America As Represented By The United States Department Of Energy | Method for preparing configured silicon carbide whisker-reinforced alumina ceramic articles |
| US4789277A (en) * | 1986-02-18 | 1988-12-06 | Advanced Composite Materials Corporation | Method of cutting using silicon carbide whisker reinforced ceramic cutting tools |
| US4789277B1 (fr) * | 1986-02-18 | 1990-08-28 | Advanced Composite Materials | |
| US4657877A (en) * | 1986-05-21 | 1987-04-14 | The United States Of America As Represented By The United States Department Of Energy | Silicon carbide whisker-zirconia reinforced mullite and alumina ceramics |
| US4749667A (en) * | 1987-02-03 | 1988-06-07 | Carboloy Inc. | Alumina - zirconia ceramics reinforced with silicon carbide whiskers and methods of making the same |
| US4867761A (en) * | 1987-03-20 | 1989-09-19 | Sandvik Ab | Ceramic cutting tool reinforced by whiskers |
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| Title |
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| ADVANCED CERAMIC MATERIALS, Vol. 1, No. 1, (1986), JOHN W. MILEWSKI, "Efficient use of Whiskers in the Reinforcement of Ceramics", pages 36-41. * |
Cited By (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0592871A1 (fr) * | 1992-10-12 | 1994-04-20 | Sumitomo Electric Industries, Limited | Matériau composite céramique et son procédé de fabrication |
| EP2002694A4 (fr) * | 2006-03-30 | 2009-09-02 | Advanced Composite Materials L | Matériaux composites et dispositif comprenant un carbure de silicium monocristallin chauffé par rayonnement magnétique |
| US9688583B2 (en) | 2006-03-30 | 2017-06-27 | Advanced Composite Materials, Llc | Composite materials and devices comprising single crystal silicon carbide heated by electromagnetic radiation |
| CN100417617C (zh) * | 2006-04-14 | 2008-09-10 | 山东大学 | 原位生长碳氮化钛晶须增韧氧化铝基陶瓷刀具材料粉末及其制备工艺 |
| CN100417618C (zh) * | 2006-04-17 | 2008-09-10 | 山东大学 | 原位生长碳化钛晶须增韧氧化铝基陶瓷刀具材料粉末及其制备工艺 |
| CN100448798C (zh) * | 2007-04-29 | 2009-01-07 | 北京科技大学 | 一种制备碳化硅晶须增强碳化硅复合材料零件的方法 |
| US20110169396A1 (en) * | 2008-08-08 | 2011-07-14 | Drazenovic Beatrice | Semiconductor ceramic |
| US9115030B2 (en) * | 2008-08-08 | 2015-08-25 | Béatrice Drazenovic | Semiconductor ceramic |
| WO2010032137A1 (fr) * | 2008-09-17 | 2010-03-25 | Diamond Innovations, Inc. | Composites de céramique de nitrure de bore cubique et procédés de fabrication de ceux-ci |
| US8354353B2 (en) | 2008-09-17 | 2013-01-15 | Diamond Innovations, Inc. | Cubic boron nitride ceramic composites and methods of making thereof |
| CN111943706A (zh) * | 2020-08-21 | 2020-11-17 | 齐鲁工业大学 | 一种添加SiC晶须的自润滑陶瓷刀具及制备方法和应用 |
| CN111943706B (zh) * | 2020-08-21 | 2023-03-10 | 齐鲁工业大学 | 一种添加SiC晶须的自润滑陶瓷刀具及制备方法和应用 |
Also Published As
| Publication number | Publication date |
|---|---|
| CN1053603A (zh) | 1991-08-07 |
| IL96661A0 (en) | 1991-09-16 |
| AU7169791A (en) | 1991-07-18 |
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