From Powders to Performance-A Comprehensive Study of Two Advanced Cutting Tool Materials Sintered with Pressure...

Area of Science:

• Materials Science
• Mechanical Engineering
• Manufacturing Technology

Background:

• Inconel 718 is a challenging superalloy for machining due to its high strength and temperature resistance.
• Development of advanced cutting tool materials is crucial for efficient machining of nickel-based superalloys.
• Novel composite materials offer potential for improved tool performance and cost-effectiveness.

Purpose of the Study:

• To investigate the fabrication and performance of two novel composite tool materials for Inconel 718 machining.
• To compare the properties and machining capabilities of materials produced via High Pressure-High Temperature (HPHT) and Spark Plasma Sintering (SPS).
• To evaluate the durability and performance of cutting inserts made from these composites against commercial references.

Main Methods:

• Fabrication of a cubic boron nitride (cBN)-based composite (BNT) using HPHT sintering.
• Fabrication of an alumina-zirconia-tungsten carbide (AZW) composite using SPS.
• Characterization of material properties, including Young's modulus and hardness.
• Machining trials of Inconel 718 using cutting inserts made from BNT and AZW composites.

Main Results:

• BNT composite exhibited a Young's modulus of 580 GPa and hardness of 26 GPa.
• AZW composite showed a Young's modulus of 470 GPa and hardness of 21 GPa.
• Both BNT and AZW cutting inserts demonstrated durability comparable to commercial reference inserts in Inconel 718 machining.

Conclusions:

• HPHT and SPS are viable sintering techniques for producing high-performance composite tool materials.
• The developed BNT and AZW composites offer competitive durability for Inconel 718 machining.
• These novel materials present distinct performance and economic profiles, providing options for manufacturers.