CA1332106C - Alumina-zirconia-silicon carbide-magnesia ceramic cutting tools - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE:
A metalcutting insert is provided with an alumina based ceramic composition composed of (in volume percent, v/o): about 1.5 to 37.5 silicon carbide whiskers; about 5 to 17.5 zirconia; residue of a magnesium oxide addition added in an amount effective to enhance the metalcutting lifetime of the cutting edge of the insert; and an alumina based matrix in which the silicon carbide whiskers, zirconia and residue of magnesium oxide are substantially homogeneously distributed. At least 2 v/o of the alumina based ceramic composition is tetragonal zirconia.

Description

~332~06 `:
; ALUMINA-ZIRCONIA-SILICON CARBIDE-MAGNESIA CERAMIC
; ~ ! CUTTING TOOLS ' ;`[~ BACKGROUND OF THE INVENTION
'~ 5 The present invention relates to alumina based ceramic cutting tools containing zirconia and silicon carbide. It especially relates to ceramic ~`' cutting tools useful in the high speed, rough machining of ferrous and nonferrous metals and alloys.
10 ~ In the past, zirconia has been added in ~' specified amounts to selected alumina-silicon carbide whisker reinfqrced compositions described in United States Patent Nos. 4,534,345 and 4,507,224 to provide enha~nced fracture toughness andjor flexural strength `"
15~ sée: United~States Patent Nos. 4,657,877 and '' 4,749,667;~Japane~se Patent Publication No.
Sho~62-265182;~Clausen et al, "Whisker-Reinforced Oxide Ceramic;e," Journal de Physique Colloque Cl, Supplement au~No. 2, Tome~47, February 1986, Pages Cl-693 to ~;
20~ Cl-702; Becher et;al, "Toughening of Ceramics by Whisker Reinforcement," Fracture Mechanics of -~
Ceramics~7,` ed. by Bradt e~al, Plenum P~ess, New York ' '~
(1986)~, Pages'61-73)~
It has been indicated that the æirconia 25~ should be in~the monoclinic and/or ~metastable) ~'~
;;tetragcnal phase to obtain improved fracture toughness ~`
and/or flexural strength. It has been further indicated that the metastable tetragonal phase is ~ ~ ; .. ~ .:.
,~: ~ :: :.. : .

: .

3 obtained by reducing zirconia particle size or through Z the use of a cubic zirconia stabilization promoter such as yttria, calcia, magnesia and the rare earth oxides ` in amounts below that required to fully stabilize the ¦ 5 cubic zirconia phase.
~ Cutting tools composed of a variety of 3 compositions containing alumina, zirconia and silicon ;
carbid2 whiskers with or without other additives have : -:
been proposed (seeZ European Patent Application No.
¦ 10 86107916.8 (published January 21, 1987 as No. 0208910);
YZ United States Patent No. 4,749,667; "Multitoughening Z~
Zl Ceramic," Techno Japan, Vol. 19, No. 10, October 1986, Page 78; and European Patent Application No. 86301597.0 published September 17, 1986, as No. 0194811).
i~ 15 None of the foregoing documents teaches or suggests that, for metalcutting incerts for use in the high speed roughing of ferrous and nonferrous metals and alloys, cutting performance can be significan-tly improved by controlling the alumina based ceramic composition to within the combination of critical ranges now discovered by the applicants for zirconia, ~ ~
magnesia, silicon carbide and tetragonal zirconia ~--contents~
;~ SUMMARY OF THE INVENTION
The present invèntion provides alumina based ceramic cutting ihserts containing (in volume percent, v!o) about 1.5 to 37.5 v/o (volume percent) silicon -~
~ carbide whiskers, about 5 to 17.5 v/o zirconia, theZZ
Z~ residueZ of a magnesium oxide or other màgnesiumToxygen compound addition, and at least 2 v/o tetragonal zirconia. It has been surprisingly found that, despite ~ ~ the finding that minor magnesia additions act to reduce Z`~ the amount of tetrag~nal (i.e., metastable tetragonal) ~ zirconia at room temperature, an effective amount of ;~
Z: ~
this addition has a significant positive affect on cutting edge li~etime in the high speed rough turning . , .
, ~" ~" " ;~ ~" " ~ Z

of soft steels, such as AISI (American Iron and Steel Institute) 1045 steel.
It is preferred that magnesia be added in amounts of about .03 to 3 v/o; more preferably, about 0.03 to 2.0 v/o; and most preferably, about 0.04 to 1 . O v/ o .
Preferably, the alumina based ceramic composition according to the present invention contains about 2.5 to 35 v/o and, more preferably, about 5 to 10 32.5 v/o silicon carbide whiskers.
The zirconia content according to the present invention is preferably 7.5 to 17.5 v/o and, more preferably, 10 to 15 v/o. In accordance with the present invention, significant fraction of the zirconia 15 is in the form of tetragonal zirconia and must form at least 2 v/o of the composition. Preferably, at least 4 v/o; more preferably, at least 6 v/o; and most preferably, at least 8 v/o of the composition is in the form of tetragonal zirconia. ~
These and other aspects of the present --inv~ntion will become more apparent upon review of the detailed description of the present invention in conjunctlon with the figures briefly described below;
BRIEF_DESCRIPTION OF THE DRAWINGS
Figure l is an isometric view of an embodiment of a s~uare cutting insert in accordance with the present invention.
Y~ Figure 2 shows a graph of the volume percent -tetragonal zirconia in the composite as a function of 30 the volume percent of magnesia, or yttria, addition.
DETAILED DESCRIPTION OF TH~ INVEN~T0N
In the present invention, as shown in Figure 1, metalcutting insert 10, preferably of the indexable type, is provided having a rake face 30, a 35 flank face 50 and cutting edge 70 at the juncture of the rake and the flank faces. The cutting edge 70 is preferably in a chamfered condition (e.g., K-land) as ~ 1 332 1 06 :

shown in Figure 1. The metalcutting insert is composed of an alumina based ceramic composition containing:
about 1.5 to 37.5 v/o silicon carbide whiskers; about 5 to 17.5 v/o zirconia; and a residue of a magnesium oxide or other magnesium-oxygen compound addition added in an amount effective to enhance the metalcutting lifetime of the cutting edge. The silicon carbide whiskers, zirconia and residue of magnesia are substantially homogeneously distributed in an alumina based matrix.
The silicon carbide whiskers are present at a level of at least about 1.5 v/o to assure minimal levels of cutting edge lifetime improvement. More ~-~; preferably, silicon carbide whiskers are present at ~-about 2.5 v/o or more and, most preferably, at about 5 v/o or more. The silicon carbide whisker content preferably should not exceed about 37.5 v/o of the composition. We believe that silicon carbide whisker contents above this value result in a significant decrease in the cutting edge lifetime. Therefore, to further maximize cuttin~ edge lifetime during high speed rough turning, it is preferred that the maximum content of silicon carbide whiskers be held at or below about 35 v/o and, more preferably, 32.5 v/o of the alumina based ceramic composition. The optimum silicon ;~
carbide whisker level will depend upon the application.
The silicon carbide whiskers utilized herein may, for example, be any of the commercially available brandslwhichihave been used in the past in alumina based metalcutting inserts for machining nickel base superalloys.
While less preferred, silicon carbide particles of a generally equiaxed shape or platelet shape may be substituted for part of the silicon carbide whiskers in this invention. -, The zirconia content is in the range of about 5 to 17.5 v/o of the ceramic cQmposition. Zirconia : ~ , ~ .
~.

~ 3321 06 .
contents outside of this range are believed to provide compositions having reduced cutting edge lifetime during the high speed roughing of AISI 1045 steel.
Preferably, to maximize cutting edge lifetime, the zirconia content should be within the range of about 7.5 to 17.5 v/o and, more p~eferably, about 10 to 15 v/o of the composition. While we believe that the -concentration of tetragonal zirconia should be maximized for best cutting performance, it is equally, if not more, important in our opinion that as much of the tetragonal zirconia as possible, present at room temperature, be available for transformation toughening at, or as near as possible to, the temperatures z encGuntered at the cutting edge during machining. Itis, therefore, critical to the present invention that i~ magnesia be present in certain smail, but effective,amounts which have been found critical to the maximization of cutting edge lifetime. In accordance with the present invention, and at least 2 v/o of the ~
~- 20 ceramic composition, must be tetragonal zirconia. ~-Preferably, the tetragonal zirconia forms at least about 4 v/o of the composition, more preferably, at least about 6 v/o of the composition, and most preferably, at least about 8.0 v/o of the composition. `-~
Magnesia additions, despite tne fact that they decrease the amount of tetragonal zirconia observed at room temperature, are added in the range of about .03 to 3 v/o of the composition, preferably, about~0.03 to 2 v/o; more preferably, about 0.04 to ~
1.0 v/o. Magnesia may be blended in with the alumina or zirconia just prior to compact pressing, or it may ~' ; be preblended or prealloyed with the alumina or zirconia. Preblending of the magnesia powd2r is pre,ferred since it is believed that the preblended ~magnesia is more effective in producing high temperature metastable tetragonal zirconia, thus -~
allowing a smaller amount of magnesia to be added and ;
:''~
~ -~ 3 32 1 0~ ~
.
.

minimizing the deleterious effects of high magnesia additions (e.g., lower melting point glass and Mg-Al-O
formations). Equivalent amounts of other magnesium-oxygen compounds, such as magnesium carbonate, which may require an additional processing step such as calcination to produce magnesia, may be substituted for - all or part of the magnesia addition. After sintering of the blended compositions, the magnesia addition may not exist as a separate phase but as a residue. This residue may include, for example, magnesium aluminate, magnesia alumina solid solution, a magnesia zirconia solid solution and/or a glass, for example, formed with silicon dioxide impurities which may have existed as a -thin coating on the silicon carbide whiskers. ~ ~-The remainder of the ceramic composition is essentially alumina and preferably entirely alumina ;
except for impurities. In all cases, the present alumina based ceramic composition contains at least 40 v/o alumina, and preferably at least 50 v/o alumina.
Titanium carbide, as whiskers and/or ;
substantially e~uiaxed particulate, may be added in an ~
amount of about 2-35 v/o of the composition and, -preferably, about 10 to 30 v/o. Titanium carbide has a ~ higher thermal expansion coefficient than alumina. It `~
-~ 2S is, therefore, believed that titanium carbide additions should allow more tetragonal zirconia to be xetained at room temperature. Titanium carbide whiskers may be manufactured and harvested by the methods described in ~
A. Kato et al, "Growth Rate of Titanium Carbide ~i 30 Whiskers in Chemical Vapor Deposition," J. Cryst. -~
Growth, 37 tl977), Pages 293-300; and N. Tamari et al, ~' "Catalytic Effects of Various Metals and Refractory Oxides on the Growth o~ TiC Whiskers by Chemical Vapor Deposition," J. Cryst. Growth, 4~ (1979), Pages 221-; 35 237. Titanium carbide whiskers and their incorporation ~ and use in alumina based cutting inserts are disclosed A :

t 332 1 06 -7- ~ K-0933Y

in ~ehrotra et al Canadian Patent No. 1,308,919 issued October 20, 1992.
The alumina powders utilized herein should be high purity alumina (i.e., >99% pure) such as produced by ALCOA (e.g., grade A16SG), or by Ceralox (e.g., grade HPA - 0.5 with or without magnesia), or by Reynolds Chemicals (grade RC-HP or RC-HP-DBM).
Yttria, calcia, the rare earth oxides, and other compounds which have, through a reduction in the tetragonal to monoclinic transformation temperature, an adverse affect on cutting edge lifetime are preferably present only as impurities, if present at all.
The foregoing material, in accordance with the present invention, may be milled, blended, and -~
densified at high temperature to produce at least 98%, and preferably, at least 99% dense alumina based ~
ceramic compositions having an alumina based matrix, ~ -which is preferably entirely alumina, in which the silicon carbide, magne~ia residue from the magnesia addition, zirconia and titanium carbide, if any, are at ~-;~ least substantially homogeneously distribu~ed. Hot pressing temperatures are preferably held below 1750~C, and more preferably, below 1650C and, most preferably, below about 1600~C to minimize zirconia particle growth and thereby maximlze the tetragonal (i.e., metastable -;~
tetragonal) zirconia phase present in the final product. The average zirconia particle size in the ;~
cutting insert should not exceed about 5 microns, preferably should not exceed 2 microns, and more ii.~.
30 l preferably, should not exceed 1 micron. Howeverl, the average zirconia particle should be large enough to -` allow most tetragonal zirconia to transform to monoclinic zirconia during use. This minimum size will depend upon the ceramic composition and is presently undetermined. - -~
While not wishing to be bound by any particular theory, applicants offer the following A

~ t 332 1 06 K-0933Y

explanation of the present invention. In alumina-silicon carbide whisker-zirconia compositions, the amount of metastable tetragonal zirconia that can be obtained at room temperature can be increased by a reduction in zirconia particle size or the addition of the so-called cubic stabilizing agents, such as yttria, calcia and/or the rare earth oxides. (See: Stevens, "An Introduction to Zirconia--Zirconia and Zirconia Ceramics," Magnesium Elektron Pub. No. 113, Magnesium Elektron Ltd., England (1986)). While the literature commonly includes magnesia among the foregoing list of stabilizing agents, applicants have found that, when magnesia is added in the amount of about .03 to 3 v/o to the present compositions, magnesia decreases the amount of tetragonal zirconia present at room temperature. When yttria is added to zirconia, it ~- tends to stabilize the tetragonal and cubic phases of zirconia to a lower temperature. All the aforementioned stabilizing agents, and most impurities, ;~ ~ 20 except for magnesia, affect ZrO2 in similar ways (i.e., they reduce the temperature at which the tetragonal ~
zirconia phase is stable). At room temperature, some -of the zirconia may be present as metastable tetragonal zirconia. Under the action of tensile stress, this tetragonal zirconia may become monoclinic, giving rise to trans~ormation toughening. However, as the temperature increases, tetragonal zirconia becomes stable and, therefore, unavailable ~or transformation , to the monoclinic crystal structure. Thus, any I
impurity or additive, such as yttria, which stabilizes tetragonal zirconia at lower temperatures, is ' unsuitable for metalcutting applications since the cutting tip temperature may rise to about 1000 to 1200~C in high speed machining. Therefore, in accordance with the theory of the present invention, additives which raise the monoclinic to tetragonal transformation temperature of the zirconia are required : .-for high temperature transformation toughening. We have found that there are only two oxide additives, MgO
and HfO2, which raise the transformation temperature.
Thus, we believe that by keeping the zirconia particle size small, a large proportion of the zirconia can be retained as metastable tetragonal zirconia at the high ;
temperature of metalcutting by alloying the zirconia with magnesia or hafnia. It is our belief that this helps obtain enhanced cutting edge lifetimes during metalcutting operations. It should be noted that zirconia normally contains up to about 2 w/o (weight percent) hafnia as an impurity. -~
The significant positive impact that magnesia additions have on metalcutting performance is more clearly indicated by the following examples which are purely illustrative of the present invention.
~,~ Six compositions were prepared (Table 1) with ;~
the nominal compositions being Al2O3 - 10 v/o SiCw ~;~
(silicon carbide whiskers) - 10 v/o ZrO2. Small ~;~
~ 20 additions of Y203 an~ MgO were made. In the case of ; ~ Mix No. 6, abput 0.05 w/o (apprQximately 0.06 v/o) ~gO
had already been blended with Al203 by the powder manu~acturer. This provided Mix No. 6 with a magnesia content of abou~ .04 v/o. Fifty gram batches of these powders~ were prepared by first blending Al2O3 and ZrO2 ;(and stabilizing additives, if any) slurries (propanol) in a ~ar mill using Al203 cycloids for one hour.
Sonicated SiCw slurry was then added, and the whole mix was blended for one hour. A12O3 and ZrO2 slurries had ~ previously been milled to obtain mean particle sizes of 0.5 to 0.6 ~m and 0.6 to 0.8 ~m, respectively y~ (oorresponding specific surface areas measured by BET
were 10 to 14 m2/g and~20 to 40 m2jg, respectively).
Thèn, the mix was pan driad, screened through 100 mesh , !'`" ~35 screen, and hot pressed in a one inch diam~ter graphite `^ die at the temperatures and pressures shown below in ;~
~ Table l for one hour in argon. The resulting billets 32 t O6 were more than 99% dense, and were cut, ground and polished for measurement of physical and mechanical properties. The billets were also cut and ground to produce indexable cutting inserts for metalcutting ~
tests. -T~BLE 1: COMPOSI~IONS
Nominal Composition: A12O3 - 10 v/o SiCw - 10 v/o Zro2 -~
A12O3: Alcoa A16SG -~
SiCw: Tokai Carbon Co. (Tokyo, Japan) TOKAWHISKER (TOKAMAX) Grade 1 (0.3 - 1.0 ~m diameter; 20-50 ~m length) ZrO2: Zircar - unstabilized MgO: Fisher Scientific Corp. - Reagent Grade BET = 40.4 m2/g ~` Y2O3 MolyCorp, BET = 15.4 m2/g Hot Pressinq Mix No. Temp.(C) Pressure (psi) Composition -1. 1650 4000 Nominal 2. 1650 4500 Nominal ~ 1 v/o Y2O
3. 1625 4500 Nominal + 1 v/o MgO
4. 1600 4500 Nominal + 1 v/o Y2O3 + 1 v/o MgO
5. 1625 4500 Nominal, except that A12O3 used was Ceralox Grade HPA - 0.5 ~0.5 to 0.7 ~m median particle size)l 6. 1625 4500 Nominal, except that A12O3 used was Ceralox ~` ~ Grade HPA - 0.5 with MgO ( 0-05 w/o) ;; 35 ~ .
'~; , , ~ ~

1332106 ~ ~

TABLE 2 - PROPERTIES ~ ~ .
Tetragonal Zro22 ~;

NixFracture Toughness as v/o as v/o of 5 No. RA Hardness KIC (E&C)l (MPa m~) of ZrO2 Composite :
1 93.3 5.59 84 8.4 ~ -2 93.3 4.97 100 10 3 93.6 5.96 70 7 , 4~ 93.6 4.63 98 9.8 ~-~ 5 93.9 5.88 84 8.4 6 93.8 5.88 76 7.6 1 Evans and Charles, "Fracture Toughness ;-~
Determination by Indentation," J. American Ceramic Society, Vol. 59, No. 7-8, Pages 371, 372, usin~ an 18.5 kg load.
2 As measured by x-ray diffraction of a polished surface. The remainder of the zirconia is assumed to -~
be monoclinic zirconia. Cubic zirconia, which may be ~present in minor amount~, is included within the ; tetragonal zirconia estimate.

Physical and mechanical properties of the hot pressed composites are shown ln Table 2.
25 ~ The Porter-Heuer ~Porter et al, J. American Ceramic Society,- ~ol.; 62, No. 5-6 (1979), pages 298-305) formula~was modified and used to estimate the fraction of monoclinic ZrO2 (Vm~ from peak intensities ;;
of the 111 reflection of the monoclinic ZrO2 (I~ 13,), ;~
~and 111 reflection of;the tetragonal ZrO2 ~It(lIl)):

1.60 Im (111) ~ It (111) and Vt - 1-Vm (2) ;
35~ wherè Vt is the fraction of æro2 Which is tetragonal `~-~: : ' :-' ':

: .

` 133~2106 The estimated volume fraction of tetragonal Zr2 in the whole composite is (vt):
vt = Vt vz (3) where vz is the volume fraction of the total ZrO2 added in the mix. The above relationship assumes that ZrO2 substantially remains unchanged during consolidation except for the phase transformations discussed above.
Figure 2 shows the effect of the various additives on the amount of tetragonal zirconia in the composites. It can clearly be seen that magnesia additions lower the amount of tetragonal zirconia (curve 1), whereas, yttria additions increase the amount of tetragonal zirconia at room temperature (curve 2).
TABLE 3: TURNING AISI 1045* STEEL (192-200 BHN) InsertCutting Edge Life &Average Life MaterialFailure Mode (minutes) Mix 1 14. BK 14.7 BK 14.4 Nix 2 8. BK 12.6 ~K 10.3 , j, , ` MiX 3 15.9 BK 29.2 FW 22.6 Mix 4 1.7 FW - 7.7 FW 4.7 Mix 5 17. FW 7.5 BK 12.3 Mix 6 22.9 DN 32.9 FW 27.9 25 Test Conditions:
lOOO s~m (sur~ace feet/minute) 0.025 ipr (inch/revolution) 0.100 inch doc (depth of cut) SNGN-453T (American National Standard j Designation in accordance with ANSI B212.4 1986) indexable cutting insert style ~d (cutting edge preparation:
0.008 inch x 20 K-land) 15 lead;angle (side cutting edge angle) -5 side rake angle ~ -5 back rake angle `~ no coolant ~ .

~332~06 Cuttin~ Edqe Life Criteria:
FW - .015" uniform flank wear MW - .030" concentrated flank wear CR - .004" crater wear DN - .030" depth of cut notch CH - .030" concentrated wear or chipping BK - breakage *AISI 1045 is equivalent to Unified Numbering System (UNS) Designation - Gl0450.
Indexable insert cutting edge lifetimes in the high speed roughing of a premachined AISI 1045 steel are shown in Table 3. It can be clearly seen that a significant improvement in cutting edge life is achieved by the addition of magnesia, whereas, a :
decrease in tool life occurs when yttria is added :~:
despite the high level of tetragonal zirconia present in the yttria containing compositions. ::

TABLE 4: COMP SITIONS
Nominal Composition: Al203 - 5 v/o SiCw - 10 v/o ZrO2 ~
Al2O3: Ceralox-HPA-.5 without MgO ;.
SiCw: Tokai Grade l ~:
: ZrO2: Magnesium Elektron (SC15) ~
25 : unstabilized (.5 - .6 ~m particle :
size BET 5 - 8 m2/g) :-Hot P~essing -::
Mix No. Tem.C P~essure~psi~ Composition .:~
7. 1535C 5000 psi Nominal + .05 v/o MgO :- ~
; 30 8. ~ 1550C 5000 psi Nominal + .25 v/o MgO : .
9. ~ 1550C 5000 psi Nominal + .50 v/o MgO .`- :
10. - 1550C 5000 psi Nominal ~ 1.0 v/o MgO
ll. 1550C 5000 psi Nominal + 3.0 v/o MgO
, . .
A second series of mixes, 7 to ll shown in -~ :
:: Table 4, were made to further demonstrate the effect ~: that the level of the magnesia has on tetragonal ':

zirconia content and cutting edge lifetime. All samples were processed and hot pressed essentially as described with respect to the samples produced from Mixes 1 to 6.
The physical and mechanical properties of the materials are reported in Table 5. It can clearly be seen that the tetragonal zirconia content again clearly decreases with increasing amounts of magnesia addition.
This affect is also shown in Figure 1, curve 3. It can be seen that Mixes 7 to 11 have a higher tetragonal zirconia content than that found in the materials represented by curve 1. The affect is believed to be due to the lower SiCw content (5 vJo versus 10 v/o) used in the second group of mixes. Applicants have observed that generally, as SiC whisker content increases, the amount of tetragonal zirconia decreases for a given zirconia content and zirconia particle size, and everything else being held constant.

TABLE 5: PROPERTIES
Tetragonal Zr2 as Mix Fracture Toughness v/o of No. V/o MgO RA Hardness KIC (E~C) (MPa m~) Composite __ __ 7 0.05 93.5 5.57 8.5 8 0.25 93.4 5.00 8.1 '~ 9 0.50 93.3 5.06 8.0 1.0 93.4 4.75 ! 7.6 11 3.0 93.5 4.98 7.3 Indexable insert cutting edge lifetimes in ~ the hlgh speed roughing of AISI 1045 steel are shown in -~ Table 6.
~ 35 I~ 15- 1 332 1 06 K-0933Y

TABLE 6: TURNING AISI 1045 STEEL (197-199 BHN) Insertcutting Edge Life Average Life Material& Failure Mode (Minutes) Mix 7 19 bk5 ch/bk 12 8 12 . 6 dn/ch 1 bk 6.8 9 12.3 dn14.1 dn 13.2 9.7 bk7.1 dn 8.4 11 7.0 bk6.8 dn 6.9 The test procedures and conditions and cutting edge life criteria used to generate the data shown in Tables 5 and 6 were the same as that described -~
for Tables 2 and 3. ~ ;
In another example in accordance with the present invention, a composition containing A12O3-2.5 v/o SiCw-10v/o ZrO2-1.05 v/o MgO was made. A fifty ;~
gram batch of this composition was prepared by first blending an A12O3 (Ceralax Grade ~PA-0.5 with MgO (0.05 w/o)), ZrO2 (Magnesium Elektron SC15) and MgO (Fisher Reagent Grade) slurry (propanol) in a jar mill using ~-A12O3 cycloids for one hour. A Sonicated SiCw ~Tokai Grade 1) slurry was then added and the whole mix was blended for one hour. The A12O3 and ZrO2 containing slurries had previously been milled to obtain mean particle si~ze of about 0.5 - 0.7 ~m and 0.5 to 0.6 ~m, - ~ 25 respectively. Then the mix was pan dried, screened through a 100 mesh screen and isostatically compacted ~-at 30,000 psi at room temperature. Pieces were then cut from the resulting cold compacted blank and sintered at 1700 degrees Centigrade for one hourl in one atmosphere argon followed by hot isostatic pressing at 1600 degrees Centigrade for one hour in 17,000 psi argon. The resulting samples were greater than 99 percent dense (i.e., fully dense). As described in the prior examples, samples were then prepared for physical i! ~
`~35 and mechanical testing and ground into indexable cutting inserts. I~ was determined that the samples contained about 6.6 v/o tetragonal zirconia. It is 1 ~
:

1 3~2 1 06 estimated that material processed in this manner has a zirconia particle size of about 5 ~m, or less. Cutting inserts of the style described in Table 3 were tested under the conditions used in Table 3. Cutting edge life times of 14.4 (DN failure) and 18.9 (FW ~ CH
failure) minutes were obtained.
It is believed that cutting edge lifetime may be extended or made more uniform if the cutting edge is honed and/or the insert surface is lapped or polished to remove surface material containing a higher percentage of monoclinic and a lower percentage of tetragonal zirconia than is characteristic of the bulk of the material (i.e., a polished surface). It is known that grinding stresses create a surface layer in which a portion of the metastable tetragonal zirconia has been transformed to monoclinic zirconia. It is preferred that at least those surface areas of the insert which will encounter high temperatures during --use have the maximum amount of tetragonal zirconia available for high temperature transformation.
While the foregoing examples have shown the value of the present invention in cutting soft steels, it should be understood that cutting inserts in ~-~ accordance with the present invention may be used for z5 machining other materials by optimizing the composition ` to provide best results. For example, for high speed `~ rough turning of nickel base super alloys, compositions containing about 25 to 37.5 v/o silicon carbide whiskers may be most appropriate.
I 30 ! ' Other embodiments of the invention will be' apparent to those skilled in the art ~rom a consideration of this specification or practice o~ the invention disclosed herein. It is intended that the ;~
specification and examples be considered as exemplary A
~,. . :

: -17- 1 3 ~ 2 1 0 6 K-0933Y

only, with the true scope and spirit of the invention being indicated by the following claims. -,, '''',':
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Claims (15)

1. A metalcutting insert comprising:
a rake face;
a flank face;
a cutting edge at a juncture of said rake face and said flank face;
said cutting insert having an alumina based ceramic composition consisting essentially of:
about 1.5 to 37.5 v/o silicon carbide whiskers;
about 5 to 17.5 v/o zirconia;
a residue of a magnesia addition added in the amount of about .03 to 3 v/o;
alumina forming essentially the remainder of said composition;
wherein said silicon carbide whiskers, said zirconia and said residue of said magnesia addition are substantially homogeneously dispersed in a matrix formed of said alumina; and wherein at least about 2.0 v/o of said ceramic composition is tetragonal zirconia.

2. The metalcutting insert according to Claims 1 wherein at least about 4.0 v/o of said composition is tetragonal zirconia.

3. The metalcutting insert according to Claim 1 wherein at least 6 v/o of said composition is tetragonal zirconia.

4. The metalcutting insert according to Claim 1 containing about 0.03 to 2 v/o of said residue of said magnesia addition.

5. The metalcutting insert according to Claim 1 containing about 0.04 to 1.0 v/o of said residue of said magnesia addition.

6. The metalcutting insert according to Claim 1 containing about 7.5 to 17.5 v/o zirconia.

7. The metalcutting insert according to Claim 1 containing 10.0 to 15.0 v/o zirconia.

8. The metalcutting insert according to Claim 1 wherein said zirconia has an average particle size of less than 2 microns.

9. The metalcutting insert according to Claim 1 wherein said zirconia has an average particle size of less than or equal to one micron.

10. A metalcutting insert comprising:
a rake face;
a flank face;
a cutting edge at a juncture of said rake face and said flank face;
and said cutting insert having an alumina based ceramic composition consisting of -about 1.5 - 37.5 v/o SiCw, about 5 to 17.5 v/o ZrO2, a residue of a magnesia addition added in an amount of about .03 to 3 v/o, an alumina matrix wherein said silicon carbide whiskers, said zirconia and said residue of said magnesium oxide addition are substantially homogeneously distributed, and wherein tetragonal zirconia forms at least 2 v/o of said alumina based ceramic composition.

11. The metalcutting insert according to Claim 10 containing at least 4 v/o tetragonal zirconia.

12. The metalcutting insert according to Claim 10 containing at least 6 v/o tetragonal zirconia.

13. The metalcutting insert according to Claim 10 containing at least 8 v/o tetragonal zirconia.

14. The metalcutting insert according to Claim 10 wherein said zirconia has an average particle size no greater than 5 µm.

15. The metalcutting insert according to Claim 10 wherein said zirconia has an average particle size of less than 2 µm.