CN101209923B - 用于要求良好的抗缺口磨损性的应用的陶瓷材料及其制成的切削工具 - Google Patents
用于要求良好的抗缺口磨损性的应用的陶瓷材料及其制成的切削工具 Download PDFInfo
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- 238000005520 cutting process Methods 0.000 title claims abstract description 15
- 229910010293 ceramic material Inorganic materials 0.000 title abstract description 5
- 229910052727 yttrium Inorganic materials 0.000 claims abstract description 9
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 claims abstract description 5
- 239000000463 material Substances 0.000 claims description 36
- 229910052751 metal Inorganic materials 0.000 claims description 11
- 239000002184 metal Substances 0.000 claims description 11
- 229910052799 carbon Inorganic materials 0.000 claims description 7
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 6
- 229910052782 aluminium Inorganic materials 0.000 claims description 6
- 229910052757 nitrogen Inorganic materials 0.000 claims description 6
- 238000012545 processing Methods 0.000 claims description 6
- 239000011248 coating agent Substances 0.000 claims description 3
- 238000000576 coating method Methods 0.000 claims description 3
- 238000002425 crystallisation Methods 0.000 claims description 3
- 230000008025 crystallization Effects 0.000 claims description 3
- 238000005259 measurement Methods 0.000 claims description 3
- 229910017488 Cu K Inorganic materials 0.000 claims description 2
- 229910017541 Cu-K Inorganic materials 0.000 claims description 2
- 230000015572 biosynthetic process Effects 0.000 claims description 2
- 229910000601 superalloy Inorganic materials 0.000 abstract description 6
- 238000003754 machining Methods 0.000 abstract description 3
- 238000012360 testing method Methods 0.000 description 21
- 238000005245 sintering Methods 0.000 description 16
- 229910052581 Si3N4 Inorganic materials 0.000 description 7
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 7
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 6
- 239000000203 mixture Substances 0.000 description 6
- 238000012986 modification Methods 0.000 description 6
- 230000004048 modification Effects 0.000 description 6
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- 229910000816 inconels 718 Inorganic materials 0.000 description 4
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- 239000000843 powder Substances 0.000 description 4
- 239000003507 refrigerant Substances 0.000 description 4
- -1 silicon aluminum oxygen nitrogen Chemical compound 0.000 description 4
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 3
- 239000000919 ceramic Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 3
- 239000001301 oxygen Substances 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
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- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
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- 239000000654 additive Substances 0.000 description 2
- 239000004411 aluminium Substances 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 230000003321 amplification Effects 0.000 description 2
- 229910017052 cobalt Inorganic materials 0.000 description 2
- 239000010941 cobalt Substances 0.000 description 2
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 2
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- 238000005088 metallography Methods 0.000 description 2
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- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- 239000007858 starting material Substances 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 239000003643 water by type Substances 0.000 description 2
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- 229910052688 Gadolinium Inorganic materials 0.000 description 1
- 229910052765 Lutetium Inorganic materials 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- 229910002795 Si–Al–O–N Inorganic materials 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000002178 crystalline material Substances 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
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- 238000005516 engineering process Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000011012 grey crystal Substances 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 229910052761 rare earth metal Inorganic materials 0.000 description 1
- 150000002910 rare earth metals Chemical class 0.000 description 1
- 229910000753 refractory alloy Inorganic materials 0.000 description 1
- 229910052706 scandium Inorganic materials 0.000 description 1
- 239000002210 silicon-based material Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 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
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Abstract
本发明涉及一种陶瓷材料，由β-塞隆(Si6-zAlzOzN)、多型体12H、晶间无定形或者部分结晶相构成，并且含有钇，其中z值为0.7-＜1.5。这种陶瓷材料可用作切削刀片，用以加工超耐热合金，并且它具有良好的抗缺口性、可接受的后刀面磨损性和足够的韧性。
Description
技术领域
本发明涉及一种适合于加工镍基和钴基材料的陶瓷氮化硅基的材料，这种材料有时被称为具有良好的抗缺口磨损性、可接受的后刀面磨损性和足够的韧性的超耐热合金(HRSA)。
背景技术
由于陶瓷材料较高的热硬性，因此用于切削刀具应用的陶瓷材料适合于加工在高温下具有较高硬度、高拉伸强度以及较低热扩散性的工件材料，并且对于有时称为超耐热合金(HRSA)的自硬化材料(诸如，例如一些类型的镍基和钴基的材料)而言特别是如此。
用于切削刀具的很多氮化硅基材料都是利用氧化铝(Al2O3)作为烧结助剂进行制造。铝和氧具有分别取代氮化硅晶体结构中的硅和氮的能力，从而形成所谓的塞隆(硅铝氧氮)陶瓷，这种陶瓷由Si-Al-O-N构成，有时还利用阳离子Men+进行稳定，其中Me可以从大量的(稀土)金属和镧系元素中选择，这些元素具有适当的离子半径例如Y、Yb、Dy、Lu、Li、Ca、Mg、Sc等。
已经检测到了很多塞隆相，并且已经对其进行了表征，例如参见Izhevskiv V A，Genova L A，Bressiani J C和Aldinger F的文章“Progressin SiAlON ceramics”(J.Eur.Ceram.Soc.20，2275-2295(2000))，但是切削刀具材料中所用的主要相仍然是α-塞隆相，RxSi12-(m+n)Al(m+n)OnN(16-n)(1.0＜m＜2.7；n＜1.2)，其中R是离子半径
的上述金属或者镧系元素中的一种，和β-塞隆：Si6-zAlzOzN8-z(0＜z＜4.2)。
在烧结时，所用的原材料，通常为氮化硅、氧化铝和AlN或者一些塞隆“多相”(或“多型体”)，例如12H、21R等的混合物，与金属或镧系元素的氧化物，一起形成了过渡熔体，α和β-塞隆相，并且可能是其它相，例如(如果Y用作上述的金属离子R的话)YAG、黄长石、B相、12H等从过渡熔体中结晶出来。在烧结之后，在晶粒之间保留了晶间相。所产生的晶间相的量受到所用的原材料的成分以及烧结条件的影响。
除了稳定α-塞隆相，金属离子还用作在烧结时形成塞隆晶体的催化剂，并且促进通常呈β相的细长塞隆晶粒的形成，但是也产生了α-塞隆相的细长晶粒，参见Fang-Fang X、Shu-Lin W、Nordberg L-O和
T的文章“Nucleation and Growth of the Elongated α-SiAlON”(J.Eur.Ceram.Soc.17(13)1631-1638(1997))。还显然的是，所用的金属离子的选择影响无定形相的性质，参见Fang-Fang X、Shu-Lin W、Nordberg L-O和
T的文章“Nucleation and Growth of theElongated α-SiAlON”(J.Eur.Ceram.Soc.17(13)1631-1638(1997))；Sun E Y、Becher P F、Plucknett K P、Hsueh C-H、Alexander K B和Waters S B的文章“Microstructural Design of Silicon Nitride withImproved Fracture Toughness II：Effects of Yttria and Alumina Additives”(J.Am.Ceram.Soc.81(11)2831-2840(1998))；Hong Z L、Yoshida H、Ikuhara Y、Sakuma T、Nishimura T和Mitomo M的文章“The effect ofadditives on sintering behavior and strength retention in silicon nitridewith RE-disilicate”(J.Eur.Ceram.Soc.22，527-534(2002))；BecherP F、Waters S B、Westmoreland C G、Riester L的文章“CompositionalEffects on the Properties of Si-Al-RE-Based Oxynitride Glasses(RE＝La、Nd、Gd、Y or Lu)”(J.Am.Ceram.Soc.85(4)，897-902(2002))。β-塞隆相Si6-zAlzOzN8-z中的z值影响烧结材料中的硬度、韧性和晶粒尺寸分布，参见
T、Nygren M的文章“SiAlON ceramics”(J.Am.Ceram.Soc.75(2)，259-276(1992))。Z值涉及的是在Si3N4晶格中溶解的Al和O的量。可从开始的材料的成分计算出理论z值。可利用X射线衍射分析测量出在烧结之后的β-塞隆相的实际z值。测得的z值总是稍微低于计算出的z值，这是因为晶间相含有比β-塞隆相更多的氧和铝。
GB-A-2157282公开了一系列的适合用于金属切削刀具的塞隆材料，这些材料具有和不具有α-塞隆、耐熔添料，例如TiN和SiC，具有或者不具有晶体AlN等，但是总是含有“多型体”塞隆相。
US5370716公开了一种用于高温合金和铸铁的高速加工的切削刀具的陶瓷材料，其组分为β-塞隆(Si6-zAlzOzN8-z，其中1＜z＜3)和晶间相。
US5965471公开了一种用于耐热合金的高速加工的烧结陶瓷材料，这种材料包括塞隆晶粒和0.2-20v/o的晶间相。至少80v/o的所述塞隆相为具有1-1.5的z值的β-塞隆。这种陶瓷材料具有高于1530的维氏硬度HV1，并且它通过气压烧结而被生产出来。
发明内容
本发明的目的在于提供一种用于加工金属、优选为超耐热合金的、具有最优成分的金属切削刀具的氮化硅基陶瓷材料，它具有良好的耐缺口磨损性、可接受的后刀面磨损性以及足够的韧性。
本发明的一个方面提供了一种陶瓷材料，包括β-塞隆Si6-zAlzOzN、多型体12H、晶间无定形或者部分结晶相，并且含有钇，其特征在于：
-晶间相的量，作为在SEM图片中属于晶间相的面积相对于图片的总面积测量的，在5和15％之间，
-z值为0.7-＜1.5，
-多型体12H的量，作为在34°的2Θ值时，在Cu-K αx射线衍射图中12H的峰值高度与在33°的2Θ值时，在同一衍射图中β-赛隆的峰值高度之间的比值测量的，在2和20％之间，并且
-钇的含量为3.5-5wt％。
附图说明
图1示出根据本发明的塞隆材料的X射线衍射图案，其中β指的是β塞隆、12H为多型体12H(6AlN·SiO2)，并且Si标出与作为内部标准添加的硅的峰值；
图2是根据本发明的塞隆材料的背向散射模式下的放大4000倍的SEM(扫描电子显微镜)显微照片，其中灰色晶粒为β-塞隆，或者在极少数情形中为12H多型体，并且较亮区域为晶间相。
具体实施方式
本发明提供一种基于β-塞隆(Si6-zAlzOzN)、多型体12H、晶间无定形或者部分结晶相，并且含有3.5-5wt％、优选为3.9-4.5wt-％的钇的陶瓷材料。β-塞隆相具有0.7-＜1.5的z值。晶间相的量在5和15％之间。考虑到背景，多型体12H的量，如在34°(a)的2Θ值时，CuKα峰在x射线衍射图中的峰值高度与在33°(b)的2Θ值时，β-塞隆峰在同一衍射图中的峰值高度之间的比值测量的，，在2和20％之间。另外，这种材料可含有重量百分比达3％的YAG、B相和/或黄长石。
这种材料特别有用于加工超耐热合金(HRSA)的切削刀片。这种切削刀片可具有TiN、Ti(C，N)、Al2O3或者(Ti，Al)N形成的或者其组合形成的涂层。
根据本发明的塞隆材料由粉末冶金方法，例如碾磨、压制和烧结制造出来。将适当比例的氮化硅、氧化铝、氧化钇和氮化铝或者多相体21R粉末碾磨，并压制为刀片坯体。将刀片坯体置于烧结托盘上，而不是嵌入粉末基床中，并且将其单独地熔化，并且然后在气压烧结炉中烧结。烧结最后阶段应当在氮气压力下，在1700-1900℃的温度下进行。
在烧结之后，将坯体研磨成具有期望形状和尺寸的、用于金属切削的刀片。如本领域已知的，这种刀片可选地具有TiN、Ti(C，N)、Al2O3或者(Ti，Al)N或者其任意组合形成的涂层。
在本发明的一个示例性实施例中，z值为0.7-1.3，优选为0.7-＜1，并且12H多型体的量在5和20％之间，优选为6-15％。
在本发明的一个示例性实施例中，z值为1.2-＜1.5，优选为1.25-＜1.45，并且12H多型体的量在2和15％之间，优选为2-12％。
实例
使用塞隆碾磨介质，在水中对根据表1a中的成分的粉末原材料B、C、F和H(除了材料E和G)进行碾磨，它们为可商用的塞隆切削刀具。组分C和H具有相同的原材料成分，但是碾磨程度不同。组分H经受更加强烈的碾磨，这增加了浆液的氧含量。将有机粘结剂混合到浆液中，然后通过喷射干燥，使浆液形成颗粒。
将粉末单轴地冷压，以形成坯体，然后将坯体在650℃的温度下熔化。然后，在1810℃的最大烧结温度下，在氮气压力下烧结熔化的坯体。对烧结体进行研磨，形成ISO RPGX120700T01020型刀片。
关于孔隙度，利用金相学方法分析材料。X射线衍射被用于确定z值，并且12H多型体的量被确定为在34°的2θ角度时，12H的CuKαx射线衍射峰的高度与在33°时，β-塞隆峰的高度的比值，见图1。
图2是塞隆材料C的背向散射模式下的放大4000倍的SEM(扫描电子显微镜)显微照片。灰色区域为β-塞隆和12H多型体，白色区域为晶间相。相对于图片的总面积，如属于晶间相的面积测量的，晶间相的量为10％。
表1a组分，wt-％原材料
| 材料 | Si3N4 | Al2O3 | 21R-F | Y2O3 | TiN |
| B | 58.35 | 7.90 | 14.54 | 4.24 | 16.3 |
| C | 68.62 | 9.28 | 17.11 | 4.99 | 0 |
| E | N/A | N/A | N/A | (7％Yb) | 0 |
| F | 68.86 | 15 | 10.69 | 4.99 | 0 |
| G | N/A | N/A | N/A | N/A | 0 |
| H | 68.62 | 9.28 | 17.1l | 4.99 | 0 |
表1b 组分和性质，烧结材料
1)在34°的2Θ值时，12H峰在x射线衍射图中的高度与在33°的2Θ值时，β-塞隆峰在同一衍射图中的高度的比值测得的。
2)根据孔隙度的金相学确定的ISO 4505标准。
3)在SEM图片中属于晶间相的面积与图片总面积比值测得的。
4)因为不能定量地测量出12H的百分比，因此不能确定β-塞隆的比例。
5)可由X射线衍射方法探测到的，在试样中结晶材料的比例表达的。
实例l
使用225m/min的速度、0.1mm/转的进给和2.5mm的切削深度，在Inconel 718中进行纵向车削操作，对根据表1中的组分B、C和F的刀片进行测试。使用了冷却剂。在几个测试循环中运行刀片，其中，一个测试循环相当于30秒的加工时间。进行了两次测试运行，每次利用一套新的刀片，并且记录每个刀片直至有lmm的缺口磨损或者0.5mm的后刀面磨损深度(VB)时所承受的循环数目。作为两次测试运行的平均值的所实现的寿命(按分钟计)示于表2中。变型C显示出在抗后刀面磨损和缺口磨损方面具有明显的优点。变型B在组分上与变型C基本相同，但是添加了TiN，它显示出显著的缺口磨损，这也是变型B的寿命长度的限制因素。
表2
| 材料 | 平均寿命长度(min) |
| B | 1.5 |
| C | 3.5 |
| F | 2.75 |
实例2
使用280m/min的速度、0.2mm/rev的进给和2.5+2.5mm的切削深度，在Inconel 718中进行对台肩的双端面车削操作，对根据表1中的组分B、C、F和G的刀片进行测试。使用了冷却剂。在几个测试循环中运行刀片，其中，一个测试循环相当于所述的端面车削操作。进行三次测试运行，每次利用一套新的刀片。记录每个刀片直至出现刀刃断裂或者1.0mm或更大的后刀面磨损深度(VB)时所承受的循环数目。作为所有三次测试运行的平均值的结果示于表3中。材料C再次地，以及具有组分H的材料在测试材料中表现得最好。
表3
| 材料 | 平均寿命长度(循环数) |
| B | 6.3 |
| C | 13.7 |
| F | 7 |
| G | 9.7 |
| H | 15.3 |
实例3
使用250m/min的速度、0.2mm/rev的进给和2.5+2.5mm的切削深度，在Inconel 718中对台肩进行双端面车削操作，对根据表1中的组分B、C、F和G的刀片进行测试。使用了冷却剂。在测试循环中运行刀片，其中，一个测试循环相当于所述的端面车削操作。进行三次测试运行，每次利用一套新的刀片。记录每个刀片直至出现切削刃断裂或者1.0mm或更大的后刀面磨损深度(VB)时所承受的循环数目。作为所有三次测试运行的平均值的结果示于表4中。
材料C，具有0.9的z值的β-塞隆具有非常接近材料E的性能，材料E是商业可获得的、具有大约0.6的z值的α/β塞隆，一般预期材料E具有比材料C显著更高的韧性
表4
| 材料 | 平均寿命长度(循环数) |
| C | 9.7 |
| E | 10 |
| F | 6 |
| G | 8.7 |
实例4
使用225m/min的速度、0.124mm/rev的进给和1.5mm的切削深度，在Inconel 718中进行纵向车削操作，对根据表1中的组分C和E的刀片进行测试。使用了冷却剂。在测试循环中运行刀片，其中，一个测试循环相当于30秒的加工时间。进行三次测试运行，每次利用一套新的刀片，并且记录每个刀片直至出现0.5mm的缺口磨损长度或者后刀面磨损深度(VB)时所承受的循环数目。作为测试运行的平均值的结果示于表5中。变型C显示出比变型E更长的寿命。
表5
| 材料 | 平均寿命长度(min) |
| C | 3.75 |
| E | 3.2 |
Claims (6)
1.一种陶瓷材料，包括β-塞隆Si6-zAlzOzN、多型体12H、晶间无定形或者部分结晶相，并且含有钇，其特征在于：
-晶间相的量，作为在SEM图片中属于晶间相的面积相对于图片的总面积测量的，在5和15％之间，
-z值为0.7-＜1.5，
-多型体12H的量，作为在34°的2Θ值时，在Cu-K αx射线衍射图中12H的峰值高度与在33°的2Θ值时，在同一衍射图中β-赛隆的峰值高度之间的比值测量的，在2和20％之间，并且
-钇的含量为3.5-5wt％。
2.根据权利要求1的陶瓷材料，其中钇的含量为3.9-4.5wt-％。
3.根据权利要求1的陶瓷材料，其中z值为0.7-1.3，并且12H多型体的量在5和20％之间。
4.根据权利要求1的陶瓷材料，其中z值为1.2-＜1.5，并且12H多型体的量在2和15％之间。
5.一种用于成屑金属加工的切削刀片，由根据权利要求1-4所述的材料制成。
6.根据权利要求5的切削刀片，具有由TiN、Ti(C，N)、Al2O3或者(Ti，Al)N形成或者其任意组合形成的涂层。
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| KR20080061319A (ko) | 2008-07-02 |
| CN101209923A (zh) | 2008-07-02 |
| SE530251C8 (sv) | 2008-05-06 |
| IL188211A0 (en) | 2009-02-11 |
| US20080167174A1 (en) | 2008-07-10 |
| SE530251C2 (sv) | 2008-04-08 |
| JP2008162882A (ja) | 2008-07-17 |
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