CN1204308A - 晶须增强陶瓷切削刀具及其组合物 - Google Patents

晶须增强陶瓷切削刀具及其组合物 Download PDF

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CN1204308A
CN1204308A CN96198917A CN96198917A CN1204308A CN 1204308 A CN1204308 A CN 1204308A CN 96198917 A CN96198917 A CN 96198917A CN 96198917 A CN96198917 A CN 96198917A CN 1204308 A CN1204308 A CN 1204308A
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volume percent
matrix
ceramic
whisker
titanium
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CN1088689C (zh
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P·K·梅罗特拉
W·R·胡斯顿
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Kennametal Inc
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Kennametal Inc
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Abstract

本发明提供了一种由起始组分的混合物烧结制成的陶瓷组合物。所说的组合物包括含有一种或多种数量占基质50体积百分比以上的铪、钼、锆、钽、铌、钒、钨、钛的碳化物、氮化物和碳氮化物及其固溶相的一种基质,所说的基质占该组合物的60～99.8体积百分比。在整个基质内均匀分散有陶瓷晶须,所说的陶瓷晶须占所说的组合物的0.2～40体积百分比。

Description

晶须增强陶瓷切削刀具及其组合物
本发明涉及一种具有晶须增强的陶瓷切削刀具及其组合物。更确切地说，本发明涉及一种具有陶瓷晶须增强的陶瓷切削刀具及其组合物，其中陶瓷基质的至少50％以上体积百分含量为钛、铪、钼、锆、钽、铌、钒和/或钨的碳化物、氮化物和/或碳氮化物。
过去一直有用晶须增强的陶瓷体，例如授权予Wei的美国专利No4,543,345所揭示的陶瓷体。Wei专利揭示了一种用碳化硅晶须增强的氧化铝基质，一种用碳化硅晶须增强的碳化硼基质，一种用碳化硅晶须增强的莫来石基质。根据Wei专利，碳化硅晶须的加入提高了基质的断裂韧性。
Yamagawa等人在特许公报(Japanese Publication)No.63-10758揭示了一种以氧化铝为主成分的陶瓷复合材料。其它成分为5～40重量百分比的TiC和2～40重量百分比的碳化硅晶须。碳化钛和碳化硅晶须的总量不能超过50重量百分比，即，在50重量百分比以下。该专利也说明可含有最高10重量百分比的铝、硅和Ⅳa、Ⅴa、Ⅵa族元素的氧化物、碳化物或氮化物。
Toibana等人发明的美国专利No.4,507,224概述了对作为适宜基质的材料的特定氮化物和碳化物，以及导电粉末，进行SiC纤维增强。SiC纤维的加入量为5～50重量百分比。该专利特别描述了氮化硅、氮化铝、氮化硼、碳化硅、碳化硼和碳化钛的基质。该专利给出了使用氧化铝、氧化锆、氮化硅为基质以及碳化硅纤维的实施例。该专利的目的是制备适于电火花加工的陶瓷部件。在这一方面，该专利说明书表明基体的电阻不能超过10ohm-cm。
Kpochmal的文章“纤维增强陶瓷：综述及其前景评价”(9～16页)揭示了以HfC或ZrC为基质的陶瓷(具有纤维增强)。纤维材料包括钨、钼、钽、硼、碳、碳化硅、碳化硼和氧化铝。
也有用晶须增强的陶瓷切削刀具。Rhodes等人发明的美国专利No.4,789,277揭示了在陶瓷基质中使用陶瓷晶须(含量为2～40体积百分比)例如氧化铝、氮化铝、氧化铍、碳化硼、石墨、碳化硅(优选的)和氮化硅。该陶瓷基质优选地是氧化铝，但也包括掺杂有最高30％的氧化锆、氧化铪和碳化钛的氧化铝。该氧化铝一直为基质的主成分。
Rhodes等人发明的题目为“高密度的增强陶瓷体及其制备方法”的专利申请PCT\US86\00528的目的是无压烧结晶须增强陶瓷体。该专利提出的晶须含量在0.5到21体积百分比。其特定实施例揭示了掺有6.1～29.2体积百分比的SiC晶须的氧化铝基质。
Mehrotra等人发明的标题为“氧化铝-碳化钛-碳化硅组合物”的美国专利No.5,059,564揭示了一种弥散有SiC晶须和TiC相的氧化铝基质。弥散的SiC晶须量为1.0到小于30体积百分比，最优选的范围是2.5～20体积百分比。所含的TiC量为5～40体积百分比，并且优选地含有最高3体积百分比的烧结助剂残余相。
Mehrotra等人发明的标题为“用于加工ⅥB族基材料的ⅣB族硼化物基切削刀具”的美国专利No.5,427,987涉及硼化锆、硼化铪，特别是硼化钛切削刀具。在硼化物粉末中加入W和Co可提高组合物的致密化。
Whitney等人的1969空军报告(Air Force Report)揭示了在ZrN和HfN基质中使用普遍高含量的颗粒增强来制作切削刀具。该报告没有提到晶须能增强这些基质。
Brandt等人发明的美国专利No.5,231,060提出用Ti、Zr、Hf、V、Nb、Ta的氮化物、碳化物和硼化物来增强一种氧化物基基质例如氧化铝，从而制作一种切削刀具。
Suzuki等人发明的美国专利No.5,439,854涉及一种含有40重量百分比以上的TiC和5～40重量百分比的碳化硅晶须(长度等于或小于20微米)的切削刀具。该切削刀具也可含有最高40重量百分比的氧化铝，以及烧结助剂。最高40重量百分比的TiC也可用Ti或Ti-基化合物例如一种氮化物、硼化物或氧化物代替。
下文的表1给出了一些现有技术商业切削刀具的特定物理性质。
                      表1
         一些工业切削刀具的某些物理性质
 切削刀具    HRA  VHN(GPa)[载荷18.5kg]    KIC(E&C)[MPam1/2]
  WG-300    94.6    19.4      6.1
   HC6    94.6    19.4      5.1
   K090    94.8    19.1      4.7
关于这些工业切削刀具，WG-300切削刀具是由Saegertown，Pennsylvania的Greenleaf公司出售的，其组成含有约25体积百分比的SiC晶须，其余为氧化铝。HC6切削刀具是由Farmington Hills,Michigan的NGK Spark Plugs(USA)公司的NTK切削刀具分部出售的，其组成含有约70重量百分比的TiC，其余为氧化铝。K090切削刀具是由Latrobe,Pennsylvania的Kennametal公司出售的，其组成含有约70体积百分比的氧化铝和30重量百分比的TiC。这些组合物的每一种也可含有少量的烧结助剂。
本发明的一个目的是提供一种具有晶须增强的高性能陶瓷切削刀具及其组合物。
本发明的另一个目的是提供一种具有晶须增强的高性能陶瓷切削刀具及其组合物，其中陶瓷基质的约50％的体积百分含量为钛、铪、钼、锆、钽、铌、钒和/或钨的一种或多种碳化物、氮化物和/或碳氮化物。
本发明的再一个目的是提供一种具有晶须增强的高性能陶瓷切削刀具及其组合物，其中陶瓷基质的药50％的体积百分含量为钛、铪、钼、锆、钽、铌、钒和/或钨的一种或多种碳化物、氮化物和/或碳氮化物，并且任选地，该基体进一步含有选自氧化铝、碳化硅或者钛、锆、铪的硼化物中的一种或多种颗粒。
本发明的再一个目的是提供一种具有晶须增强的高性能陶瓷切削刀具及其组合物，其中晶须包括选自氧化铝、碳化硅或者钛、锆、铪的碳化物、氮化物、硼化物或碳氮化物中的一种。
本发明的再一个目的是提供一种具有晶须增强的高性能陶瓷切削刀具及其组合物，其中陶瓷基质的约50％的体积百分含量为钛、铪、钼、锆、钽、铌、钒和/或钨的一种或多种碳化物、氮化物和/或碳氮化物，并且任选地，该基体进一步含有选自氧化铝、碳化硅或者钛、锆、铪的硼化物中的一种或多种颗粒。该晶须包括选自氧化铝，碳化硅，氮化硅，碳化硼，或者钛、锆、铪的碳化物、氮化物、硼化物或碳氮化物，或者锆或铪的氧化物中的一种或多种。
其一种形式是，本发明是由起始组分的混合物的烧结制备的组合物。该组合物包括含有一种或多种数量占基质50体积百分比以上的铪、钼、锆、钽、铌、钒、钛、钨的碳化物、氮化物和/或碳氮化物和它们的固溶相的一种基质。该基质进一步含有因使用数量小于或等于起始组分的1重量百分比的一种或多种烧结助剂作为起始组分而形成的烧结助剂残余相。该基质占该组合物的60～99.8体积百分比。该组合物进一步包括在基质内均匀分散的陶瓷晶须，其中该陶瓷晶须为该组合物的0.2～40体积百分比。
其另一种形式是，本发明是一种包括一个前倾面和一个侧面的陶瓷刀具。在前倾面与侧面的交界处有切削刃。该刀具所含有的陶瓷组合物包括一种含有约45～小于50体积百分比的碳化钛钼和小于约55体积百分比的氧化铝的基质。该基质占陶瓷组合物的约60～约90体积百分比。该组合物进一步包括在基质内均匀分散的陶瓷晶须，其中该陶瓷晶须为该组合物的约2～约35体积百分比。
下面简要描述本发明所包括的附图。
图1是本发明切削刀具特定具体实施方案的一种陶瓷刀片的透视图。
图2是根据本发明与本文的实施例2相应的热压复合材料垂直于热压轴的抛光面的扫描电镜(SEM)二次电子像显微照片(放大倍数5000x)。
图3是根据本发明与本文的实施例4相应的热压复合材料垂直于热压轴的抛光面的扫描电镜(SEM)二次电子像显微照片(放大倍数2000x)。
图4是根据本发明与本文的实施例6相应的热压复合材料垂直于热压轴的抛光面的扫描电镜(SEM)二次电子像显微照片(放大倍数2000x)。
图5是本发明具体实施方案与现有技术组合物的切口磨损与切削时间之间的关系图。
图6是本发明具体实施方案与现有技术组合物的侧面磨损与切削时间之间的关系图。
图7是本发明具体实施方案与现有技术组合物的刀尖磨损与切削时间之间的关系图。
本发明涉及一种陶瓷组合物，特别地，该陶瓷组合物含有陶瓷晶须增强。一般来说，该陶瓷切削刀具包括一种陶瓷基质和一种增强该基质的陶瓷晶须。基质与晶须的组合形成了基体(substrate)。该基体可涂敷有一种硬质材料。这种硬质材料的例子有氧化铝、碳化钛、氮化钛、碳氮化钛、氮化钛铝、立方氮化硼和金刚石以及他们的组合。施加涂敷的工艺可以是化学气相沉积(CVD)(参见Mehrotra等人发明的标题为“涂敷有氧化铝的碳化硅晶须-氧化铝组合物”的美国专利No.4,801,510)或物理气相沉积(PVD)(参见Jindal等人发明的标题为“在不导电基体上物理气相沉积氮化钛”的美国专利No.5,264,297)或者是一种某些层用PVD涂敷、某些层用CVD涂敷的程序(参见Santhanam等人发明的标题为“涂敷切削刀具”的美国专利No.5,232,318)。具有高含量的碳化钛或碳氮化钛—即至少25～30体积百分比的碳化钛或碳氮化钛—的基体的导电程度使得它们尤其适用于PVD涂敷和EDM加工。
本发明的特定基质包括选自钛、铪、钼、锆、钽、铌、钒和/或钨中的一种或多种的碳化物、碳氮化物和/或氮化物以便该组分占基质的约50体积百分比或以上。
该碳化物、氮化物、碳氮化物的优选含量在基质的50体积百分比以上的原因是，这样可得到更高的硬度和更高的断裂韧性。关于这一点，当该碳化物、氮化物、碳氮化物组分在基质的50体积百分比以上时，断裂韧性大于或等于6.3MPam1/2KIC，更优选地大于或等于6.6MPam1/2KIC，并且硬度大于或等于94.7Rockwell A。高硬度和高断裂韧性的组合使得这些组合物适于制作切削刀具、轴承、密封环、磨擦板和喷嘴。
另外，该基质可包括碳化硅、硼化钛、硼化锆、硼化铬、硼化铪、氧化铝、氧化锆和氧化铪的颗粒以及烧结助剂残余物。烧结助剂的优选含量是小于或等于1重量百分比，烧结助剂的更优选含量是小于或等于0.5重量百分比。优选的烧结助剂包括氧化钇、氧化镁和氧化锆，它们或者单独使用或者合并使用。
该基质占整个陶瓷切削刀具组合物的60～99.8体积百分比。
对于陶瓷晶须，这些晶须选自下述材料的任意种：碳化硅、碳化钛、碳氮化钛、氮化钛、硼化钛、碳化锆、碳氮化锆、氮化锆、硼化锆、碳化铪、氮化铪、碳氮化铪、硼化铪、氧化铝、氮化硅和碳化硼。该陶瓷晶须占整个陶瓷切削刀具组合物的0.2～40体积百分比。
为了使本发明中的断裂韧性最大化，优选地用选自由Al2O3、Si3N4、TiB2、SiC、TiC和B4C组成的族的一种或多种晶须增强的ⅣB族(钛、铪或锆)氮化物或碳氮化物基基质，更优选地一种氮化钛或碳氮化钛基基质。该TiC、TiB2、SiC或B4C晶须对氮化钛或碳氮化钛基基质提供最大的断裂韧性。
参阅图1和特定具体实施方案的几何形状，图1描述了一种一般标记作10的切削刀具。切削刀具10有一个前倾面12和一个侧面14。前倾面和侧面相交形成切削刃16。该特定形状，根据美国关于切削刀具索引刀片鉴定系统(American National Standard for Cutting Tools-Indexable Inserts-Identification System)ANSI B212.4-1986(切削刃制备：0.002-0.004英寸x20°倒角)的国家标准，是具有T棱面的SNGN-453T型切削刀片。可以使用其它型号的切削刀片和切削刃制备，它们被认为在本发明的范围内。
如下文的实施例所述，符合上述定义的陶瓷切削刀具具有优异的密度、硬度和断裂韧性。这些性能提供了优异的切削刀具，特别是对于高速加工钢、铸铁和镍基高温合金。
在与耐化学磨损性相比更要求耐磨蚀磨损性的加工应用中，优选地用碳化钛基基质。然而，如果与耐磨蚀磨损性相比更要求耐化学磨损性，则优选地用碳化铪基或碳氮化钛基基质。通过对刀片施加硬质涂层例如氮化钛、碳氮化钛、氮化钛铝、碳化钛和氧化铝，也可提高耐化学磨损性。
对于加工镍基高温合金，或者对于要求高硬度和高化学惰性的任何工件，优选地用碳氮化钛(TiCxNy)基基质，其中x大于0但小于0.95并且y+x=1。更优选地，y大于或等于0.5。当x=0时，即氮化钛，硬度可能会降低并且在这些材料的高温制备过程中氮化钛与SiC晶须之间可能发生反应。因此，y应小于0.95。碳氮化钛[Ti(CxNy)]的x和y的另一个范围是y小于0.90且大于或等于0.55并且x+y=1。碳氮化钛[Ti(CxNy)]的x和y的再一个范围是y小于0.75且大于或等于0.6并且x+y=1。任选地，可用碳氮化铪或碳氮化锆代替碳氮化钛。
如下文的表Ⅱ～Ⅳ所述，下面的实施例是本发明的示例并且根据下述方法制备。对于所有的实施例，碳化硅晶须都用超声波在异丙醇中分散1小时。
对于实施例1～7,9和10，碳化硅晶须是由Tokyo,Japan的TokaiCarbon Co.以牌号为Grade No.1提供的。该Tokai晶须的平均长度为20～50微米，平均直径为0.3～1微米。这些Tokai SiC晶须的晶体结构大多是β-碳化硅。
对于实施例11～12，碳化硅晶须是由Greer,South Carolina的Advanced Composite Materials Corporation以牌号为SC-9提供的。该SC-9晶须的平均长度为10～80微米，平均直径为0.6微米。这些SC-9SiC晶须的晶体结构为α-碳化硅。
对于实施例1～7和9～12的制备方法，组分的其它物质在球磨机中用异丙醇混合1小时。经过超声的碳化硅晶须然后与其它组分混合物在球磨机中混合20分钟。然后该混合物过200目筛，在旋转式蒸发器中干燥，再过100目筛。干燥混合物在1750℃～1850℃的温度范围内在氩气气氛下用4500psi的压力单向热压60分钟。所得的产物被研磨成具有一个T棱面的如上所述的SNGN-453T型切削刀片(切削刃制备：002-004英寸×20°倒角)。
如果组分的供应商多于一个，下文的表Ⅱ～Ⅳ中在括号内给出了供应商的表征。对于所有实施例，Y2O3是由Hermann C.Strack BerlinGmbH&Co(KG,P O Box 1229,D-7887 Lauterburg,Baden,Germany)提供的。
下文的表Ⅱ～Ⅳ中由Tokai提供的碳化硅晶须标作“(T)”。由AdvancedComposite Materials Corporation提供的碳化硅晶须标作“(A)”。
对于某些实施例，Al2O3是由Darien,Illinois的NanophaseTechnologies Corporation以牌号为Nanotek Al2O3 Gamma/Delta提供的。在表Ⅱ～Ⅳ中，标记“(N)”表示Al2O3粉末是从Nanophase得到的。该Nanotek Al2O3粉末的BET比表面积为56.2平方米/克。该Al2O3的纯度大于99.9％。所存在的相有δ和γ。对于使用该Nanotek Al2O3粉末的实施例(实施例No.2)，混合物中添加了0.05体积百分比的MgO。该NanotekAl2O3粉末基本上是等轴的。
其余实施例使用的Al2O3是由Ceralox(Vista Chemical Company)在牌号HPA-0.5下提供的几组Al2O3粉末。在表Ⅱ～Ⅳ中，标记“(C)”表示Al2O3粉末是从Ceralox得到的。该Ceralox粉末的BET比表面积为10.0～11.5平方米/克。该Ceralox Al2O3粉末中含有0.05体积百分比的MgO。该Ceralox Al2O3粉末基本上是等轴的。
由New York的Biesterfeld U.S.Inc.,Advanced Materials Department ofNew York提供的TiC的牌号为Furukawa TiC，其BET比表面积为8.52平方米/克。在表Ⅱ中，标记“(F)”表示TiC粉末是Furukawa TiC。该Furukawa TiC粉末基本上是等轴的。
由Macro Division of Kennametal Inc.在牌号Grade A下提供的TiC的BET比表面积为5.9平方米/克。在表Ⅱ中，标记“(M)”表示TiC粉末来自Macro Division of Kennametal。该Macro Divsion TiC粉末基本上是等轴的。
由Macro Division of Kennametal Inc.of Port Coquitlam,BritishColumbia,Canada提供的Ti0.8Mo0.2C固溶体粉末的BET比表面积为4.6平方米/克。该Ti0.8M0.2C固溶体粉末基本上是等轴的。
由Macro Division of Kennametal Inc.提供的碳氮化钛粉末的BET比表面积为5.2平方米/克。该组分的分子式是TiC0.7N0.3。该Macro Division碳氮化钛粉末基本上是等轴的。
下文的表Ⅱ～Ⅳ给出了组合物(以及所指明的供应商)和热压温度。所有组成是以整个组合物的体积百分比形式给出的。对于是基质一部分的那些组分来说，该组分占基质的体积百分比带有括号。对于1～7和9～12的所有实施例，氧化铝组分含有0.05体积百分比的氧化镁。
另外，下文的表Ⅱ～Ⅳ给出了测试结果以确定实施例的下列性能：密度(克/cc)，Rockwell A硬度，Vickers硬度，及由Evans&Charles测得的断裂韧性(MPam1/2)(参见Evans&Charles，“压痕法测量断裂韧性”，J.American Ceramic Society,Vol.59，Nos.7-8,371-372页，载荷为18.5kg)。
                      表Ⅱ实施例Nos.1～3、9、10的TiC-Al2O3-SiC晶须组合物和物理性能
实施例/比较例以及物理性能    实施例1    实施例2    实施例3    实施例9    实施例10
TiC     39.75(F)[53]     39.75(F)[53]    39.75(M)[53]     40(M)[62]     50(M)[59]
TiC0.7N0.3     －     －     －     －     －
Ti0.8Mo0.2C     －     －     －     －     －
Al2O3     35(C)[46.7]     35(N)[46.7]    35(C)[46.7]     24.75(C)[37.7]     34.75(C)[40.7]
Y2O3     0.25[.3]     0.25[.3]    0.25[.3]     0.25[.3]     0.25[.3]
SiCw     25(T)     25(T)    25(T)     35(T)     15(T)
温度(℃)     1750     1750    1775     1800     1800
密度(g/cc)     4.147     4.147     4.137     4.069     4.318
HRA     95.0     95.1    94.9     94.9     94.7
VHN(GPa)(载荷18.5kg)     21.0     20.8    19.7     21.1     20
KIC(E&C)MPam1/2      6.3      6.3     6.6      7.2      6.7
                      表Ⅲ实施例Nos.4、7、11、12的TiC0.7N0.3-Al2O3-SiC晶须组合物和物
                      理性能
实施例/比较例以及物理性能     实施例4      实施例7      实施例11    实施例12
TiC       －       －       －       －
TiC0.7N0.3      39.03[53]       39.75[53]       39.75[53]     39.75[53]
Ti0.8Mo0.2C       －       －       －       －
Al2O3      35.43(C)[47.4]       35(C)[46.7]       35(C)[46.7]     35(C)[46.7]
Y2O3      0.25[.3]      0.25[.3]      0.25[.3]     0.25[.3]
SiCw      25.29(T)       25(T)       25(A)     25(A)
温度(℃)      1800       1800       1800     1850
密度(g/cc)      4.214       4.228       4.223     4.241
HRA      95.0       95.0       94.8     94.9
VHN(GPa)(载荷18.5kg)      20.7       21.1       19.8     20.1
KIC(E&C)MPam1/2       6.3        6.6        7.5      7.5
                      表Ⅳ实施例Nos.5、6的Ti0.8Mo0.2C-Al2O3-SiC晶须组合物和物理性能
实施例/比较例以及物理性能     实施例5     实施例6
TiC       －       －
TiC0.7N0.3       －       －
Ti0.8Mo0.2C      34.7[47.6]      39.75[53]
Al2O3      38(C)[52]      35(C)[46.7]
Y2O3      0.27[.4]      0.25[.3]
SiCw      27.03[T]      25[T]
温度(℃)      1800      1800
密度(g/cc)      4.371      4.473
HRA      95.2      95.0
VHN(GPa)(载荷18.5kg)      20.7      21.3
KIC(E&C)MPam1/2       63       6.5
对这些实施例物理性能的评述表明这些组合物提供了能制备优异切削刀具的物理性能。
例如，参见表Ⅱ中复合材料的物理性能，实施例Nos.1～3和9～10给出了TiC，氧化铝和SiC晶须的组合物，这些组合物的密度范围在4.069g/cc～4.318g/cc。Rockwell A硬度(HRA)范围在94.7～95.1并且Vickers硬度范围在19.7～21.1。断裂韧性KIC(E&C)范围在6.3～7.2MPam1/2。
实施例10与实施例9的比较表明，TiC含量(从40vol.％增加到50vol.％)和氧化铝含量(从24.75vol.％增加到34.75vol.％)的增加以及SiC晶须含量(从35vol.％减少到15vol.％)的减少，结果造成烧结复合材料的密度从4.069g/cc增加到4.318g/cc。
参见表Ⅱ中的所有实施例，硬度指标(Rockwell A硬度and Vickers硬度)没有明显的变化趋势。
实施例No.1与实施例No.2的比较表明，氧化铝粉末的粗细对物理性能没有显著的影响。
仍然参见表Ⅱ中的复合材料，实施例9与实施例Nos.1～3的比较表明，当氧化铝含量降低以及碳化硅晶须含量增加时，断裂韧性(KIC)显著增加。更确切地说，当TiC含量保持不变，氧化铝从约35vol.％降低到25vol.％以及碳化硅晶须含量从约25vol.％增加到35vol.％时，断裂韧性(KIC)从6.3～6.6增加到7.2MPam1/2。
实施例9与实施例10的比较表明，当TiC和氧化铝含量降低、SiC晶须含量增加时，断裂韧性(KIC)从6.7提高到7.2 MPam1/2。
参见表Ⅲ中TiC0.7N0.3-氧化铝-SiC晶须复合材料的物理性能，可见使用Advanced Composite Materials Corporation提供的SC-9碳化硅晶须使TiCN-氧化铝-SiC晶须复合材料的断裂韧性从6.3～6.6增加到7.5MPam1/2。虽然复合材料多少有点类似，但与Tokai碳化硅晶须相比，断裂韧性的增加似乎与SC-9晶须的本质有关。
参见表Ⅳ中的实施例(实施例Nos.5和6)，这些实施例给出了Ti0.8Mo0.2C-SiC晶须复合材料的物理性能，实施例No.5与实施例No.6的比较表明，Ti0.8Mo0.2C减少5体积百分比、氧化铝增加3体积百分比以及SiC晶须增加2体积百分比没有显著影响Ti0.8Mo0.2C-Al2O3-SiC晶须复合材料的性能。
总之从表Ⅰ可见，上述根据本发明的复合材料具有现有技术切削刀具组合物不能比拟的硬度与断裂韧性的综合性能。
图2、3、4是根据本发明组合物实施例的典型显微照片。图2对应于实施例2，其中，最浅色相是氧化铝，灰色相是碳化钛，细长(或最黑色)相是碳化硅晶须。图3对应于实施例4，其中，最浅色相也是氧化铝，最黑色相也是碳化硅晶须，然而灰色相是碳氮化钛。图4对应于实施例6，其中，最浅色相和最黑色相分别是氧化铝和碳化硅晶须，然而灰色相是碳化钛钼。
根据本发明，表Ⅱ中所示实施例1、3、4、6、7的组合物被研磨成SNGN-453T指数切削刀具并用来在车削试验中加工Inconel718(RockwellC硬度38)，车削条件是：切削速度800表面英尺/分，进给量0.006英寸/转，切深0.050英寸，使用冷却剂，导角45度。所用的寿命判据是：侧面磨损(FW)=0.030英寸；最大侧面磨损(MW)=0.040英寸；刀尖磨损(NW)=0.040英寸；切口深(DN)=0.080英寸；月牙洼磨损(CR)=0.004英寸。实验中为了进行比较也使用了同一刀片几何形状的WG-300试样(实施例No.8)。这些实验的结果如下文的表Ⅴ和图5、6、7所示，每一实施例在图5、6、7中由其等同参考数表示。这些结果表明，基质以碳氮化钛或碳化钛钼为基的刀具在上述条件下有最好的切削刃寿命。最快的磨损机理和导致失效的磨损机理是在如表Ⅴ所示的所有材料上的切口深。
表Ⅴ
实施例Nos.1、3、4、6、7和WG-300的刀具寿命与失效方式
实施例  Rep.1(分钟)  Rep.2(分钟)  平均刀具寿命(分钟)  刀具寿命与WG-300的比较值％
    1  5.8DN  1.5DN     3.7     78％
    3  4.3DN  1.3DN     2.8     60％
    4  9.7DN  8.8DN     9.3     197％
    6  7.3DN  6.4DN     6.9     146％
    7  4.7DN  6.9DN     5.8     123％
    8  4.3DN  5.1DN     4.7     100％
然而，根据本发明刀具的耐侧面磨损比所测试的现有技术品牌刀具的相应值低。据认为，通过增加形成基质的碳氮化钛中的氮含量或增加基质所用的碳化钛钼中的钼含量，可以改善耐侧面磨损。通过对由根据本发明组合物制成的切削刀片施加硬质涂层，也可改善根据本发明的耐侧面磨损。优选的硬质涂层包括：通过PVD和/或CVD技术施加的氮化钛、碳氮化钛、氮化钛铝和氧化铝涂层。
所测试的现有技术品牌刀具(实施例No.8/WG-300)的耐侧面磨损似乎比实施例Nos.1、3、4、6、7的相应值好。这可能因为现有技术品牌刀具(实施例No.8/WG-300)中有更高的氧化铝含量。更确切地说，与实施例Nos.1、3、4、6、7的氧化铝含量为约35～约40体积百分比相比，现有技术品牌刀具(实施例No.8/WG-300)中的氧化铝含量为约75体积百分比。通过增大氧化铝的含量或降低所存在的碳化硅晶须的数量并增加一种或多种基质相例如碳氮化钛或氧化铝的数量，可以改善根据本发明刀具的耐侧面磨损。
本文中所引用的所有申请、专利和其它文献包括在本文内作为参考文献。
根据本文中所揭示的本发明的说明或实践，对那些在本领域技术熟练的人来说本发明的其它具体实施方案是显而易见的。本文中的说明和实施例只是为了描述，下文的权利要求书指出了本发明的真正范围和实质。

Claims (31)

1  一种由起始组分的混合物烧结制成的组合物，所说的组合物包括：含有一种或多种数量占基质50体积百分比以上的铪、钼、钨、锆、钽、铌、钒、钛的碳化物、氮化物和碳氮化物及其固溶相的一种基质，所说的基质进一步含有因使用数量小于或等于起始组分的0.5重量百分比的一种或多种烧结助剂作为起始组分而形成的烧结助剂残余相，其中，烧结助剂包括氧化钇、氧化镁和氧化锆中的一种或几种，所说的基质占所说的组合物的60～99.8体积百分比；以及，
在整个基质内均匀分散的陶瓷晶须，所说的陶瓷晶须占所说的组合物的0.2～40体积百分比。
2  根据权利要求1的组合物，其中，所说的陶瓷晶须选自下述材料的一种或几种：氧化铝、碳化硅、碳化硼、氮化硅以及钛、锆、铪的碳化物、氮化物、硼化物和碳氮化物。
3  根据权利要求1的组合物，其中，所说的基质进一步包含选自由下述材料组成的族中的一种或多种的陶瓷颗粒：碳化硅、硼化钛、硼化锆、硼化铪、氧化铝、氧化锆和氧化铪。
4  根据权利要求1的组合物，其中，所说的基质包含50体积百分比以上的碳氮化钛，并且基质的其余部分包含至少40体积百分比的氧化铝。
5  根据权利要求5的组合物，其中，所说的陶瓷晶须包括碳化硅晶须，并且碳化硅晶须占该组合物的约2体积百分比到约35体积百分比。
6  根据权利要求5的组合物，其中，所说的陶瓷晶须包括碳化硅晶须，并且碳化硅晶须占该组合物的约10体积百分比到约30体积百分比。
7  根据权利要求1的组合物，其中，所说的基质包含50体积百分比以上的碳氮化钛，并且基质的其余部分包含至少40体积百分比的氧化铝。
8  根据权利要求1的组合物，其中，所说的基质包含50体积百分比以上的碳化钛钼，并且基质的其余部分包含至少40体积百分比的氧化铝。
9  根据权利要求8的组合物，其中，所说的陶瓷晶须包括碳化硅晶须，并且碳化硅晶须占该组合物的约2体积百分比到约35体积百分比。
10  根据权利要求1的组合物，其中，所说的基质包含50体积百分比以上的碳化钛钼，并且基质的其余部分包含50体积百分比以下的氧化铝。
11  一种陶瓷切削刀具，包括：
一个前倾面；一个侧面；在该前倾面与该侧面的交界处有切削刃；
一种陶瓷组合物，它含有一种或多种数量至少占基质50体积百分比的铪、钼、锆、钽、铌、钒、钨、钛的碳化物、氮化物和碳氮化物及其固溶相的一种基质，所说的基质进一步含有因使用数量小于或等于起始组分的0.5重量百分比的一种或多种烧结助剂作为起始组分而形成的烧结助剂残余相，其中，烧结助剂包括氧化钇、氧化镁和氧化锆中的一种或几种，所说的基质占所说的陶瓷组合物的60～99.8体积百分比；以及，
在整个基质内均匀分散的陶瓷晶须，其中所说的陶瓷晶须占所说的组合物的0.2～40体积百分比。
12  根据权利要求12的陶瓷切削刀具，其中，所说的陶瓷晶须选自下述材料的一种或几种：氧化铝、碳化硅、氮化硅、碳化硼或钛、锆、铪的碳化物、氮化物、硼化物和碳氮化物。
13  根据权利要求12的陶瓷切削刀具，其中，所说的基质进一步包含选自由下述材料组成的族中的一种或多种的陶瓷颗粒：碳化硅、硼化钛、硼化锆、硼化铪、氧化铝、氧化锆和氧化铪。
14  根据权利要求12的陶瓷切削刀具，该刀具进一步在前倾面和侧面上具有涂层。
15  根据权利要求15的陶瓷切削刀具，其中，该涂层包含一层选自下述的材料：氧化铝、TiC、TiN、TiCN和TiAlN。
16  根据权利要求16的陶瓷切削刀具，其中，所说的涂层是通过化学气相沉积施加的。
17  根据权利要求16的陶瓷切削刀具，其中，所说的涂层是通过物理气相沉积施加的。
18  一种由起始组分的混合物烧结制成的陶瓷组合物，其中，所说的陶瓷组合物包括：
含有一种或多种数量占基质50体积百分比以上的氮化钛、碳氮化钛以及铪、钼、铌、钨的碳化物、氮化物和碳氮化物及其固溶相的一种基质，所说的基质占所说的组合物的60～99.8体积百分比；以及，
在整个基质内均匀分散的陶瓷晶须，所说的陶瓷晶须占所说的组合物的0.2～40体积百分比。
19  根据权利要求19的组合物，其中，所说的陶瓷晶须选自下述材料的一种或几种：氧化铝、碳化硅、氮化硅、碳化硼或钛、锆、铪的碳化物、氮化物、硼化物和碳氮化物。
20  根据权利要求19的组合物，其中，所说的基质进一步包含选自由下述材料组成的族中的一种或多种的陶瓷颗粒：碳化硅、硼化钛、硼化锆、硼化铪、硼化铬、氧化铝、氧化锆和氧化铪。
21  根据权利要求19的组合物，其中，所说的基质进一步含有碳化钛和锆、钽、钒的碳化物、碳氮化物及氮化物；所说的基质进一步含有因使用数量小于或等于起始组分的1重量百分比的一种或多种烧结助剂作为起始组分而形成的烧结助剂残余相。
22  根据权利要求22的组合物，其中，所说的基质包含50体积百分比以上的碳化钛，并且基质的其余部分包含至少40体积百分比的氧化铝和烧结助剂残余相。
23  根据权利要求23的组合物，其中，所说的陶瓷晶须包括碳化硅晶须，并且碳化硅晶须占该组合物的约10体积百分比到约40体积百分比。
24  根据权利要求22的组合物，其中，所说的基质包含50体积百分比以上的碳化钛，并且基质的其余部分包含50体积百分比以下的氧化铝和烧结助剂残余相。
25  一种陶瓷切削刀具，包括：
一个前倾面；一个侧面；在该前倾面与该侧面的交界处有切削刃；
一种陶瓷组合物，它含有数量占基质约45～小于50体积百分比的碳化钛钼，小于约55体积百分比的氧化铝，其中，所说的基质占所说的陶瓷组合物的约60～约90体积百分比；以及，
在整个基质内均匀分散的陶瓷晶须，其中所说的陶瓷晶须占所说的组合物的2～35体积百分比。
26  根据权利要求26的陶瓷切削刀具，其中，所说的基质含有在约55体积百分比到大于约50体积百分比的氧化铝。
27  根据权利要求26的陶瓷切削刀具，其中，所说的陶瓷晶须占所说的陶瓷组合物的约10体积百分比到约30体积百分比。
28  根据权利要求1的组合物，其中，一种或多种烧结助剂的数量占所说的起始组分的小于或等于0.3重量百分比。
29  根据权利要求5的组合物，其中，碳氮化钛的分子式为Ti(CxNy)，y小于0.95且大于0.5并且x+y=1。
30  根据权利要求5的组合物，其中，碳氮化钛的分子式为Ti(CxNy)，y小于0.90且大于或等于0.5并且x+y=1。
31  根据权利要求5的组合物，其中，碳氮化钛的分子式为Ti(CxNy)，y小于0.75且大于或等于0.6并且x+y=1。
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