JP5603954B2 - 超硬要素、その使用方法及びその製造方法 - Google Patents
超硬要素、その使用方法及びその製造方法 Download PDFInfo
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- JP5603954B2 JP5603954B2 JP2012552407A JP2012552407A JP5603954B2 JP 5603954 B2 JP5603954 B2 JP 5603954B2 JP 2012552407 A JP2012552407 A JP 2012552407A JP 2012552407 A JP2012552407 A JP 2012552407A JP 5603954 B2 JP5603954 B2 JP 5603954B2
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- cemented carbide
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- carbide
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- 238000000034 method Methods 0.000 title claims description 10
- 238000004519 manufacturing process Methods 0.000 title claims description 9
- 239000000463 material Substances 0.000 claims description 79
- 239000011159 matrix material Substances 0.000 claims description 37
- 229910000601 superalloy Inorganic materials 0.000 claims description 22
- 239000000843 powder Substances 0.000 claims description 21
- 238000002156 mixing Methods 0.000 claims description 17
- 239000002002 slurry Substances 0.000 claims description 17
- 238000003754 machining Methods 0.000 claims description 13
- 239000011230 binding agent Substances 0.000 claims description 11
- 238000005520 cutting process Methods 0.000 claims description 11
- 239000013078 crystal Substances 0.000 claims description 10
- 239000008187 granular material Substances 0.000 claims description 10
- 239000002243 precursor Substances 0.000 claims description 8
- 238000005245 sintering Methods 0.000 claims description 8
- 239000000203 mixture Substances 0.000 claims description 5
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 4
- 229910052804 chromium Inorganic materials 0.000 claims description 3
- 238000001035 drying Methods 0.000 claims description 3
- 229910052759 nickel Inorganic materials 0.000 claims description 3
- 238000012545 processing Methods 0.000 claims description 3
- 239000007788 liquid Substances 0.000 claims description 2
- 239000002904 solvent Substances 0.000 claims description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 12
- 229910010271 silicon carbide Inorganic materials 0.000 description 11
- 239000000758 substrate Substances 0.000 description 10
- 239000010936 titanium Substances 0.000 description 9
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 7
- 229910010293 ceramic material Inorganic materials 0.000 description 7
- 229910052719 titanium Inorganic materials 0.000 description 7
- 229910052582 BN Inorganic materials 0.000 description 6
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 6
- 229910018487 Ni—Cr Inorganic materials 0.000 description 6
- 150000001875 compounds Chemical class 0.000 description 5
- 238000012360 testing method Methods 0.000 description 5
- 239000002202 Polyethylene glycol Substances 0.000 description 4
- 239000000919 ceramic Substances 0.000 description 4
- 229920001223 polyethylene glycol Polymers 0.000 description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 3
- 229910001026 inconel Inorganic materials 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 229910052718 tin Inorganic materials 0.000 description 3
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- NRTOMJZYCJJWKI-UHFFFAOYSA-N Titanium nitride Chemical compound [Ti]#N NRTOMJZYCJJWKI-UHFFFAOYSA-N 0.000 description 2
- 238000005219 brazing Methods 0.000 description 2
- 239000002775 capsule Substances 0.000 description 2
- 239000011651 chromium Substances 0.000 description 2
- 239000010432 diamond Substances 0.000 description 2
- 229910003460 diamond Inorganic materials 0.000 description 2
- 239000002270 dispersing agent Substances 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 239000000725 suspension Substances 0.000 description 2
- 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 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910001030 Iron–nickel alloy Inorganic materials 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 238000005275 alloying Methods 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
- 238000013459 approach Methods 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000011195 cermet Substances 0.000 description 1
- VNNRSPGTAMTISX-UHFFFAOYSA-N chromium nickel Chemical compound [Cr].[Ni] VNNRSPGTAMTISX-UHFFFAOYSA-N 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 239000002826 coolant Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000001493 electron microscopy Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- WHJFNYXPKGDKBB-UHFFFAOYSA-N hafnium;methane Chemical compound C.[Hf] WHJFNYXPKGDKBB-UHFFFAOYSA-N 0.000 description 1
- 238000003698 laser cutting Methods 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 231100000241 scar Toxicity 0.000 description 1
- 238000005482 strain hardening Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
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Description
本発明の実施形態は、超硬要素(elements)、詳しくは、排他的ではないが、超合金材料を機械加工するための超硬要素、その製造方法及びその使用方法に関する。
第2の局面から見ると、cBN結晶粒などの超硬材料の結晶粒を含んでなるPCBNなどの超硬多相材料と、マトリックス内に分散したセラミック材料のウィスカーとを含んでなり、超硬結晶粒の含量が少なくとも約30質量パーセントである超硬要素の使用方法であって、超硬多相材料を含む工作機械を準備する工程と、この工作機械を用いて、超合金を含むワークピース体を機械加工する工程とを含む方法を提供することができる。
第3の局面から見ると、(超硬)PCBN要素の製造方法であって、cBNの結晶粒を、液体媒体中のマトリックス用構成材料を含有する結晶粒と混ぜ合わせてスラリーを形成する工程;このスラリーをせん断混合する工程;スラリーを乾燥させて顆粒を形成し、この顆粒を混ぜ合わせて圧粉体(green body)を形成し、この圧粉体を焼結させて焼結体を形成し、この焼結体を加工して工作機械用超硬要素を形成する工程を含む方法を提供することができる。
(図面の簡単な紹介)
工作機械用の材料及び超硬要素の非限定配置について添付図面を参照して説明する。
以下に、本明細書で使用する特定の用語について簡単に説明する。
本明細書では、超硬材料は約25GPaより大きいヴィッカース硬度を有する。多結晶性立方晶窒化ホウ素(PCBN)は、超硬材料の例である。
ウィスカーは、材料の細長いストランド、ファイバー又はフィラメントであり、その長さは実質的に幅より大きい。
PCBN材料は、金属又はセラミック材料を含むマトリックス内に分散した立方晶窒化ホウ素(cBN)の結晶粒を含む。例えば、PCBN材料は、チタン炭窒化物などのTi含有化合物並びに/或いは窒化アルミニウムなどのAl含有化合物、並びに/或いはCo及び/又はWなどの金属含有化合物を含んでなるバインダーマトリックス材料に分散した少なくとも約50又は60体積パーセントのcBN結晶粒を含み得る。PCBN材料のいくつかのバージョン(又は「グレード」)は、少なくとも約80体積パーセント又は少なくとも約85体積パーセントさえのcBN結晶粒を含み得る。
図1に概略を示すように、超硬多相材料10の実例ミクロ構造は、立方晶窒化ホウ素12の結晶粒と、炭化ケイ素などのセラミック材料のウィスカー14を含み、これらはマトリックス16内に分散しており、超硬結晶粒の含量はマトリックスの少なくとも約50質量パーセントであり、ウィスカー14の含量はマトリックスの最大約10質量パーセントである。例えば、ウィスカー14は、約5ミクロン〜約15ミクロンの範囲の平均長と、約0.5ミクロン〜約2ミクロン、又は約1ミクロン〜約2ミクロンの範囲の平均幅を有し得る。
例えば、超硬多相材料は、マトリックス内に分散した超硬材料の結晶粒と、セラミック材料のウィスカーとを含むことができ、超硬結晶粒の含量は、少なくとも約30質量パーセント、少なくとも約35質量パーセント又は少なくとも約50質量パーセントである。他の例では、超硬結晶粒の含量は少なくとも約60質量パーセント又は少なくとも約65質量パーセントである。いくつかの例では、超硬材料の結晶粒はcBNを含むか又はcBNから成り、超硬結晶粒の含量は最大約90質量パーセント、最大約85質量パーセント、又は最大約70質量パーセントである。いくつかの例では、マトリックスは、金属材料、超合金材料、セラミック材料又はサーメット材料を含む。
マトリックスは、チタン炭窒化物及び/又はクロムを含むことができる。他の例では、マトリックスは、PCT特許出願公開第WO2008/072180号及びWO2009/150601号に開示されたバインダー相材料の変形、又は炭素、マンガン、銅、リン、ホウ素、窒素及びスズから選択される1種以上の元素を含むことができる。
いくつかの例では、超硬多相材料は、Tiを含むマトリックス内に分散したcBNの結晶粒及びSiC材料の粒子を含み、超硬結晶粒の含量は、マトリックスの少なくとも50質量パーセントであり、SiCの含量は、マトリックスの最大約10質量パーセント、最大約8質量パーセント、最大約6質量パーセント又はマトリックス最大約5質量パーセントである。
超硬多相材料の製造方法例は、超硬材料の結晶粒をマトリックス用の前駆粉末にブレンドしてベース粉末を形成する工程;複数のセラミックウィスカーを有機バインダー及び溶媒と混ぜ合わせてスラリーを形成する工程;このスラリーをせん断混合する工程;ある量のベース粉末をスラリーに混ぜ合わせる工程;このスラリーを乾燥させて顆粒を作り出す工程;この顆粒を混ぜ合わせて圧粉体を形成し、この圧粉体を焼結させて焼結体を形成する工程を含む。この手法は、ウィスカーとマトリックスの間の優れた結合性をもたらすという局面を有し得る。
特定の超合金材料、詳しくは、非排他的であるが、InconelTMなどのNi-Cr基超合金材料を機械加工するために使用する場合、開示のPCBN材料は、驚くべき長期間の動作寿命をもたらすという局面を有する。動作寿命は、工業規模で商業的に実行可能である超合金の機械加工で超硬多相材料を使うためには十分に長い、ウィスカーの無い超硬多相材料の動作寿命より少なくとも20パーセント又は少なくとも50パーセントさえも長いことがある。開示のPCBN材料は、切削深さが最大約0.5mmであると見込まれる仕上げ作業に特に(排他的ではないが)有用であり得る。
さらなる非限定例をさらに詳細に後述する。
チタン炭窒化物とSiCウィスカーを含むマトリックス内に分散した約60質量パーセントのcBN結晶粒を含んでなるPCBN要素であって、SiCウィスカー含量がマトリックスの約5質量パーセントであるPCBN材料を以下のように調製した。
当技術分野で知られているように、TiN及びAlの粉末を一緒にブレンドし、前反応させてマトリックス用の前駆粉末を形成した。この前駆粉末を摩擦粉砕してから、この粉砕粉末にcBN結晶粒をブレンドしてベース粉末を得た。
水と、PEG(ポリエチレングリコール)バインダーと、懸濁を促す分散剤と、SiCウィスカーとを含むスラリーを調製し、このスラリーをせん断混合に供した。SiCウィスカーは、約10ミクロンの平均長及び約0.7ミクロンの平均幅を有した。次にベース粉末をスラリーに導入し、この混ぜ合わせた材料をさらにせん断混合に供した。混合材料のスラリーを造粒し、乾燥させて顆粒を形成した。顆粒をまとめて圧縮することによって圧粉体を形成し、この圧粉体をコバルト-硬結炭化タングステン基板上に組み立てて焼結前アセンブリを形成した。当技術分野で知られているように、この焼結前アセンブリを超高圧炉用カプセルにし、PCBN用の超高圧の高温焼結サイクルを用いて焼結して、硬結炭化物基板に一体的に結合したPCBN構造を含む超硬多相材料を形成した。
PCBNのミクロ構造を電子顕微鏡によって解析すると、ウィスカーがバインダーマトリックスとよく一体化していることが観察された。
3種の異なるセットの要素を用いて試験を3回繰り返した。対照要素の約4分及びDBC50(登録商標)要素の約2.5分に比し、実施例(すなわち、ウィスカー含有)のPCBNの平均工具寿命は約5.8分であった。
Claims (5)
- バインダーマトリックスと、前記バインダーマトリックス中に分散したcBN結晶粒及びウィスカーとからなる工作機械用の超硬要素の製造方法であって、
TiN及びAlの粉末をまとめてブレンドし、前反応させてバインダーマトリックス用の前駆粉末を形成する工程と、
前記前駆粉末を前記cBN結晶粒及び前記ウィスカーと混合し、混合物を得る工程と、
前記混合物を、少なくとも1250℃、少なくとも5GPaで焼結し、超硬要素を得る工程と、
を含み、
前記ウィスカーは、SiCからなり、
前記ウィスカーの含量は、最大で前記バインダーマトリックスの5質量パーセントであり、
前記ウィスカーは、5ミクロン〜15ミクロンの範囲の平均長及び0.5ミクロン〜2ミクロンの範囲の平均幅を有している
超硬要素の製造方法。 - 超合金材料を含む物体を機械加工するための、請求項1に記載の製造方法により得られた超硬要素の使用方法。
- 前記物体が、Cr及びNiを含有する超合金材料を含む、請求項2に記載の方法。
- 最大0.5mmの切削深さを用いて前記物体を機械加工する、請求項2又は請求項3に記載の方法。
- 請求項1に記載の超硬要素の製造方法であって、
混合物を得る工程は、
前記前駆粉末にcBN結晶粒をブレンドしてベース粉末を得る工程と、
前記ベース粉末を、前記ウィスカーを含む液体溶媒と混ぜ合わせてスラリーを形成する工程と、
前記このスラリーをせん断混合する工程と
前記スラリーを乾燥させて顆粒を形成し、この顆粒を混ぜ合わせて前記混合物として圧粉体を得る工程と、
を含み、
前記超硬要素を得る工程は、
前記圧粉体を焼結させて焼結体を形成し、この焼結体を加工して工作機械用の超硬要素を形成する工程を含む製造方法。
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CN109082611A (zh) * | 2018-09-01 | 2018-12-25 | 芜湖德加智能科技有限公司 | 复合pcbn刀片粘结剂及其制备方法 |
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GB201918892D0 (en) * | 2019-12-19 | 2020-02-05 | Element Six Uk Ltd | Friction stir welding using a PCBN-based tool containing superalloys |
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