WO2016114190A1 - サーメット、切削工具、及びサーメットの製造方法 - Google Patents
サーメット、切削工具、及びサーメットの製造方法 Download PDFInfo
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- WO2016114190A1 WO2016114190A1 PCT/JP2016/050218 JP2016050218W WO2016114190A1 WO 2016114190 A1 WO2016114190 A1 WO 2016114190A1 JP 2016050218 W JP2016050218 W JP 2016050218W WO 2016114190 A1 WO2016114190 A1 WO 2016114190A1
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- Prior art keywords
- hard phase
- cermet
- hard
- raw material
- particle size
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
- B23B27/14—Cutting tools of which the bits or tips or cutting inserts are of special material
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/05—Mixtures of metal powder with non-metallic powder
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
- C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
- C22C29/04—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbonitrides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
Definitions
- the present invention relates to a cermet suitable for a constituent material of a cutting tool, a cutting tool using the cermet, and a method for manufacturing the cermet.
- the present invention relates to a cermet suitable for a constituent material of a cutting tool having excellent fracture resistance even in a severe cutting environment.
- cermet has been used for the main body (base material) of a cutting tool.
- the cermet is a bonded phase containing a Ti compound such as titanium carbide (TiC), titanium nitride (TiN), and titanium carbonitride (TiCN) as a main hard phase, and an iron group metal element such as cobalt (Co) and nickel (Ni).
- TiC titanium carbide
- TiN titanium nitride
- TiCN titanium carbonitride
- an iron group metal element such as cobalt (Co) and nickel (Ni).
- the cermet is [1] can reduce the amount of W used as a rare resource, [2] has excellent wear resistance, and [3] steel compared to a cemented carbide with tungsten carbide (WC) as the main hard phase.
- WC tungsten carbide
- Patent Literature 1 discloses that the particle size of the hard phase contained in the cermet is sized, and Patent Literature 2 discloses in order to improve the cutting performance by increasing the fracture resistance and wear resistance of the cermet. It is disclosed that the raw material powder is equalized, and Patent Document 3 discloses that the raw material powder is highly purified.
- a raw material powder for forming a hard phase and a raw material powder for forming a metal binder phase prepared as raw materials are prepared ⁇ mixing ⁇ press forming ⁇ 1 torr ( ⁇ 0.133 kPa) ) In a nitrogen atmosphere of 1400 ° C. ⁇ 1 hour.
- the raw material powder in Japanese Patent Application Laid-Open No. 2003-228620 is mixed with one or two of Co and Ni at a base of 0.1 to 0 on the basis of the titanium carbonitride powder. .3 wt% is added, and these mixed powders are heat-treated at 1500 ° C. to 1750 ° C.
- the high purity of the raw material powder in Patent Document 3 is a uniform mixing of the raw material titanium oxide powder and carbon powder, hydrogen gas and nitrogen gas controlled at a temperature of 1800 ° C. to 2000 ° C. and a pressure of 20 to 40 kPa. After being held in, it is further deoxidized by heat treatment at a pressure of 5 kPa.
- the present invention has been made in view of the above circumstances, and one of the objects of the present invention is to provide a cermet suitable for a constituent material of a cutting tool having excellent fracture resistance even in a severe cutting environment. is there.
- Another object of the present invention is to provide a cermet suitable for a constituent material of a cutting tool that can suppress sudden breakage and has a small variation in fracture resistance between products.
- Another object of the present invention is to provide a cutting tool using the cermet as a base material.
- Another object of the present invention is to provide a method for producing a cermet capable of producing the cermet.
- the cermet according to one embodiment of the present invention is a cermet in which a hard phase containing Ti is bonded by a binder phase containing at least one of Ni and Co, and the hard phase has 200 or more hard phases in an arbitrary cross section of the cermet.
- the particle size of the hard phase of 70% or more with respect to the total number of hard phases is ⁇ 30 of the average particle diameter of the total hard phases. %.
- the cutting tool according to one embodiment of the present invention uses the cermet as a base material.
- the manufacturing method of the cermet which concerns on 1 aspect of this invention is equipped with a preparatory process, a mixing process, a formation process, and a sintering process.
- the preparation step prepares a first hard phase raw material powder, a second hard phase raw material powder, and a binder phase raw material powder.
- the first hard phase raw material powder includes at least one of Ti carbide, Ti nitride, and Ti carbonitride.
- the second hard phase raw material powder contains at least one selected from W, Mo, Ta, Nb, and Cr.
- the binder phase raw material powder contains at least one of Co and Ni.
- the first hard phase raw material powder, the second hard phase raw material powder, and the binder phase raw material powder are mixed by an attritor to produce a mixed powder.
- the mixed powder is formed to produce a formed body.
- a sintering process sinters a molded object.
- the first hard phase raw material powder uses Ti oxide as a starting material, has an average particle size of 0.5 ⁇ m or more and 5.0 ⁇ m or less, and a standard deviation of particle size distribution of 1.5 ⁇ m or less.
- the cermet is suitable as a constituent material of a cutting tool having excellent fracture resistance even in a severe cutting environment.
- the cutting tool is excellent in fracture resistance even under severe cutting environment.
- the cermet manufacturing method can manufacture a cermet that can provide a cutting tool having excellent fracture resistance even in a severe cutting environment.
- the cermet according to the embodiment is a cermet in which a hard phase containing Ti is bonded by a binder phase containing at least one of Ni and Co, and there are 200 or more hard phases in an arbitrary cross section of the cermet.
- the particle size of the hard phase of 70% or more with respect to the total number of hard phases is ⁇ 30 of the average particle diameter of the total hard phases. %.
- the particle size of the hard phase in the cermet is substantially uniform, the stress concentration on the hard phase is relaxed, and the occurrence of fracture starting points at the time of chipping can be reduced, thereby improving chipping resistance. Can do. Therefore, it is possible to have excellent fracture resistance even in a severe cutting environment such as intermittent cutting with a large cutting speed and feed amount.
- the average particle size of the all hard phases is 0.5 ⁇ m or more and 5.0 ⁇ m or less.
- the average particle size of all the hard phases is 0.5 ⁇ m or more, a certain fracture toughness can be obtained.
- the average particle size is 5.0 ⁇ m or less, sufficient hardness can be obtained.
- the finer the hard phase the more the cermet having excellent wear resistance is obtained, but the cermet is inferior in chipping resistance.
- the average particle size of the hard phase is 5.0 ⁇ m or less. The cermet can improve wear resistance and has excellent fracture resistance.
- the hard phase includes the following first hard phase, second hard phase, and third hard phase.
- the first hard phase is a hard phase having a core structure having a core portion and a peripheral portion covering the entire periphery of the core portion, and the core portion includes at least one of TiC, TiN, and TiCN. It is comprised as a main component and the said peripheral part is a hard phase comprised with the composite compound solid solution containing at least 1 type of W, Mo, Ta, Nb, and Cr and Ti.
- the second hard phase is a hard phase having a single phase structure composed mainly of at least one of TiC, TiN, and TiCN.
- a 3rd hard phase is a hard phase of the single phase structure comprised with the said composite compound solid solution.
- Hard phase can have both the function which each hard phase fulfills because the 1st hard phase, the 2nd hard phase, and the 3rd hard phase coexist.
- the hard phase (mainly, the first hard phase and the second hard phase) having a high hardness is excellent in wear resistance
- the hard phase mainly, excellent in wettability with the binder phase
- the presence of the second hard phase and the third hard phase can maintain good wettability with the binder phase and can provide a structure in which the binder phase exists uniformly, improving the fracture resistance. it can.
- thermal conductivity can be improved by the presence of a hard phase (mainly the third hard phase) having excellent thermal characteristics, and thermal cracking suppression and welding resistance can be improved.
- the cutting tool using the cermet according to the present embodiment is less likely to be worn or chipped, so that it is possible to stabilize the tool life and prolong the life, and to prevent the occurrence of welding. And the quality of the machined surface of the work material can be expected to improve. The function of each hard phase will be described later.
- the cutting tool according to the embodiment uses the cermet described in any one of (1) to (3) as a base material.
- the chipping resistance is excellent even in a severe cutting environment. This is because the above-described cermet has a substantially uniform particle size of the hard phase and excellent fracture resistance.
- the form of the cutting tool is not particularly limited, and examples thereof include a cutting edge exchange type cutting tip, a drill, and a reamer.
- the cutting tool it may be provided with a hard film coated on at least a part of the surface of the substrate.
- the wear resistance can be improved while maintaining the toughness and the bending strength of the base material.
- the hard film is coated on the base material, chipping hardly occurs on the cutting edge of the base material, so that the state of the finished surface of the work material can be improved.
- the hard film include ceramics and hard carbon.
- the cermet manufacturing method includes a preparation step, a mixing step, a forming step, and a sintering step.
- the preparation step prepares a first hard phase raw material powder, a second hard phase raw material powder, and a binder phase raw material powder.
- the first hard phase raw material powder includes at least one of Ti carbide, Ti nitride, and Ti carbonitride.
- the second hard phase raw material powder contains at least one selected from W, Mo, Ta, Nb, and Cr.
- the binder phase raw material powder contains at least one of Co and Ni.
- the mixing step the first hard phase raw material powder, the second hard phase raw material powder, and the binder phase raw material powder are mixed by an attritor to produce a mixed powder.
- the mixed powder is formed to produce a formed body.
- a sintering process sinters a molded object.
- the first hard phase raw material powder uses Ti oxide as a starting material, has an average particle size of 0.5 ⁇ m or more and 5.0 ⁇ m or less, and a standard deviation of particle size distribution of 1.5 ⁇ m or less.
- a molded object is heated to 1300 degreeC or more and 1500 degrees C or less in nitrogen atmosphere which makes nitrogen partial pressure 5.0 to 10.0 kPa. Can be mentioned.
- the particle size of a hard phase is substantially uniform. It is easy to make the particle size of the hard phase substantially uniform because the Ostwald growth of the particles constituting the first hard phase raw material powder can be suppressed by setting the nitrogen partial pressure to 5.0 kPa or more, which is relatively large. This is because particle growth can be suppressed and shrinkage of relatively small particles can be suppressed. Moreover, it is because it is easy to suppress the grain growth of the particle
- the cermet which concerns on embodiment is comprised by the hard phase, the binder phase which couple
- Inevitable impurities include oxygen and metal elements in the order of ppm, which are contained in the raw material or mixed in the manufacturing process.
- the main feature of this cermet is that the particle size of the hard phase in the cermet is substantially uniform.
- the hard phase is a compound of at least one metal element selected from Group 4, 5, 6 metals of the periodic table and at least one element of carbon (C) and nitrogen (N), that is, carbide of the above metal element, nitriding A material, carbonitride, and at least one selected from these solid solutions.
- the cermet of this embodiment is a TiCN-based cermet containing at least a carbonitride solid solution containing Ti carbonitride (TiCN) and Ti. It is preferable that a hard phase contains 3 types from which a composition differs called the following 1st hard phase, 2nd hard phase, and 3rd hard phase.
- each hard phase can be easily discriminated by the density of micrographs taken with a scanning electron microscope (SEM).
- SEM scanning electron microscope
- the composition of each hard phase can be quantitatively analyzed using an SEM-EDX apparatus (SEM ... Scanning Electron Microscope, EDX ... Energy-dispersive X-ray Spectroscopy).
- the first hard phase is a hard phase having a core structure having a core part and a peripheral part covering the entire periphery of the core part.
- the core part is composed mainly of at least one of TiC, TiN, and TiCN.
- a core part is comprised only by Ti compound substantially.
- the core portion is substantially composed only of TiCN.
- TiCN is contained in an amount of 80% by mass or more, and further 90% by mass or more.
- content of Ti in a core part is 60 mass% or more, Furthermore, 70 mass% or more.
- the peripheral portion is composed of a complex compound solid solution of Ti and at least one metal selected from Group 4, 5, 6 metals other than Ti.
- the peripheral portion may be composed of a composite compound solid solution (composite carbonitride solid solution) containing Ti and at least one of W, Mo, Ta, Nb, and Cr.
- a composite compound solid solution composite carbonitride solid solution
- the composition of the peripheral portion include (Ti, W) CN, (Ti, W, Mo) CN, (Ti, W, Nb) CN, (Ti, W, Mo, Nb) CN, and the like.
- the Ti content in the peripheral part is 10% by mass or more, and further 20% by mass or more.
- the total content of W, Mo, Ta, Nb, and Cr in the peripheral part is 40% by mass or more, and further 50% by mass or more.
- the first hard phase there is a peripheral part that has good wettability with the binder phase throughout the periphery of the core part with high hardness, thereby reducing the occurrence of nests in the cermet and homogenizing the structure. Can be achieved and the hardness can be stabilized. Further, the fracture resistance can be improved by forming a structure in which the binder phase is present uniformly. Accordingly, the presence of the first hard phase in the cermet can particularly improve the wear resistance and fracture resistance.
- the second hard phase is a hard phase having a single phase structure composed mainly of at least one of TiC, TiN, and TiCN.
- the second hard phase is substantially composed of only a Ti compound.
- the second hard phase is substantially composed of TiCN.
- TiCN is contained in an amount of 80% by mass or more, and further 90% by mass or more.
- the Ti content is 60% by mass or more, and more preferably 70% by mass or more.
- the second hard phase contains a large amount of Ti as compared with the first hard phase, so that the hardness is high and the reactivity with steel widely used for work materials is low. Accordingly, the presence of the second hard phase in the cermet can particularly improve the wear resistance and adhesion resistance.
- the third hard phase is a hard phase having a single phase structure composed of a complex compound solid solution of Ti and at least one metal selected from Group 4, 5, 6 metals other than Ti.
- the third hard phase is composed of a composite compound solid solution (composite carbonitride solid solution) containing Ti and at least one of W, Mo, Ta, Nb, and Cr.
- the specific composition of the third hard phase is, for example, (Ti, W) CN, (Ti, W, Mo) CN, (Ti, W, Nb) CN, (Ti, W, Mo, Nb) CN, etc. Can be mentioned.
- the Ti content in the third hard phase is 10% by mass or more, and further 20% by mass or more.
- the total content of W, Mo, Ta, Nb, and Cr in the third hard phase is 40% by mass or more, and further 50% by mass or more.
- the third hard phase contains W
- the fracture toughness can be improved while maintaining high hardness.
- the hardness of the third hard phase is slightly reduced, the uniform hardness makes it difficult for cracks to develop in the hard phase, and the inclusion of W has high thermal conductivity. Accordingly, the presence of the third hard phase in the cermet can particularly improve the fracture resistance and the thermal crack resistance.
- the main feature of the cermet of the present embodiment is that when an observation visual field including 200 or more hard phases is taken in an arbitrary cross section of the cermet, among the hard phases existing in the observation visual field, the total number of hard phases is The particle diameter of the hard phase of 70% or more is within ⁇ 30% (within the set particle diameter range) of the average particle diameter of all the hard phases. That is, in the cermet of this embodiment, the particle size of the hard phase is substantially uniform. When the particle size of the hard phase in the cermet is substantially uniform, the stress concentration on the hard phase is relieved, the occurrence of fracture starting points at the time of chipping can be reduced, and chipping resistance can be improved.
- the particle size of the hard phase in the cermet is more uniform, the fracture resistance can be further improved. Therefore, the ratio of the hard phase within the set particle size range in the entire hard phase is 75% or more. It is preferable that it is 80% or more. Moreover, since the design particle size range can make the particle size of the hard phase in the cermet more uniform as the range is narrower, it is within ⁇ 25% of the average particle size of all the hard phases, and ⁇ of the average particle size of all the hard phases. It is preferably within 20%.
- the particle size of the hard phase in the present embodiment is obtained by analyzing the image of the observation visual field when taking an observation visual field including 200 or more hard phases in an arbitrary cross-section of the cermet (micrograph by SEM). The average value of the horizontal ferret diameter and the vertical feret diameter in each hard phase in the image is used. The average particle size of all hard phases is determined by measuring the horizontal ferret diameter and the vertical feret diameter for each of the hard phases in the cross-sectional image of the observation field of view, and calculating the average value of both ferret diameters of each hard phase. The total is obtained by dividing by the number of measured hard phases.
- the number of hard phases in the observation field is preferably large, and is preferably 250 or more, and more preferably 300 or more.
- a plurality of observation visual fields (for example, three visual fields) can be taken and an average value of the plurality of observation visual fields can be obtained.
- the average particle diameter of the entire hard phase is 0.5 ⁇ m or more and 5.0 ⁇ m or less.
- the average particle size of all the hard phases is 0.5 ⁇ m or more, a certain fracture toughness can be obtained.
- the average particle size is 5.0 ⁇ m or less, sufficient hardness can be obtained.
- the finer the hard phase the more the cermet having excellent wear resistance is obtained, but the cermet is inferior in chipping resistance.
- the cermet according to the present embodiment can improve the fracture resistance by having a substantially uniform particle size. Therefore, the average particle size of the hard phase is 5.0 ⁇ m or less, and thus wear resistance. In addition to improving the properties, it also has excellent fracture resistance.
- the average particle size of the entire hard phase is 0.5 ⁇ m or more and 2.0 ⁇ m or less, and particularly 1.0 ⁇ m or more and 1.5 ⁇ m or less.
- the binder phase contains at least one of Ni and Co and bonds the hard phase.
- the binder phase is substantially composed of at least one of Ni and Co, but contains constituent elements (Ti, W, Mo, Ta, Nb, Cr, C, N) of the hard phase and inevitable impurities. Also good.
- the said cermet can be used for the base material of a cutting tool. Since the cermet has excellent fracture resistance even in a severe cutting environment, it is suitable for a base material of a cutting tool.
- the form of the cutting tool is not particularly limited, and examples thereof include a cutting edge exchange type cutting tip, a drill, and a reamer.
- the base material may include a hard film coated on at least a part of its surface.
- the hard film By covering the base material with the hard film, the wear resistance can be improved while maintaining the bending strength of the base material.
- the hard film is coated on the base material, chipping hardly occurs on the cutting edge of the base material, so that the state of the finished surface of the work material can be improved.
- the coated portion of the hard film is preferably at least the blade edge and the vicinity thereof, and may cover the entire surface of the substrate.
- the number of layers of the hard film may be a single layer or multiple layers.
- the film thickness of the hard film (total thickness in the case of multiple layers) is preferably 1 to 20 ⁇ m.
- a chemical vapor deposition method such as a thermal CVD method (CVD method) or a physical vapor deposition method such as an arc ion plating method (PVD method) can be used.
- the composition of the hard film is one or more elements selected from the group consisting of periodic table 4, 5, 6 metal, aluminum (Al), and silicon (Si), carbon (C), nitrogen (N), A compound with one or more elements selected from the group consisting of oxygen (O) and boron (B), that is, carbides, nitrides, oxides, borides, and solid solutions of elements such as the above metals And one or more selected from the group consisting of cubic boron nitride (cBN), diamond, and diamond-like carbon (DLC).
- Specific film quality includes TiCN, Al 2 O 3 , (Ti, Al) N, TiN, TiC, (Al, Cr) N, and the like.
- the chipping resistance is excellent even in a severe cutting environment. Therefore, it can be suitably used not only for continuous cutting but also for intermittent cutting in which the cutting environment is severer than continuous cutting.
- the manufacturing method of the cermet of this embodiment is equipped with a preparation process, a mixing process, a shaping
- the preparation step prepares a first hard phase raw material powder, a second hard phase raw material powder, and a binder phase raw material powder.
- the powders prepared in the preparation step are mixed to produce a mixed powder.
- the mixed powder is formed to produce a formed body.
- a sintering process sinters a molded object.
- the main features of this cermet manufacturing method are that the first hard phase raw material powder to be prepared is composed of a specific starting material, the average particle size satisfies a specific range, and the standard deviation of the particle size distribution is There is a small point.
- the mixing ratio of the first hard phase raw material powder, the second hard phase raw material powder, and the binder phase raw material powder prepared in the preparation step can be appropriately selected according to the characteristics of the target cermet.
- the mass ratio of the first hard phase raw material powder: the second hard phase raw material powder is 4: 1 to 1: 1
- the ratio of both hard phase raw material powder: binder phase raw material powder is 9: 1 to 7: 1.
- the first hard phase raw material powder includes at least one of Ti carbide (TiC), Ti nitride (TiN), and Ti carbonitride (TiCN).
- TiC Ti carbide
- TiN Ti nitride
- TiCN Ti carbonitride
- TiCN powder it is suitable for producing the first hard phase and the second hard phase of the cermet.
- the average particle size of the first hard phase raw material powder is 0.5 ⁇ m or more and 5.0 ⁇ m or less. By setting the average particle size of the first hard phase raw material powder to 0.5 ⁇ m or more, it is easy to increase the bending strength and to improve the fracture resistance.
- the first hard phase raw material powder is easy to handle. By setting the average particle size of the first hard phase raw material powder to 5.0 ⁇ m or less, it is easy to increase hardness and wear resistance.
- the average particle diameter of the first hard phase raw material powder is 0.7 ⁇ m or more, further 1.0 ⁇ m or more, 3.0 ⁇ m or less, further 2.0 ⁇ m or less, 1.5 ⁇ m or less, particularly 1.4 ⁇ m or less. Is mentioned.
- the average particle size of the first hard phase raw material powder is the particle size obtained by the Fisher method.
- the average particle size of the first hard phase raw material powder is different from the average particle size of the hard phase particles in the cermet.
- Each particle constituting the first hard phase raw material powder is pulverized and deformed through a mixing process and a molding process described later. These points are the same for the second hard phase raw material powder and the binder phase raw material powder described later.
- the standard deviation of the particle size distribution of the first hard phase raw material powder is 1.5 ⁇ m or less. This standard deviation affects the particle size distribution of the hard phase of the cermet obtained. By setting the standard deviation to 1.5 ⁇ m or less, the particle size distribution of the produced hard phase can be made substantially uniform. That is, it is easy to make the alloy structure of the cermet substantially uniform by using this powder. Therefore, it is easy to obtain a cermet that is excellent in fracture resistance and has a high average bending force and a small variation in bending force between products. Therefore, it is easy to construct a cutting tool that has excellent fracture resistance even in a severe cutting environment, and that can suppress sudden fracture and has a small variation in fracture resistance between products.
- This standard deviation is preferably 1.0 ⁇ m or less, more preferably 0.5 ⁇ m or less, because the smaller the standard deviation, the more uniform the particle size of the hard phase produced.
- the standard deviation of the first hard phase raw material powder is a value obtained by particle size distribution measurement by the microtrack method. This also applies to Ti oxide powder described later.
- the production of the first hard phase raw material powder includes using Ti oxide as a starting material. If Ti oxide is used as a starting material, the first hard phase raw material powder can be obtained without strong pulverization. Therefore, it is easy to smooth the surface properties of the first hard phase raw material powder. Since the surface property of the first hard phase raw material powder is smooth, the wettability with the binder phase with respect to the first hard phase raw material powder can be improved during sintering. Therefore, it is easy to firmly bond the hard phase and the binder phase, and it is easy to obtain a cermet having a high average bending strength and a small variation in bending strength between products. Therefore, it is easy to construct a cutting tool that can suppress sudden breakage and has a small variation in fracture resistance between products.
- the specific production of the first hard phase raw material powder is carried out by mixing a Ti oxide powder and a carbon powder and subjecting the mixed powder to a heat treatment.
- the Ti oxide powder has an average particle size of 0.5 ⁇ m or more and 5.0 ⁇ m or less and a standard deviation of the particle size distribution of 1.5 ⁇ m or less.
- the average particle size and standard deviation of the starting material are substantially reflected in the average particle size and standard deviation of the particle size distribution of the first hard phase raw material powder. That is, when the average particle size of the Ti oxide powder is 0.5 ⁇ m or more and 5.0 ⁇ m or less and the standard deviation is 1.5 ⁇ m or less, the average particle size is 0.5 ⁇ m or more and 5.0 ⁇ m or less, and the standard deviation Can be obtained as a first hard phase raw material powder of 1.5 ⁇ m or less.
- the average particle size of the soot carbon powder can be appropriately selected according to the average particle size of the Ti oxide, and examples include 0.3 ⁇ m or more and 1.0 ⁇ m or less.
- the ratio of the carbon powder is, for example, 8% by mass or more and 11% by mass or less when the total of the carbon powder and the Ti oxide is 100% by mass.
- the conditions for the heat treatment may be 1500 ° C. or higher and 1800 ° C. or lower and 0.5 hours or longer and 5.0 hours or shorter in a nitrogen atmosphere. Furthermore, the temperature is 1500 ° C. or more and 1650 ° C. or less, and the treatment time is 0.5 hour or more and 1.5 hours or less.
- the heat treatment temperature is 1500 ° C. or more and the treatment time to 0.5 hours or more
- the Ti oxide and the carbon powder can be sufficiently reacted to produce the first hard phase raw material powder (for example, TiCN powder).
- the heat treatment temperature By setting the heat treatment temperature to 1800 ° C. or less and the treatment time to 1.5 hours or less, it is easy to suppress grain growth of the obtained first hard phase raw material powder (for example, TiCN powder), and the average particle diameter of the starting raw material And TiCN powder with standard deviation maintained.
- the second hard phase raw material powder is selected from at least one metal selected from Group 4, 5, 6 metals (excluding Ti), specifically, W, Mo, Ta, Nb, and Cr. Including at least one of the above.
- the presence form of the second hard phase raw material powder is a compound (for example, carbide powder, carbonitride powder, solid solution) of these at least one metal and at least one element of carbon (C) and nitrogen (N). Powder).
- carbide powder, carbonitride powder, solid solution powder, etc. of the periodic table 4 5, 6 metal (excluding Ti) and the above-described TiCN powder are used, the first hard phase and the third hard phase of the cermet described above are used. Suitable for phase generation.
- the average particle size of the second hard phase raw material powder is preferably 0.5 ⁇ m or more and 3.0 ⁇ m or less, may be 2.0 ⁇ m or less, and may be 1.0 ⁇ m or less.
- the second hard phase raw material powder is easy to handle.
- the binder phase raw material powder constitutes the binder phase of the cermet described above.
- the binder phase raw material powder contains at least one iron group metal of Co and Ni.
- the average particle size of the binder phase raw material powder is preferably 0.5 ⁇ m or more and 3.0 ⁇ m or less, may be 2.0 ⁇ m or less, and may be 1.0 ⁇ m or less.
- the mixing step the first hard phase raw material powder, the second hard phase raw material powder, and the binder phase raw material powder are mixed with a mixer such as an attritor to produce a mixed powder.
- a mixer such as an attritor to produce a mixed powder.
- a molding aid for example, paraffin
- a vertical attritor is a mixer that includes a rotating shaft and a plurality of stirring rods that protrude in the circumferential direction of the rotating shaft.
- the peripheral speed (rotational speed) of the attritor is 100 m / min to 400 m / min, and the mixing time is 1.5 hours to 15 hours. If both the peripheral speed and the mixing time of the attritor are within the specified range, the raw material powders are sufficiently mixed, and the accumulation of the binder phase and the aggregated phase can be suppressed in the cermet.
- the preferable values of the mixing conditions are an attritor peripheral speed: 200 m / min to 300 m / min, and a mixing time: 1.5 hours to 5 hours.
- mixing by an attritor may be performed using a ball-shaped medium made of cemented carbide, or may be performed without a medium.
- the mixed powder is filled in a mold and press-molded to produce a molded body.
- the press pressure can be appropriately changed depending on the composition of the raw material powder, and examples thereof include 50 MPa or more and 250 MPa or less.
- the pressing pressure is more preferably 90 MPa or more and 110 MPa or less.
- the molded body is sintered to produce a sintered body.
- this sintering step it is preferable to perform stepwise sintering.
- sintering having a molding auxiliary agent removal period, a first temperature raising period, a second temperature raising period, a holding period, a first cooling period, and a second cooling period may be mentioned.
- the removal period of the molding aid is a period in which the temperature is raised to the volatilization temperature of the molding aid.
- the compact is heated to 350 ° C. or higher and 500 ° C. or lower.
- the molded body is heated to about 1200 ° C. to about 1300 ° C. in a vacuum atmosphere.
- Examples of the temperature increase rate during the first temperature increase period include about 2 ° C./min to 20 ° C./min.
- the molded body is heated to about 1300 ° C. to 1500 ° C. in a nitrogen atmosphere of 5.0 kPa to 10.0 kPa.
- Examples of the temperature increase rate in the second temperature increase period include about 2 ° C./min to 20 ° C./min.
- the main feature of the cermet manufacturing method of this embodiment is that the temperature is raised at a high nitrogen partial pressure of 5.0 kPa to 10.0 kPa in the second temperature raising period. If the nitrogen partial pressure is less than 5.0 kPa, denitrification tends to occur during sintering, and the amount of carbon tends to increase relatively. If the amount of carbon is large, the liquid phase appearance temperature decreases and the time for exposure to the liquid phase increases, so that solid solution reprecipitation by Ostwald growth is promoted, large particles grow and become coarser, and small particles shrink. And become finer. In particular, the peripheral portion of the first hard phase and the third hard phase are easier to grow as the amount of nitrogen is smaller (the amount of carbon is larger).
- the particle size of the particles becomes non-uniform.
- the Ostwald growth can be suppressed when the nitrogen partial pressure is 5.0 kPa or more. Therefore, in the sintered body (cermet) obtained through the sintering process in which the nitrogen partial pressure is 5.0 kPa or more, the particle size of the hard phase can be made substantially uniform.
- the nitrogen partial pressure is 10.0 kPa or more, no change in the effect of suppressing the grain growth of each particle is observed.
- ⁇ ⁇ Sintering temperature in the second temperature rising period is 1300 ° C. or higher, so that a dense sintered body (cermet) can be obtained. If the sintering temperature is too high, each raw material powder, in particular each particle constituting the first hard phase raw material powder, is likely to grow, and the particle size distribution of the hard phase of the resulting sintered body (cermet) becomes wider. It is easy and the particle size of the hard phase may be uneven. Therefore, when the standard deviation of the first hard phase raw material powder is 1.5 ⁇ m or less, the sintering temperature is preferably low, and is preferably 1400 ° C. or less, and more preferably 1350 ° C. or less.
- the compact In the soot holding period, the compact is held for 0.5 hour or more and 3 hours or less at the final temperature of the second temperature raising period.
- the holding time By making the holding time 0.5 hours or longer, it is easy to suppress denitrification during sintering.
- the compact is cooled to about 1000 ° C. or higher and about 1300 ° C. or lower in a vacuum atmosphere.
- the cooling rate in the first cooling period include about 2 ° C./min to 20 ° C./min.
- the cooling rate By setting the cooling rate to the above temperature range to 2 ° C./min or more, it is easy to suppress the grain growth of the hard phase.
- the cooling rate By setting the cooling rate to the above temperature range to 20 ° C./min or less, it is easy to smooth the surface properties of the cermet.
- the molded body is pressure-cooled to room temperature in a nitrogen atmosphere.
- the cooling rate in the second cooling period include about 2 ° C./min to 100 ° C./min. By setting the cooling rate in the second cooling period to 2 ° C./min or more, it is easy to produce a dense cermet. By setting the cooling rate in the second cooling period to 100 ° C./min or less, it is easy to suppress the bleeding of the binder phase.
- the sintered body (cermet) obtained by the cermet manufacturing method described above is fine because the Ostwald growth and grain growth of the raw material powder can be suppressed in the manufacturing process, and the particle size of the hard phase is substantially uniform. is there.
- the first hard phase having Ti oxide as a starting material, an average particle size of 0.5 ⁇ m to 5.0 ⁇ m, and a standard deviation of particle size distribution of 1.5 ⁇ m or less.
- the raw material powder it is easy to make the particle size of the hard phase of the cermet substantially uniform.
- Test Example 1 Cermets were actually produced, and the composition / structure, particle size, and toughness / hardness of the cermets were examined.
- Samples 1-8, 101-103 The cermets of Samples 1 to 8 and 101 to 103 were prepared in the order of preparation process ⁇ mixing process ⁇ molding process ⁇ sintering process.
- WC powder As the second hard phase material powder, WC powder, Mo 2 C powder, NbC powder, TaC powder, and Cr 3 C 2 powder were prepared.
- the average particle diameter of each prepared powder is WC: 1.2 ⁇ m, Mo 2 C: 1.2 ⁇ m, NbC: 1.0 ⁇ m, TaC: 1.0 ⁇ m, Cr 3 C 2 : 1.4 ⁇ m.
- Binder phase raw material powder Co powder and Ni powder were prepared as binder phase raw material powder.
- the average particle diameter of each prepared powder is Co: 0.7 ⁇ m and Ni: 2.6 ⁇ m.
- the first hard phase raw material powder, the second hard phase raw material powder, and the binder phase raw material powder are blended so as to have the mass ratio shown in Table 1, and further ethanol as a solvent and paraffin as a molding aid.
- the mixture was mixed by an attritor to produce a slurry-like mixed raw material.
- the blending amount of paraffin was 2% by mass.
- the mixing conditions using an attritor were 1.5 to 15 hours at a peripheral speed of 250 m / min (sample Nos. 1 to 3, 6, 7, 103 were 1.5 hours, sample Nos. 4, 5, 8, and 101 were 15 hours). Time, sample No. 102 was 5 hours).
- the solvent was volatilized from the raw material powder slurry to obtain a mixed powder.
- the produced mixed powder was filled in a mold and press-molded at a pressure of 98 MPa to produce a molded body.
- the shape of the molded body was SNG432 of ISO standard.
- the produced molded body was sintered. Specifically, the molded body was first heated to 370 ° C. to remove paraffin as a molding aid (removal period). Subsequently, the molded body was heated to 1200 ° C. in a vacuum atmosphere (first heating period). And the molded object was heated up to 1500 degreeC in the nitrogen atmosphere which made the nitrogen partial pressure 10.0 kPa (2nd temperature rising period), and the molded object was hold
- composition and structure of cermet The cross section of the cermet of each obtained sample was examined by SEM (JSM-7000F, manufactured by JEOL Ltd.). As a representative, sample no. The SEM photograph (5000 times) of 1 cermet is shown in FIG. As a result, black particles (first hard phase), particles (second hard phase) that are entirely covered with a gray region around the black particles, and gray particles (third hard phase) were confirmed. . It was also confirmed that a binder phase was present between the particles.
- the composition of each particle was examined with a SEM-EDX apparatus.
- the black particles were substantially composed of TiCN.
- the gray particles were composed of a composite carbonitride solid solution with Ti and W.
- the binder phase was substantially composed of Co.
- each element in the entire cermet is equal to the content of each element in the mixed powder. Therefore, sample no.
- the Ti content in 1 was about 50% by mass, and the W content was about 18% by mass.
- the composition and the structure were examined as described above. As a result, all the cermets were sample No. As in 1, the first hard phase, the second hard phase, and the third hard phase were confirmed, and it was confirmed that a binder phase was present between the hard phases.
- the black particles constituting each hard phase are substantially composed of TiCN, and the gray particles are composite charcoal containing Ti and at least one of W, Mo, Ta, Nb, and Cr. It was composed of a nitride solid solution.
- the average particle diameter of all the hard phases was calculated
- a sample No. using a TiCN powder having a standard deviation of 1.5 ⁇ m or less As shown in Table 1, as a raw material powder, a sample No. using a TiCN powder having a standard deviation of 1.5 ⁇ m or less.
- the hard phase within ⁇ 30% (within the set particle size range) of the average particle size of all the hard phases was 70% or more of the total hard phase. That is, the particle size of the hard phase in the cermet was substantially uniform. This is due to the fact that the particle size of the raw material powder itself was substantially uniform, but the Ostwald growth of the raw material powder (each particle) could be suppressed by heating at a high nitrogen partial pressure during sintering. It is thought that.
- Sample No. The cermets 1 to 8 had a hardness of about 15 GPa or higher.
- the average particle size of all the hard phases is as small as 1.5 ⁇ m or less.
- sample no. The cermets 1 to 8 have a particle diameter within the set range of 70% or more of the hard phase with respect to the entire hard phase, that is, the hard phase of 70% or more has a particle diameter of 1.95 ⁇ m at the maximum. Is considered to be highly hard because it is uniformly fine. In particular, when the average particle size of all the hard phases was less than 1.0 ⁇ m, the hardness was 15.7 GPa or more, which was even higher. Sample No. Cermets 1 to 8 had high toughness with a toughness of 6.5 MPa ⁇ m 1/2 or more. This is considered due to the fact that the particle size of the hard phase is substantially uniform.
- Test Example 2 the influence of the sintering process on the composition / structure, particle size, and toughness / hardness of the cermet was examined. Specifically, the influence of sintering temperature and nitrogen partial pressure was examined.
- the cross section of the cermet of each sample obtained was examined in the same manner as in Test Example 1. As a result, the first hard phase, the second hard phase, the third hard phase, and the binder phase existing between the hard phases were confirmed. Further, the black particles constituting each hard phase were substantially composed of TiCN, and the gray particles were composed of a composite carbonitride solid solution containing Ti and W.
- sample No. 1 was heated at a sintering temperature of 1300 ° C. or more and 1500 ° C. or less.
- the hard phase within ⁇ 30% of the average particle size of all the hard phases was present in an amount of 70% or more with respect to the total hard phase. That is, the particle size of the hard phase in the cermet was substantially uniform. This is considered to be due to the fact that Ostwald growth of the raw material powder (each particle) by sintering could be suppressed by setting the nitrogen partial pressure as high as 5 kPa or higher.
- the cermets 11 to 14 had a high hardness of about 15 GPa or higher and a toughness of 6.8 MPa ⁇ m 1/2 or higher.
- No. 1 cermet had 83% of the hard phase in the set particle size range with respect to the total hard phase, and in particular, the toughness was very high toughness of 7.5 MPa ⁇ m 1/2 . From this, it can be seen that the higher the nitrogen partial pressure, the more the Ostwald growth can be suppressed, the hard phase particle size can be made more uniform, and the toughness can be improved.
- sample No. 1 having a low nitrogen partial pressure of 1 kPa.
- the hard phase within the set particle size range was as small as 67% or less with respect to the total hard phase, the toughness was 6.3 MPa ⁇ m 1/2 or less, and the hardness was low with 14.8 GPa or less. . This is considered to be due to the fact that the Ostwald growth of the raw material powder (each particle) due to sintering cannot be suppressed because the nitrogen partial pressure is low, and the particle size distribution of the produced hard phase becomes non-uniform.
- the Ostwald growth cannot be suppressed, large particles grow and become coarser, so that a coarse hard phase is present and the hardness is considered to have decreased. From this, even if the particle size of the raw material powder itself is substantially uniform, if the nitrogen partial pressure during sintering is low, the hard phase grows Ostwald, and the particle size of the hard phase becomes substantially uniform. It turns out that this is difficult. Further, the sample No. 1 whose sintering temperature is as high as 1600 ° C. In the cermet No. 113, the hard phase in the set particle size range was as small as 63% of the total hard phase, the toughness was 6.0 MPa ⁇ m 1/2 , and the hardness was low with 14.8 GPa. This is thought to be because the growth of the raw material powder (each particle) due to sintering could not be suppressed because the sintering temperature was high, and the particle size distribution of the produced hard phase became non-uniform.
- Test Example 3 A cutting tool was prepared using some of the samples obtained in Test Example 1 and Test Example 2, and a cutting test was actually performed using the prepared cutting tool.
- the cutting test is a fracture resistance test.
- Sample No. The cermets 1, 4, 11, 14, 101, 103, and 111 were each subjected to a surface polishing process and a cutting edge process to produce SNG432-shaped cutting edge-exchangeable chips (cutting tools).
- Test Example 4 As in Test Example 1, the cermets of Samples 21 to 25 were prepared through the following steps in the order of preparation step ⁇ mixing step ⁇ molding step ⁇ sintering step, and the bending strength of the cermet and the cutting work made with this cermet Cutting performance (defect probability) was examined.
- Example 21 to 25 As the first hard phase raw material powder, TiCN powder having an average particle size and standard deviation shown in Table 4 was prepared. Preparation of the TiCN powders of Samples 21 to 25 was performed as follows. The TiCN powders of Samples 21 to 23 were prepared by mixing a Ti oxide powder having an average particle diameter of 1.2 ⁇ m and a standard deviation of 1.2 ⁇ m with a carbon powder, and at 1700 ° C. for 1 hour in a nitrogen atmosphere. The heat treatment was performed. The TiCN powders of Samples 24 and 25 were prepared in the same manner as Sample 21 except that the average particle diameter and standard deviation of the Ti oxide powder were 0.7 ⁇ m and 0.3 ⁇ m, respectively. As the second hard phase raw material powder and binder phase raw material powder, those having the same type and the same average particle diameter as those of Test Example 1 were prepared.
- each of the samples 211 and 212 is different from the sample 21 in that TiCN powder having a standard deviation of more than 1.5 ⁇ m (both 2.5 ⁇ m here) is used.
- the TiCN powders of Samples 211 and 212 were prepared in the same manner as Sample 21 except that the average particle diameter and standard deviation of the Ti oxide powder were 2.7 ⁇ m and 2.5 ⁇ m, respectively.
- sample 213 As shown in Table 4, the sample 213 uses a TiCN powder having a standard deviation of more than 1.5 ⁇ m (here 2.1 ⁇ m), and a total of 0.1 to 0 of Co and Ni with respect to the TiCN powder. .3 mass% is the main difference from the sample 21.
- the TiCN powder of sample 213 was prepared by adding the total particle size of Co and Ni to the TiCN powder obtained in addition to the Ti oxide powder and carbon powder having average particle diameters and standard deviations of 1.8 ⁇ m and 2.1 ⁇ m. Co and Ni were added so that it might be 0.1-0.3 mass%, and it heat-processed at 1700 degreeC for 0.5 hour in nitrogen atmosphere.
- Samples 221 to 223 the starting material of the TiCN powder is not Ti oxide but Ti hydroxide powder, and the standard deviation in the particle size distribution of TiCN powder is more than 1.5 ⁇ m as shown in Table 4 (here, The main difference from the sample 21 is that both are 3.2 ⁇ m).
- the TiCN powders of Samples 221 to 223 were prepared by mixing a powder of Ti hydroxide having an average particle diameter of 1.4 ⁇ m and a standard deviation of 3.2 ⁇ m with a carbon powder, and at 0 at 1700 ° C. in a nitrogen atmosphere. . Performed by heat treatment for 5 hours.
- the average bending strength of samples 21 to 25 is 2.2 GPa or more, which is higher than samples 211 to 213 and 221 to 223.
- the standard deviations of the bending strengths of the samples 21 to 25 are all less than 0.20 GPa and further 0.15 GPa or less, and are smaller than those of the samples 211 to 213 and 221 to 223. Therefore, using TiCN powder with an average particle size of 0.5 ⁇ m or more and 5.0 ⁇ m or less, further 3.0 ⁇ m or less, and a standard deviation of particle size distribution of 1.5 ⁇ m or less, starting from Ti oxide.
- TiCN powder with an average particle size of 0.5 ⁇ m or more and 5.0 ⁇ m or less, further 3.0 ⁇ m or less, and a standard deviation of particle size distribution of 1.5 ⁇ m or less, starting from Ti oxide.
- the defect probability of samples 21 to 25 is 30% or less, further 20% or less, which is very low as compared with samples 211 to 213 and 221 to 223. From this, using TiCN powder with a Ti oxide as a starting material, an average particle size of 0.5 ⁇ m or more and 5.0 ⁇ m or less, further 3.0 ⁇ m or less, and a standard deviation of particle size distribution of 1.5 ⁇ m or less. It was found that by using the produced cermet as a base material for a cutting tool, sudden defects can be suppressed and variation in defect resistance between products can be reduced.
- the cermet of the present invention can be suitably used as a base material for a cutting tool.
- the manufacturing method of the cermet of this invention can be utilized suitably for manufacture of the cermet suitable for the base material of a cutting tool.
- the cutting tool of the present invention can be suitably used for intermittent cutting as well as continuous cutting.
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Abstract
Description
最初に本発明の実施形態の内容を列記して説明する。
硬質相の粒度を実質的に均一とし易いのは、窒素分圧を5.0kPa以上とすることで、第一の硬質相原料粉末を構成する粒子のオストワルド成長を抑制できて、相対的に大きな粒子の成長を抑制すると共に、相対的に小さな粒子の収縮を抑制できるからである。また、焼結温度を1500℃以下とすることで、第一の硬質相原料粉末を構成する粒子の粒成長を抑制し易いからである。緻密なサーメットとし易いのは、焼結温度が1300℃以上と高温で焼結するからである。
本発明の実施形態の詳細を、以下に説明する。なお、本発明はこれらの例示に限定されるものではなく、特許請求の範囲によって示され、特許請求の範囲と均等の意味及び範囲内でのすべての変更が含まれることが意図される。
実施形態に係るサーメットは、硬質相と、硬質相を結合する結合相と、不可避不純物とにより構成される。不可避不純物は、原料に含有したり、製造工程で混入したりする、酸素やppmオーダーの金属元素が挙げられる。このサーメットの主たる特徴とするところは、サーメット中の硬質相の粒度が実質的に均一である点にある。
(組成)
硬質相は、周期表4,5,6族金属から選ばれる少なくとも1種の金属元素と炭素(C)及び窒素(N)の少なくとも1種の元素との化合物、すなわち上記金属元素の炭化物、窒化物、炭窒化物及びこれらの固溶体から選択される少なくとも1種を含む。特に、本実施形態のサーメットは、Ti炭窒化物(TiCN)及びTiを含む炭窒化物固溶体を少なくとも含有するTiCN基サーメットである。硬質相は、以下の第一硬質相、第二硬質相、及び第三硬質相という組成が異なる3種を含有することが好ましい。これら3種の硬質相の存在形態は、走査型電子顕微鏡(Scanning Electron Microscope:SEM)による顕微鏡写真の濃淡により容易に判別できる。また、各硬質相の組成は、SEM-EDX装置(SEM…Scanning Electron Microscope、EDX…Energy-dispersive X-ray Spectroscopy)を用いて定量分析が可能である。
第一硬質相は、芯部と、この芯部の周囲の全体を覆う周辺部と、を有する有芯構造の硬質相である。芯部は、TiC、TiN、及びTiCNの少なくとも一つを主成分として構成される。例えば、芯部は、実質的にTi化合物のみで構成されることが挙げられる。特に、芯部は、実質的にTiCNのみで構成されることが挙げられる。具体的には、TiCNを80質量%以上、さらに90質量%以上含有する。また、芯部におけるTiの含有量は、60質量%以上、さらに70質量%以上であることが挙げられる。周辺部は、Tiと、Ti以外の周期表4,5,6族金属から選ばれる少なくとも1種の金属と、の複合化合物固溶体で構成される。特に、周辺部は、Tiと、W、Mo、Ta、Nb、及びCrの少なくとも一種と、を含む複合化合物固溶体(複合炭窒化物固溶体)で構成されることが挙げられる。周辺部の具体的な組成は、例えば、(Ti,W)CN、(Ti,W,Mo)CN,(Ti,W,Nb)CN,(Ti,W,Mo,Nb)CNなどが挙げられる。周辺部におけるTiの含有量は、10質量%以上、さらに20質量%以上であることが挙げられる。また、周辺部におけるW,Mo,Ta,Nb,Crの合計含有量は、40質量%以上、さらに50質量%以上であることが挙げられる。第一硬質相は、高硬度な芯部の周囲の全体に亘って結合相と良好な濡れ性を有する周辺部が存在することで、サーメット中の巣の発生を低減して組織の均質化を図ることができ、硬度を安定化させることができる。また、結合相が均一的に存在する組織とできることで、耐欠損性を向上できる。従って、サーメット中に第一硬質相が存在することで、特に、耐摩耗性及び耐欠損性を向上することができる。
第二硬質相は、TiC、TiN、及びTiCNの少なくとも一つを主成分として構成される単相構造の硬質相である。例えば、第二硬質相は、実質的にTi化合物のみで構成されることが挙げられる。特に、第二硬質相は、実質的にTiCNで構成されることが挙げられる。具体的には、TiCNを80質量%以上、さらに90質量%以上含有する。Tiの含有量は、60質量%以上、さらに70質量%以上であることが挙げられる。第二硬質相は、第一硬質相に比較してTiを多く含むことにより、硬度が高く、かつ被削材に汎用される鋼との反応性が低い。従って、サーメット中に第二硬質相が存在することで、特に、耐摩耗性及び耐凝着性を向上することができる。
第三硬質相は、Tiと、Ti以外の周期表4,5,6族金属から選ばれる少なくとも1種の金属と、の複合化合物固溶体で構成される単相構造の硬質相である。特に、第三硬質相は、Tiと、W、Mo、Ta、Nb、及びCrの少なくとも一種と、を含む複合化合物固溶体(複合炭窒化物固溶体)で構成されることが挙げられる。第三硬質相の具体的な組成は、例えば、(Ti,W)CN、(Ti,W,Mo)CN,(Ti,W,Nb)CN,(Ti,W,Mo,Nb)CNなどが挙げられる。第三硬質相におけるTiの含有量は、10質量%以上、さらに20質量%以上であることが挙げられる。また、第三硬質相におけるW,Mo,Ta,Nb,Crの合計含有量は、40質量%以上、さらに50質量%以上であることが挙げられる。特に、第三硬質相がWを含んでいる場合、高い硬度を維持したまま破壊靭性の向上が望める。また、第三硬質相は、硬度が若干低下するものの、硬度が一様なことで硬質相内での亀裂進展が起こり難く、Wを含むことで熱伝導性が高い。従って、サーメット中に第三硬質相が存在することで、特に、耐欠損性及び耐熱亀裂性を向上することができる。
本実施形態のサーメットの主たる特徴は、サーメットの任意の断面において硬質相が200個以上含まれる観察視野をとったとき、この観察視野内に存在する硬質相のうち、全硬質相数に対して70%以上の硬質相の粒径が、全硬質相の平均粒径の±30%以内(設定粒径範囲内)であることにある。つまり、本実施形態のサーメットは、硬質相の粒度が実質的に均一である。サーメット中の硬質相の粒度が実質的に均一であることで、硬質相への応力集中が緩和され、欠損時の破壊起点の発生を低減でき、耐欠損性を向上することができる。よって、切削速度や送り量の大きい断続切削のような過酷な切削環境下においても優れた耐欠損性を有することができる。サーメット中の硬質相の粒度がより均一的であることで、さらに耐欠損性を向上することができるため、硬質相全体に占める設定粒径範囲内の硬質相の割合は、75%以上、さらに80%以上であることが好ましい。また、設計粒径範囲は、範囲が狭いほどサーメット中の硬質相の粒度をより均一的にできるため、全硬質相の平均粒径の±25%以内、さらに全硬質相の平均粒径の±20%以内であることが好ましい。
結合相は、Ni及びCoの少なくとも一方を含み、上記硬質相を結合させる。結合相は、実質的にNi及びCoの少なくとも一方で構成されているが、硬質相の構成元素(Ti,W,Mo,Ta,Nb,Cr,C,N)や、不可避不純物を含んでいてもよい。
上述したサーメットによれば、サーメット中の硬質相の粒度が実質的に均一であるため、切削速度や送り量の大きい断続切削のような過酷な切削環境下においても優れた耐欠損性を有することができる。
[基材]
切削工具の基材には、上記サーメットを用いることができる。上記サーメットは、過酷な切削環境下においても優れた耐欠損性を有するため、切削工具の基材材料に好適である。切削工具の形態は特に限定されず、例えば刃先交換型の切削チップや、ドリル、リーマなどが挙げられる。
上記基材は、その表面の少なくとも一部に被覆された硬質膜を備えてもよい。基材に硬質膜が被覆されることで、基材の抗折力を維持したまま、耐摩耗性を向上させることができる。また、基材に硬質膜が被覆されることで、基材の刃先にチッピングが生じ難くなることから、被削材の仕上げ面の状態を良好にすることができる。硬質膜の被覆箇所は、少なくとも刃先及びその近傍であることが好ましく、基材表面の全面に亘っていてもよい。
硬質膜の層数は、単層でも多層でもよい。硬質膜の膜厚(多層の場合は合計厚さ)は、1~20μmが好ましい。硬質膜の形成方法は、熱CVD法といった化学蒸着法(CVD法)、アークイオンプレーティング法といった物理蒸着法(PVD法)のいずれも利用できる。
上述の切削工具によれば、上述のサーメットを基材とすることで、過酷な切削環境下においても耐欠損性に優れる。そのため、連続切削は勿論、連続切削よりも切削環境の過酷な断続切削でも好適に利用できる。
本実施形態のサーメットの製造方法は、準備工程と混合工程と成形工程と焼結工程とを備える。準備工程は、第一の硬質相原料粉末と第二の硬質相原料粉末と結合相原料粉末とを準備する。混合工程は、準備工程で準備した各粉末を混合して混合粉末を作製する。成形工程は、混合粉末を成形して成形体を作製する。焼結工程は、成形体を焼結する。このサーメットの製造方法の主たる特徴とするところは、準備する第一の硬質相原料粉末が、特定の出発原料からなる点と、平均粒径が特定の範囲を満たし、かつ粒度分布の標準偏差が小さい点とにある。
準備工程で準備する第一の硬質相原料粉末と第二の硬質相原料粉末と結合相原料粉末の配合割合は、目的とするサーメットの特性に応じて適宜選択できる。例えば、第一の硬質相原料粉末:第二の硬質相原料粉末は、質量比で4:1~1:1が挙げられ、両硬質相原料粉末:結合相原料粉末は、質量比で9:1~7:1が挙げられる。
第一の硬質相原料粉末は、Ti炭化物(TiC)、Ti窒化物(TiN)、およびTi炭窒化物(TiCN)の少なくとも一種を含む。例えば、TiCN粉末を用いると、上述のサーメットの第一硬質相及び第二硬質相の生成に好適である。
第二の硬質相原料粉末は、周期表4,5,6族金属(ただしTiを除く)から選ばれる少なくとも一種の金属、具体的には、W,Mo,Ta,Nb,およびCrから選択される少なくとも一種を含むことが挙げられる。この第二の硬質相原料粉末の存在形態は、これらの少なくとも一種の金属と、炭素(C)及び窒素(N)の少なくとも一種の元素との化合物(例えば、炭化物粉末や炭窒化物粉末、固溶体粉末など)からなることが挙げられる。この周期表4,5,6族金属(ただしTiを除く)の炭化物粉末や炭窒化物粉末、固溶体粉末などと上述のTiCN粉末とを用いると、上述のサーメットの第一硬質相及び第三硬質相の生成に好適である。
結合相原料粉末は、上述のサーメットの結合相を構成する。結合相原料粉末は、CoおよびNiの少なくとも一方の鉄族金属を含む。結合相原料粉末の平均粒径は、0.5μm以上3.0μm以下が好ましく、2.0μm以下、さらには1.0μm以下としてもよい。結合相原料粉末の平均粒径を0.5μm以上とすることで、焼結した際、サーメットの硬質相間に結合相を行き渡らせ易く、硬質相と強固に結合させられる。結合相原料粉末の平均粒径を3.0μm以下とすることで、焼結した際、硬質相間の間隔が広くなり難く緻密なサーメットを作製し易い。
混合工程では、第一の硬質相原料粉末と、第二の硬質相原料粉末と、結合相原料粉末とをアトライターなどの混合機で混合して混合粉末を作製する。この混合時には必要に応じて成形助剤(例えば、パラフィン)を添加してもよい。
成形工程では、上記混合粉末を金型に充填し、プレス成形して成形体を作製する。プレス圧力は、原料粉末の組成によって適宜変更することができ、例えば50MPa以上250MPa以下が挙げられる。プレス圧力は、90MPa以上110MPa以下がより好ましい。
焼結工程では、上記成形体を焼結して焼結体を作製する。この焼結工程では、段階的な焼結を行うことが好ましい。例えば、成形助剤の除去期間、第一昇温期間、第二昇温期間、保持期間、第一冷却期間、第二冷却期間を有する焼結を行うことが挙げられる。
上述したサーメットの製造方法によれば、Ti酸化物を出発原料とすると共に、平均粒径が0.5μm以上5.0μm以下、かつ粒度分布の標準偏差が1.5μm以下の第一の硬質相原料粉末を用いることで、サーメットの硬質相の粒度を実質的に均一にし易い。その上、焼結時に第一の硬質相原料粉末に対して結合相原料粉末を強固に結び付け易い上に、第一の硬質相原料粉末の粒度を維持し易い。そのため、硬質相への応力集中を緩和できて、欠損時の破壊起点が発生し難いサーメットを製造できる。その上、抗折力の平均値が高くて製品間の抗折力のばらつきの小さいサーメットを製造できる。従って、過酷な切削環境下においても耐欠損性に優れる切削工具が得られるサーメットを製造できる。その上、突発的な欠損を抑制できて製品間の耐欠損性のばらつきの小さい切削工具が得られるサーメットを製造できる。
サーメットを実際に作製し、サーメットの組成・組織、粒度、及び靱性・硬度を調べた。
試料1~8、101~103のサーメットの作製は、準備工程→混合工程→成形工程→焼結工程の順に行なった。
(第一の硬質相原料粉末)
第一の硬質相原料粉末として、TiCN:0.7~1.4μm、TiC:1.2μmを用意した。平均粒径は、フィッシャー法によって測定した。平均粒径の測定方法は、第二の硬質相原料粉末及び結合相原料粉末でも同様である。上記TiCN粉末については、表1に示す標準偏差のものを用いた。標準偏差は、マイクロトラック法による粒度分布測定により求めた。標準偏差の測定方法は、後述する試験例4のTi酸化物の粉末でも同様である。
第二の硬質相原料粉末として、WC粉末、Mo2C粉末、NbC粉末、TaC粉末、Cr3C2粉末を用意した。用意した各粉末の平均粒径は、WC:1.2μm、Mo2C:1.2μm、NbC:1.0μm、TaC:1.0μm、Cr3C2:1.4μmである。
結合相原料粉末として、Co粉末とNi粉末とを用意した。用意した各粉末の平均粒径は、Co:0.7μm、Ni:2.6μmである。
表1に示す質量割合となるように第一の硬質相原料粉末と第二の硬質相原料粉末と結合相原料粉末とを配合し、更に溶媒であるエタノールと、成形助剤であるパラフィンとをアトライターによって混合し、スラリー状の混合原料を作製した。パラフィンの配合量は、全体の2質量%とした。アトライターによる混合条件は、周速250m/minで1.5~15時間(試料No.1~3,6,7,103は1.5時間、試料No.4,5,8,101は15時間、試料No.102は5時間)とした。原料粉末のスラリーから溶媒を揮発させて、混合粉末を得た。
作製した混合粉末を金型内に充填し、98MPaの圧力でプレス成形して成形体を作製した。成形体の形状は、ISO規格のSNG432とした。
作製した上記成形体を焼結した。具体的には、まず成形体を370℃まで加熱し、成形助剤であるパラフィンを除去した(除去期間)。次いで、真空雰囲気にて1200℃まで成形体を昇温した(第一昇温期間)。そして、窒素分圧を10.0kPaとした窒素雰囲気にて1500℃まで成形体を昇温し(第二昇温期間)、その状態で成形体を1時間保持した(保持期間)。その後、真空雰囲気で1150℃まで冷却し(第一冷却期間)、さらに、窒素雰囲気にて室温まで加圧冷却を行ない(第二冷却期間)、焼結体(サーメット)を得た(試料No.1~8、101~103)。
得られた各試料のサーメットの断面をSEM(日本電子株式会社製 JSM-7000F)により調べた。代表して、試料No.1のサーメットのSEM写真(5000倍)を図1に示す。その結果、黒色の粒子(第一硬質相)、黒色の粒子の周囲の全体が灰色の領域に覆われている粒子(第二硬質相)、灰色の粒子(第三硬質相)が確認された。各粒子間には、結合相が存在することも確認された。
また、得られた各試料のサーメットについて、SEM写真(5000倍)と、画像解析装置:Mac-VIEW(株式会社マウンテック製)とを用いて、サーメットの任意の断面において硬質相が200個以上含まれる観察視野(33μm×25μm)を取得し、この観察視野内の各硬質相の粒径と、全硬質相の平均粒径と、を求めた。各硬質相の粒径は、この観察視野において、各硬質相について、水平方向のferet径と垂直方向のferet径とを測定して、その平均値とした。また、全硬質相の平均粒径は、上記観察視野において、全硬質相のそれぞれについて測定して求めたferet径の平均値を合算して、測定硬質相数で除することで求めた。そして、全硬質相のうち、全硬質相の平均粒径の±30%以内(設定粒径範囲内)の粒径を有する硬質相の数を調べ、全硬質相に占める設定粒径範囲内の硬質相の割合を調べた。全硬質相の平均粒径と、全硬質相に占める設定粒径範囲内の硬質相の割合の、各結果を表1に併せて示す。
得られた各試料のサーメットについて、靱性(MPa・m1/2)、及びビッカース硬度(GPa)を、それぞれJIS R 1607(1995年)、及びJIS Z 2244(2009年)に従って求めた。その結果を表1に併せて示す。
試験例2では、サーメットの組成・組織、粒度、及び靱性・硬度に及ぶ焼結工程の影響を調べた。具体的には、焼結温度と窒素分圧との影響を調べた。
特に、窒素分圧を10kPaとした試料No.1のサーメットは、設定粒径範囲内の硬質相が、全硬質相に対して83%も存在しており、特に靱性が7.5MPa・m1/2と非常に高靱性であった。このことから、窒素分圧は高いほどオストワルド成長を抑制でき、硬質相の粒度をより均一とでき、靱性の向上に効果的であることがわかる。
上記試験例1及び試験例2で得られた一部の試料を用いて切削工具を作製し、作製した切削工具で実際に切削試験を行った。切削試験は、耐欠損性試験である。
試験例1と同様に準備工程→混合工程→成形工程→焼結工程の順に各工程を経て、試料21~25のサーメットを作製し、サーメットの抗折力と、このサーメットでできた切削加工の切削性能(欠損確率)とを調べた。
[準備工程]
第一の硬質相原料粉末として、表4に示す平均粒径でかつ標準偏差のTiCN粉末を用意した。試料21~25のTiCN粉末の準備は、以下のようにして作製することで行った。試料21~23のTiCN粉末の作製は、平均粒径が1.2μmで、標準偏差が1.2μmのTi酸化物の粉末と炭素粉末とを混合し、窒素雰囲気下、1700℃で1時間の熱処理を施すことで行った。試料24,25のTiCN粉末の作製は、Ti酸化物の粉末の平均粒径及び標準偏差をそれぞれ0.7μm及び0.3μmとした点を除き、試料21と同様にして行った。第二の硬質相原料粉末と結合相原料粉末は、試験例1と同じ種類で同じ平均粒径のものを用意した。
混合工程では、アトライターによる混合条件を周速250m/minで5時間とした点を除き、試験例1と同様にして表4に示す質量割合となるように各粉末を混合した。
成形工程では、試験例1と同様にして同様の形状の成形体を作製した。
焼結工程では、第二昇温期間において、窒素分圧を5.0kPaとした窒素雰囲気にて1450℃まで成形体を昇温した点を除き、試験例1と同様にして焼結体(サーメット)を得た(試料21~25)。
試料211、212はそれぞれ、表4に示すように標準偏差が1.5μm超(ここではいずれも2.5μm)のTiCN粉末を用いた点が試料21との主たる相違点である。試料211、212のTiCN粉末の作製はそれぞれ、Ti酸化物の粉末の平均粒径及び標準偏差を2.7μm及び2.5μmとした点を除き、試料21と同様にして行った。
試料213は、表4に示すように標準偏差が1.5μm超(ここでは2.1μm)のTiCN粉末を用いた点と、TiCN粉末に対してCoとNiとが合計で0.1~0.3質量%含まれている点とが試料21との主たる相違点である。試料213のTiCN粉末を作製は、平均粒径及び標準偏差が1.8μm及び2.1μmのTi酸化物の粉末と炭素粉末に加えて、得られるTiCN粉末に対してCoとNiとの合計が0.1~0.3質量%となるようにCoとNiとを添加し、窒素雰囲気中、1700℃で0.5時間の熱処理を施すことで行った。
試料221~223は、TiCN粉末の出発原料がTi酸化物ではなく、水酸化Tiの粉末である点と、表4に示すようにTiCN粉末の粒度分布における標準偏差が1.5μm超(ここではいずれも3.2μm)である点とが試料21との主たる相違点である。試料221~223のTiCN粉末の作製は、平均粒径が1.4μmで、標準偏差がいずれも3.2μmの水酸化Tiの粉末と炭素粉末とを混合し、窒素雰囲気下、1700℃で0.5時間の熱処理を施すことで行った。
各試料21~25,211~213,221~223のサーメットの抗折力を測定した。ここでは、各試料のサーメットを8個ずつ用意し、8個の抗折力の平均値及び抗折力の標準偏差を測定した。その結果を表1に示す。抗折力の測定は、「ファインセラミックスの室温曲げ強さ試験方法 JIS R 1601(2008)」に準拠して行った。
各試料のサーメットを基材とする切削工具を作製し、作製した切削工具で切削試験を行なった。サーメットに研削加工(平面研磨)を施した後、刃先処理加工を施してチップを得た。そして、そのチップをバイトの先端に固定し、切削工具を得た。得られた切削工具を用いて表5に示す条件で断続切削加工を行ない、切削性能を調べた。ここでは、切削性能として欠損確率((欠損数/8個)×100)を求め、製品間の耐欠損性のばらつきに関して評価した。その結果を表6に示す。
Claims (7)
- Tiを含む硬質相が、Ni及びCoの少なくとも一方を含む結合相により結合されてなるサーメットであって、
このサーメットの任意の断面において硬質相が200個以上含まれる観察視野をとったとき、
この観察視野内に存在する硬質相のうち、全硬質相数に対して70%以上の硬質相の粒径が、前記全硬質相の平均粒径の±30%以内であるサーメット。 - 前記全硬質相の平均粒径は、0.5μm以上5.0μm以下である請求項1に記載のサーメット。
- 前記硬質相は、以下の第一硬質相と、第二硬質相と、第三硬質相と、を含有する請求項1又は請求項2に記載のサーメット。
第一硬質相:芯部と、前記芯部の周囲の全体を覆う周辺部と、を有する有芯構造の硬質相であり、前記芯部は、TiC、TiN、及びTiCNの少なくとも一つを主成分として構成され、前記周辺部は、W、Mo、Ta、Nb、及びCrの少なくとも一種と、Tiと、を含む複合化合物固溶体で構成される硬質相
第二硬質相:TiC、TiN、及びTiCNの少なくとも一つを主成分として構成される単相構造の硬質相
第三硬質相:前記複合化合物固溶体で構成される単相構造の硬質相 - 請求項1~請求項3のいずれか1項に記載のサーメットを基材として用いた切削工具。
- 前記基材の表面の少なくとも一部に被覆された硬質膜を備える請求項4に記載の切削工具。
- Ti炭化物、Ti窒化物、及びTi炭窒化物の少なくとも一種を含む第一の硬質相原料粉末と、W、Mo、Ta、Nb、及びCrから選択される少なくとも一種を含む第二の硬質相原料粉末と、Co及びNiの少なくとも一方を含む結合相原料粉末とを準備する準備工程と、
前記第一の硬質相原料粉末と、前記第二の硬質相原料粉末と、前記結合相原料粉末とをアトライターで混合して混合粉末を作製する混合工程と、
前記混合粉末を成形して成形体を作製する成形工程と、
前記成形体を焼結する焼結工程とを備え、
前記第一の硬質相原料粉末は、Ti酸化物を出発原料とし、平均粒径が0.5μm以上5.0μm以下、かつ粒度分布の標準偏差が1.5μm以下であるサーメットの製造方法。 - 前記焼結工程では、窒素分圧を5.0kPa以上10.0kPa以下とする窒素雰囲気下、前記成形体を1300℃以上1500℃以下に加熱する請求項6に記載のサーメットの製造方法。
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EP16737261.4A EP3246422B1 (en) | 2015-01-16 | 2016-01-06 | Cermet, cutting tool, and method for manufacturing cermet |
KR1020167028107A KR102441723B1 (ko) | 2015-01-16 | 2016-01-06 | 서멧, 절삭 공구, 및 서멧의 제조 방법 |
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JP2000073136A (ja) * | 1998-08-31 | 2000-03-07 | Mitsubishi Materials Corp | 耐欠損性のすぐれたTi系複合金属炭窒化物サーメット製切削工具の製造方法 |
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