Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
  • B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
  • B24D18/0009—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using moulds or presses
• • 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
  • B22F3/12—Both compacting and sintering
  • B22F3/14—Both compacting and sintering simultaneously
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
  • C04B35/58—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
  • C04B35/583—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on boron nitride
  • C04B35/5831—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on boron nitride based on cubic boron nitrides or Wurtzitic boron nitrides, including crystal structure transformation of powder
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
  • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
  • C04B35/6303—Inorganic additives
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/64—Burning or sintering processes
  • C04B35/645—Pressure sintering
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
• • 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
  • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
  • B22F2005/002—Tools other than cutting tools
• • 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
  • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
  • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
  • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
  • B22F2007/066—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts using impregnation
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/40—Metallic constituents or additives not added as binding phase
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/40—Metallic constituents or additives not added as binding phase
  • C04B2235/402—Aluminium
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/40—Metallic constituents or additives not added as binding phase
  • C04B2235/404—Refractory metals
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/40—Metallic constituents or additives not added as binding phase
  • C04B2235/405—Iron group metals
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
  • C04B2235/54—Particle size related information
  • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
  • C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
  • C04B2235/80—Phases present in the sintered or melt-cast ceramic products other than the main phase
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
  • C22C2026/003—Cubic boron nitrides only

Definitions

• a polycrystalline cubic boron nitride (PcBN) compact comprised of, in volume percent, from about 80% to of about 95% of cBN; and a metallic binder system.
• the PcBN compact is especially useful in machining iron and similarly chemical reactive parts, such as sintered powder metal alloys.
• Fig. 1 is an electron microscope image of the preferred embodiment of the present invention.
• Fig. 2 is an elemental map of an embodiment of the invention with each specific color representing each individual substance.
• Fig. 3 is an electron microscope image of an elemental map of conventional material A
• Fig. 4 is an electron microscope image of an elemental map of conventional material B
• Fig. 5 is a chart representation summary of the elemental map image analysis of Fig. 1, Fig. 3 and Fig. 4.
• Fig. 6 is a graph representing summary of the tool life vs. CoB/Co ratio BACKGROUND
• a compact as used in the cutter art comprises a mass of abrasive particles bonded together in a self-bonded relationship, by means of a bonding medium, or by means of combinations thereof.
• a composite compact is a compact bonded to a substrate material, such as cemented metal carbide.
• U.S. Pat. No. 3,918,219 describes the catalytic conversion of hexagonal boron nitride (HBN) to cBN in contact with a carbide mass to form a composite cBN compact.
• HBN hexagonal boron nitride
• Compacts or composite compacts may be used in blanks for cutting tools, drill bits, dressing tools, and wear parts
• novel cBN compacts are especially useful in forming tools, such as are used in the machining of workpieces.
• chemically reactive materials 1 means materials that chemically react with the tool material such as, ferrous workpieces that react with diamond tools at elevated temperature.
• Inventive sintered cBN compacts may be machine powder metal parts made from powder meiai s thai are consolidated or den si tied to form workpieces or parts, and may be densified from iron powder by powder metal processing.
• the sintered cBN compacts of the present invention demonstrate excellent performance in machining chemically reactive materials, such as, powder metal iron.
• the inventive cBN sintered compacts excel in machining powder metal parts manufactured by consolidation of metal powder), such as now are common in the automotive industry, such as gears, valve seats, and the like.
• the metric comparing the inventive cBN sintered compacts is the useful life of the tool, which is determined by the quantity of machining it can complete before the tool fractures or the surface finish of the machined metal becomes unacceptable.
• the inventive cBN sintered compacts have tested and found in one embodiment, to perform better than conventional compacts by a factor of more than 3 to 1.
• feedstock powder can be milled to the desired panicle size and mixed by a variety of techniques, including, for example, ultrasonic mixing, ball mill mixing, attrition mill mixing, and the like.
• Milling often is accomplished in the presence of a solvent such as, but not limited to, alcohols, acetones, and like solvents that can be readily removed and do not promote undesirable oxidation of the metal powders being milled. Such milling usually does not result in the oxidation of the powders to any undesirable degree. Milling temperatures will be ambient and times can range up to several hours. Adjusting the size of the bal l mi lling apparatus proportionately may make blended mixtures ranging in size from 100 g to 2 kg, or larger. [00015] The blended mixture is dried to remove the solvent (such as, isopropyl alcohol, acetone) at a temperature below the flash point of the solvent. The powder subsequently is granulated to aid in further processing. The composition of the blended material can be modified so that the relative contents of the ingredients adhere to the ranges desired.
• a solvent such as, but not limited to, alcohols, acetones, and like solvents that can be readily removed and do not promote undesirable oxidation of the metal powders being milled.
• the powder may be subjected to sintering using conventional HPHT techniques and apparatus well known in the art, such as described above.
• the powder is loaded in refractory metal cups (e.g., Ta or Nb).
• the size of the cups limits the size of the final sintered compact.
• A. backing substrate material can he loaded into the cup for in situ bonding to the sintered cBN compact, as is known in this art.
• Suitable substrates include, for example, refractory metal (e.g., W) carbides.
• This sealed cup assembly then is loaded into a high pressure cel l which consists of pressure transmission and pressure sealing materials and then subjected to high pressure (e.g., 4.5-6.5 GPa) and high temperature (above 1200° C.) for 30-40 minutes to sinter the powder mixture and braze it to the substrate.
• high pressure e.g., 4.5-6.5 GPa
• high temperature above 1200° C.
• the sintered blank is removed from the cell and machined to remove the cup material and to bring it. to the desired dimensions.
• the finished blank is cut, either by electro-discharge machining
• the sintered cBN compac product comprises between about 80 vol % and 95 vol % cBN grains with mean size of about 1 -2 microns (um ) with the remainder of the material consisting of the binder phase, which is uniformly dispersed among the cBN grains.
• an alummum-containing compound added into the powder during the milling and blending step begins to react with the cubic boron nitride and begins the sintering.
• Cobalt from the cemented carbide substrate also liquefies during HPHT and infiltrates the powder bed, eliminating any porosity and further aiding sintering.
• the binder contains stoichiometric carbides, nitrides, or borides.
• the binder phase contains several phases that can be identified by X-ray diffraction techniques including, for example, aluminum nitride, cobalt, tungsten carbide, tungsten boride, and compounds of tungsten, boron and/or cobalt. These phases are formed during the sintering process by reaction of the blended powder components. Careful selection of the powder formulation and HPHT conditions results in a final material with lower unreacted cobalt than conventional materials. This inventive material has been shown to have measurable performance benefits over conventional material s.
• the sintered cBN compact then, can be formed into a tool for machining chemically reactive materials, such as, powder metal iron.
• chemically reactive materials such as, powder metal iron.
• the formation of such tools and the machining conditions used may be well known in the art and well -practiced commerci lly.
• Figure 1 presents a fine-grained high-cBN content material with roughly 90 vol% cBN hereinafter referred to as the inventive material.
• This preferred embodiment of the invention may comprise: Black region 1 10 at 3.607 vol % is a color that is not assigned.
• Yellow region at 120, 7.001 vol % represents CoB, W undetected.
• Green region 130 at 70.814 vol % represents B, Co and W undetected.
• Red region 140 at 1.142 vol % represents Co, B and W undetected.
• Blue region 150 at 3.23 vol % represents W, Co and B undetected
• Cyan region 160 at 9.72 vol % represents WB, Co undetected.
• Magenta region 170 at 2.281 vol % represents CoW, B undetected.
• White region 180 at 2.973 vol % represents CoWB.
• Figure 2 presents the elemental map of the substances 200 contained in the preferred embodiment.
• a color or combination of colors corresponds to the associated substance.
• a scanning electron microscope (SEM) was used to generate an Energy Dispersive X-Ray Spectroscopy (EDS) map of cBN materials such that the three elements of interest are chosen and assigned to a color channel. Cobalt is assigned to Red 240, W is assigned to Blue 250 and Boron is assigned to green 230.
• the three color channels are merged to create a composite image with each color indicating a specific element or combination of elements.
• the colors representative of the elements, mixtures and compounds comprise:
• the yellow region 220 represents cobalt boride.
• the green region 230 represents boron alone.
• the red region 240 represents cobalt alone.
• the blue region 250 represents tungsten.
• the cyan region 260 represents tungsten boride.
• the magenta region 270 represents cobalt tungsten.
• the white 280 represents cobalt tungsten boride.
• Figure 3 presents conventional grade material A which is different from the inventive material and comprises:
• Yellow region 320 at 7.49 vol % represents CoB.
• Green region 330 at 71.934 vol % represents B.
• Red region 340 at 6.076 vol % represents Co.
• Blue region 350 at 1.803 vol % represents W.
• Cyan region 360 at 3.75 vol % represents WB.
• Magenta region 370 at 3.212 vol % represents CoW.
• White region 380 1.334 vol % represents CoWB.
• the presented material 300 differs from the inventive material because the amount of element 1 cobalt in the inventive material is significantly lower than the cobalt in other conventional grades.
• the reacted amount of cBN (CoB + WB) is significantly higher in the inventive material than in conventional grades.
• Figure 4 presents conventional grade material B which comprises:
• Yellow region 420 3.156 represents CoB.
• Green region 430 at 78.841 vol % represents B.
• Red region 440 at 3.83 vol % represents Co.
• Blue region 450 at 1.681 vol % represents W.
• Cyan region 460 at 3.64 vol % represents WB.
• Magenta region 470 at 1.681 vol % represents CoW.
• White region 480 0.704 vol % represents CoWB.
• Figure 5 presents a summary of the elemental map image analysis 500.
• inventive material 510 with the conventional material A 520 and conventional material B 530 is presented.
• the amount of elemental cobalt 540 is significantly lower in the inventive material 550 than in the conventional materials 560 or
• the amount of reacted B (CoB + WB) is significantly higher in the inventive material 580 than in the conventional material 590.
• Testing revealed in machining of sintered metal alloy gears, the inventive material resulted in longer tool life which exceeded the tool life of conventional materials.
• the tool life of the inventive materials exceeded the tool life of conventional material A by 3.8 times and the inventive material exceeded the life of conventional material B by 2.6 times.
• Figure 6 presents a graphical representation of tool life, wherein the X-axis is a ratio of CoB volume (vol %) to Co volume (vol%) and the Y-axis is tool life (minutes) in machining of sintered alloy gears at cutting conditions of 150 m/min, feed rate of 0.15 mm/rev and depth of cut of 0.1 mm with coolant.
• This figure clearly shows that an increase in tool life is directly proportional to an increase in CoB/Co ratio.

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Manufacturing & Machinery (AREA)
• Ceramic Engineering (AREA)
• Materials Engineering (AREA)
• Organic Chemistry (AREA)
• Inorganic Chemistry (AREA)
• Structural Engineering (AREA)
• Mechanical Engineering (AREA)
• Crystallography & Structural Chemistry (AREA)
• Metallurgy (AREA)
• Cutting Tools, Boring Holders, And Turrets (AREA)
• Ceramic Products (AREA)
• Powder Metallurgy (AREA)
• Drilling Tools (AREA)

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• 2017
  • 2017-10-25 US US15/793,098 patent/US10406654B2/en active Active
  • 2017-10-31 EP EP17199332.2A patent/EP3476819B8/en active Active
  • 2017-10-31 PL PL17199332.2T patent/PL3476819T3/pl unknown
  • 2017-11-10 JP JP2017216905A patent/JP7388810B2/ja active Active
• 2018
  • 2018-10-22 CN CN201880069296.9A patent/CN111511703A/zh active Pending
  • 2018-10-22 KR KR1020207014000A patent/KR102696047B1/ko active Active
  • 2018-10-22 WO PCT/US2018/056879 patent/WO2019083887A1/en not_active Ceased
• 2022
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