Classifications

• • 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
  • C22C29/06—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 carbides, but not containing other metal compounds
  • C22C29/08—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 carbides, but not containing other metal compounds based on tungsten carbide
• • 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
  • C22C29/06—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 carbides, but not containing other metal compounds
  • C22C29/067—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 carbides, but not containing other metal compounds comprising a particular metallic binder
• • 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
  • B22F2003/1032—Sintering only comprising a grain growth inhibitor
• • 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
  • B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
• • 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

Definitions

• the present application relates to cemented carbides having improved properties, such as improved galling resistance, Vickers hardness, Palmqvist fracture toughness and coercive force.
• Cemented carbides are commonly used metallurgical products due to their hardness and fracture toughness.
• cemented carbides have a hard phase containing hard constituents, such as refractory carbides, nitrides, etc.
• Cemented carbides also generally have a binder phase that contains a ductile metallic binder, such as Co, Ni, Fe, etc.
• the hard phase and a metallic binder phase can be processed into a wide variety of microstructures that achieve different mechanical and physical properties. Even though different mechanical and physical properties have been achieved, such properties are generally unpredictable.
• cemented carbides continue to be researched and developed in an attempt to achieve further improvements.
• An embodiment of the present application includes a cemented carbide, including a hard phase composed of WC.
• the cemented carbide further includes a binder phase including Co, and an additive being a grain growth inhibitor selected from the group consisting of M02C, TiC, TaC, and NbC, and mixtures thereof.
• the hard phase is 87 wt.% to 91 wt.% of the cemented carbide.
• the binder phase is 9 wt.% to 11 wt.% of the cemented carbide.
• the grain growth inhibitor is 0.1 wt.% to 2 wt.% of the cemented carbide.
• the grain growth inhibitor includes Mo, and the Mo is 0.1 wt.% to 1 .50 wt.% of the cemented carbide.
• the grain growth inhibitor is not CrsC2, VC, or mixtures thereof.
• the cemented carbide has a HV30 Vickers hardness of at least 1400 HV30.
• the cemented carbide has a Palmqvist fracture toughness, Kic, of at least 7.5 MPaVm.
• the cemented carbide has a coercive force, He, of at least 9 kA/m.
• the Mo is in a range approximately between 0.40 wt.%-0.60 wt.% of the cemented carbide.
• Another embodiment of the present application includes a cemented carbide, including a hard phase composed of WC.
• the cemented carbide further includes a binder phase including Co, and an additive being a grain growth inhibitor selected from the group consisting of ZrC, and BN, and mixtures thereof.
• the grain growth inhibitor is 0.1 wt.% to 1 wt.% of the cemented carbide.
• the additive further includes a grain growth inhibitor selected from the group consisting of M02C, TiC, TaC, NbC, VC, CrsC2, and mixtures thereof.
• the cemented carbide has a HV30 Vickers hardness of at least 1500 HV30.
• the cemented carbide has a Palmqvist fracture toughness, Kic, of at least 9.9 MPaVm.
• Another embodiment of the present application includes a tool including the cemented carbides disclosed herein.
• Another embodiment of the present application includes a method of improving galling resistance, including: providing a cemented carbide sample having a hard phase including WC, a binder phase including Co, and an additive being a grain growth inhibitor including either (I) M02C, TiC, TaC, and NbC, or (II) ZrC, BN, M02C, TiC, TaC, NbC, VC, and CrsC2; measuring an average coefficient of friction (COF) of the cemented carbide sample against INCONEL 718 over a sliding distance from 1 to 18 meters and from 14 to 18 meters; and adjusting the amount of the M02C in the grain growth inhibitor comprising either (I) M02C, TiC, TaC, and NbC, or (II) ZrC, BN, M02C, TiC, TaC, NbC, VC, and CrsC2 based on the measured average coefficient of friction (COF) of the cemented carbide sample against INCONEL 718 over a sliding distance from 1 to
• the cemented carbide sample including M02C in a range approximately between 0.40 wt.%-0.60 wt.% has the most optimal galling resistance.
• FIGS. 1-8 are scanning electron microscope images of the microstructures of particular embodiments of the cemented carbides of the present application.
• FIGS. 9-15 are scanning electron microscope images of the microstructures of particular embodiments of the cemented carbides of the present application showing the influence of Mo thereon.
• FIG. 16 is a chart showing the average coefficient of friction (COF) against INCONEL 718 with varied amounts of Mo.
• FIG. 17 is a chart showing the coefficient of friction against (COF) INCONEL 718 for particular exemplary embodiments.
• FIG. 18 is a chart showing the coefficient of friction (COF) against INCONEL 718 for the embodiment with 0.47 wt.% Mo and the embodiment with 0.1 wt.% Mo.
• FIG. 19 is a chart showing the coefficient of friction (COF) against INCONEL
• FIG. 20 is a chart showing the coefficient of friction (COF) against INCONEL 718 for the embodiment with 0.47 wt.% Mo and the embodiment with 0.75 wt.% Mo.
• FIG. 21 is a chart showing the coefficient of friction (COF) against INCONEL 718 for the embodiment with 0.47 wt.% Mo and the embodiment with 1 wt.% Mo.
• FIG. 22 is a chart showing the coefficient of friction (COF) against INCONEL 718 for the embodiment with 0.47 wt.% Mo and the embodiment with 1 .25 wt.% Mo.
• FIG. 23 is a chart showing the coefficient of friction (COF) against INCONEL 718 for the embodiment with 0.47 wt.% Mo and the embodiment with 1 .50 wt.% Mo.
• FIGS. 24-28 are scanning electron microscope images of the microstructures of particular embodiments of the cemented carbides of the present application containing ZrC, BN, or a mixture thereof.
• FIG. 29 is a chart showing the galling resistance of particular embodiments of the cemented carbides of the present application by measuring the average coefficient of friction (COF) against a reference-grade material.
• COF average coefficient of friction
• FIG. 30 shows the milling performance on INCONEL 718 of a grade composed of 0.47 wt.% Mo compared to a reference grade.
• wt.% refers to a given weight percent of the total weight of a cemented carbide composition, unless specifically indicated otherwise.
• the terms “about” and “approximately” are used interchangeably. It is meant to mean plus or minus 1 % of the numerical value of the number with which it is being used. Thus, “about” and “approximately” are used to provide flexibility to a numerical range endpoint by providing that a given value may be “above” or “below” the given value. As such, for example a value of 50% is intended to encompass a range defined by 49.5%-50.5%.
• the term “predominantly” is meant to encompass at least 95% of a given entity.
• the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result.
• the term “lowest possible” refers to the least quantity of a value that is determined as the minimum from a set of values that are recorded.
• the term “most optimal” refers to the amount or degree of something that is most favorable, satisfactory or desirable. [0046] Wherever used throughout the disclosure, the term “generally” has the meaning of “approximately”, “typically” or “closely” or “within the vicinity or range of”.
• Palmqvist fracture toughness i.e. Kic, refers to the ability of a material with pre-cracks to resist further fracture propagation upon absorbing energy.
• HV30 Vickers hardness i.e. applying a 30 kgf load
• HV30 Vickers hardness is a measure of the resistance to localized plastic deformation, which is obtained by indenting the sample with a Vickers tip at 30 kgf.
• the ISO 28079-2009 standard specifies a method for measuring the fracture toughness and hardness of hardmetals, cermets and cemented carbides at room temperature by an indentation method.
• the ISO 28079-2009 standard applies to a measurement of fracture toughness and hardness calculated by using the diagonal lengths of indentations and cracks emanating from the corners of a Vickers hardness indentation, and it is intended for use with metal-bonded carbides and carbonitrides (e.g. hardmetals, cermets or cemented carbides).
• the test procedures proposed in the ISO 28079:2009 standard are intended for use at ambient temperatures but can be extended to higher or lower temperatures by agreement.
• the test procedures proposed in the ISO 28079:2009 standard are also intended for use in a normal laboratory-air environment. They are typically not intended for use in corrosive environments, such as strong acids or seawater.
• the ISO 28079-2009 standard is directly comparable to the standard ASTM 8771 as disclosed for example in “Comprehensive Hard Materials book”, 2014, Elsevier Ltd. Page 312, which is incorporated herein by reference in its entirety. Thus, it can be assumed that the measured fracture toughness and hardness using the ISO 28079-2009 standard will be the same as the measured values employing the ASTM B771 standard.
• the term “coercive force” i.e. He also called coercivity or magnetic coercivity, is a measure of the ability of a ferromagnetic material to withstand an external magnetic field without becoming demagnetized.
• coefficient of friction i.e. p is a ratio that is used to quantify the frictional force resisting the motion of two surfaces in contact between two objects, taken in relation to the normal force that is pressing and keeping the two objects together.
• galling is a form of wear of a material typically caused by friction and adhesion between sliding surfaces. When a material galls, some of it is pulled with the contacting surface, especially if there is a large amount of force compressing the surfaces together. Thus, galling is caused by a combination of friction and adhesion between the surfaces that is followed by slipping and tearing of crystal structures beneath the surfaces. This will generally leave some material stuck or even friction-welded to the adjacent surface, whereas the galled material may appear gouged with balled-up or torn lumps of material stuck to its surface.
• INCONEL 718 is a common superalloy based on nickel typically in an amount between 50.0 wt.%-55.0 wt.%, chromium generally in an amount between 17.0 wt.%-21.0 wt.%, molybdenum typically in an amount between 2.8 wt.%-3.3 wt.%, niobium and tantalum generally in an amount between 4.75 wt.%-5.50 wt.% with a balance of iron. INCONEL 718 is also known in the art as Nicrofer 5219, Superimphy 718, Haynes 718, Pyromet 718, Supermet 718, and Udimet 718.
• Cemented carbide grades can be classified according to the WC grain size. Different types of grades have been defined as nano, ultrafine, submicron, fine, medium, medium coarse, coarse and extra coarse.
• the term (I) “nano grade” is defined as a material with a grain size of less than about 0.2 pm;
• (II) “ultrafine grade” is defined as a material with a grain size between about 0.2 pm and about 0.5 pm;
• submicron grade is defined as a material with a grain size between about 0.5 pm and about 0.9 pm;
• IV “fine grade” is defined as a material with a grain size between about 1.0 pm and about 1.3 pm;
• V) “medium grade” is defined as a material with a grain size between about 1 .4 pm and about 2.0 pm;
• (VI) “medium coarse grade” is defined as a material with a grain size between about 2.1 pm and about 3.4 pm;
• (VII) “coarse grade” is defined as a material with
• the present application includes a cemented carbide including a hard phase having WC, a binder phase including a binder material such as, for example, Co, and/or an additive.
• the hard phase includes WC.
• the grade of the WC is submicron, fine, or mixtures thereof.
• the cemented carbide primarily contains WC with WC being present in the cemented carbide typically in a range of 87 wt.% to 91 wt.% relative to the total weight of the cemented carbide.
• the WC is present in the cemented carbide in a range of 88 wt.% to 91 wt.% relative to the total weight of the cemented carbide.
• the WC is present in the cemented carbide in a range of 89 wt.% to 91 wt.% relative to the total weight of the cemented carbide.
• the WC is present in the cemented carbide in a range of 90 wt.% to 91 wt.% relative to the total weight of the cemented carbide. In certain particular embodiments, the WC is present in the cemented carbide in a range of 88 wt.% to 89.5 wt.%, 88 wt.% to 90 wt.%, 89 wt.% to 89.5 wt.%, 89 wt.% to 90 wt.%, 90 wt.% to 90.5 wt.%, or in a range of 90.5 wt.% to 91 wt.% all of which are relative to the total weight of the cemented carbide.
• the hard phase can additionally include additional hard phase components, such as carbides, carbonitrides, and/or nitrides of Ti, Nb, V, Ta, Cr, Zr, and Hf, and mixtures thereof.
• the binder phase includes a binder component such as, e.g., Co.
• the binder is Co such that the cemented carbide is a WC-Co cemented carbide.
• the binder is typically present in the cemented carbide in a range of 9 wt.% to 11 wt.% relative to the total weight of the cemented carbide.
• the binder is present in the cemented carbide in a range of 9 wt.% to 10 wt.% relative to the total weight of the cemented carbide.
• the binder is present in the cemented carbide in a range of 9.5 wt.% to 11 wt.% relative to the total weight of the cemented carbide.
• the binder is present in the cemented carbide in a range of 10 wt.% to 11 wt.% relative to the total weight of the cemented carbide. In yet other embodiments, the binder is present in the cemented carbide in a range of 10.5 wt.% to 11 wt.% relative to the total weight of the cemented carbide. In certain particular embodiments, the binder is present in an amount of 9.5 wt.% to 10.5 wt.% and approximately 10 wt.%, all of which are relative to the total weight of the cemented carbide. The term “approximately” is understood to mean +/- 1 % of the numerical value of the number with which it is being used.
• the additive can be a grain growth inhibitor that can be selected from the group consisting of M02C, TiC, TaC, NbC, and mixtures thereof.
• the grain growth inhibitor phase is typically present in the cemented carbide in a range of 0.1 wt.% to 2 wt.% relative to the total weight of the cemented carbide. In some embodiments, the grain growth inhibitor phase is present in the cemented carbide in a range of 0.25 wt.% to 2 wt.% relative to the total weight of the cemented carbide. In other embodiments, the grain growth inhibitor phase is present in the cemented carbide in a range of 0.5 wt.% to 2 wt.% relative to the total weight of the cemented carbide.
• the grain growth inhibitor phase is present in the cemented carbide in a range of 0.75 wt.% to 2 wt.% relative to the total weight of the cemented carbide. In still other embodiments, the grain growth inhibitor phase is present in the cemented carbide in a range of 1 wt.% to 2 wt.% relative to the total weight of the cemented carbide. In further embodiments, the grain growth inhibitor phase is present in the cemented carbide in a range of 1.25 wt.% to 2 wt.% relative to the total weight of the cemented carbide.
• the grain growth inhibitor phase is present in the cemented carbide in a range of 1.50 wt.% to 2 wt.% relative to the total weight of the cemented carbide. In even other embodiments, the grain growth inhibitor phase is present in the cemented carbide in a range of 1.75 wt.% to 2 wt.% relative to the total weight of the cemented carbide. In certain particular embodiments, the grain growth inhibitor phase is present in the cemented carbide in a range of 0.4 wt.% to 1 wt.% and approximately 0.5 wt.%, all of which are relative to the total weight of the cemented carbide. The term “approximately” is understood to mean +/- 1 % of the numerical value of the number with which it is being used.
• the grain growth inhibitor does not include CrsC2 and/or VC.
• the cemented carbides of the present application can inhibit WC grain growth during sintering with refractory carbides other than the commonly used CrsC2 and/or VC.
• excellent hardness and fracture toughness can be achieved even without the addition of CrsC2 and/or VC.
• the excellent hardness and fracture toughness achieved by the cemented carbides of the present application are similar to WC-Co cemented carbides that utilize CrsC2 and/or VC as a grain growth inhibitor.
• Obtained coercive force, He, values for the cemented carbides of the present application may for example range from 9 kA/m to 16 kA/m .
• Corresponding coercive force, He, values for a WC-10Co submicron grade i.e. 10Co refers to 10 wt.% Co of the cemented carbide composition and the grade can contain CrsC2 and/or VC
• a WC-10Co coarse grade has coercive force, He, values which generally range from 6 kA/m to 8.5 kA/m.
• the cemented carbides of the present application have an HV30 Vickers hardness of at least 1400 HV30.
• the cemented carbides generally have an HV30 Vickers hardness in the range of 1400 HV30 to 1700 HV30.
• the cemented carbides have an HV30 Vickers hardness in the range of 1400 HV30 to 1500 HV30, 1400 HV30 to 1600 HV30, 1500 HV30 to 1550 HV30, 1500 HV30 to 1600 HV30, 1500 HV30 to 1700 HV30, 1550 HV30 to 1600 HV30, 1600 HV30 to 1700 HV30, or in the range of 1650 HV30 to 1700 HV30.
• the cemented carbides of the present application typically have a Palmqvist fracture toughness, Kic, of at least 7.5 MPaVm. In some embodiments, the cemented carbides have a Palmqvist fracture toughness, Kic, of 7.5 MPaVm to 12.5 MPaVm. In other embodiments, the cemented carbides have a Palmqvist fracture toughness, Kic, of 8.5 MPaVm to 12.5 MPaVm. In yet other embodiments, the cemented carbides have a Palmqvist fracture toughness, Kic, of 9.5 MPaVm to 12.5 MPaVm.
• the cemented carbides have a Palmqvist fracture toughness, Kic, of 10.5 MPaVm to 12.5 MPaVm. In further other embodiments, the cemented carbides have a Palmqvist fracture toughness, Kic, of 11.5 MPaVm to 12.5 MPaVm. In certain particular embodiments, the cemented carbides have a Palmqvist fracture toughness, Kic, of 9 MPaVm to 11 MPaVm or 9.5 MPaVm to 10.5 MPaVm.
• the cemented carbides of the present application have a coercive force, He, of at least 9 kA/m. In some embodiments, the cemented carbides have a coercive force, He, of 9 kA/m to 25 kA/m. In other embodiments, the cemented carbides have a coercive force, He, of 11 kA/m to 25 kA/m. In yet other embodiments, the cemented carbides have a coercive force, He, of 13 kA/m to 25 kA/m. In still other embodiments, the cemented carbides have a coercive force, He, of 15 kA/m to 25 kA/m.
• the cemented carbides have a coercive force, He, of 17 kA/m to 25 kA/m. In even other embodiments, the cemented carbides have a coercive force, He, of 19 kA/m to 25 kA/m. In certain embodiments, the cemented carbides have a coercive force, He, of 21 kA/m to 25 kA/m. In certain particular embodiments, the cemented carbides have a coercive force, He, of 12 kA/m to 20 kA/m, or 17 kA/m to 20 kA/m.
• the coercivity generally has an inversely proportional relationship with the microstructure of the carbide. That is, as the coercivity increases, the carbide grain size decreases. A high coercivity, therefore, indicates a small carbide grain size.
• TABLE 1 shows certain embodiments of the cemented carbides of the present application, including the HV30 Vickers hardness, Palmqvist fracture toughness, Kic, and coercive force, He.
• FIGS. 1-8 show scanning electron microscope images of the grades identified in TABLE 1.
• the grain growth inhibitor phase generally includes Mo in an amount of 0.1 wt.% to 1.50 wt.% of the cemented carbide. In certain embodiments, the grain growth inhibitor phase includes Mo in an amount of 0.1 wt.% to 1 wt.% of the cemented carbide.
• the grain growth inhibitor phase includes Mo in an amount of 0.25 wt.% to 1 .50 wt.%, 0.50 wt.% to 1 .50 wt.%, 0.75 wt.% to 1 .50 wt.%, 0.90 wt.% to 1.50 wt.%, 1.00 wt.% to 1.50 wt.%, 1.10 wt.% to 1.50 wt.%, 1.25 wt.% to 1 .50 wt.%, or 1 .40 wt.% to 1 .50 wt.% of the cemented carbide.
• the grain growth inhibitor phase is added as M02C, such that the cemented carbides contain Mo therein. If the amount of Mo exceeds 1.25 wt.%, the precipitation of the third phase can occur. To avoid such precipitation, the upper limit for the amount of Mo in the carbide composition can be limited to 1 .25 wt.% or even 1 wt.%. Even further, in certain embodiments, the cemented carbides of the present application do not form and do not contain a cubic Co and Mo phase.
• FIGS. 9-15 show scanning electron microscope images of the microstructure of the embodiments from TABLE 2.
• the aforementioned third phase is visible in FIGS. 14-15, which show the microstructure when the amount of Mo is 1.25 wt.% and 1 .50 wt.%.
• TABLE 2 indicates that the presence of the third phase negatively influences the Palmqvist fracture toughness, Kic, which decreases when the amount of Mo is 1 .25 wt.% relative to the amount of Mo being in the range of 0.1 wt.% to 1 wt.%.
• the coefficient of friction (COF) against INCONEL 718 was measured for each of the samples shown in TABLE 2.
• the coefficient of friction (COF) was measured from 1 to 18 meters of sliding distance.
• the coefficient of friction (COF) was further measured from 14 to 18 meters of sliding distance when the coefficient of friction (COF) showed a stable behavior. The results are shown in TABLE 2.
• FIG. 16 shows the coefficient of friction (COF) against INCONEL 718 plotted against the sliding distance for all the samples from TABLE 2.
• the coefficient of friction (COF) for the embodiment with 0.47 wt.% Mo is depicted as the line having the lowest coefficient of friction (COF). That is, each of the other samples has an elevated coefficient of friction (COF) as compared to the embodiment with 0.47 wt.% Mo.
• the galling resistance is not merely a function of the coefficient of friction (COF), but also considers the presence of galling events, which are depicted as peaks and valleys in the lines of FIG. 17. As seen in FIG.
• FIGS. 19, 21 and 22 extract the lines from FIG. 17 for the embodiments composed with 0.25 wt.% Mo, 1 wt.% Mo, and 1.25 wt.% Mo and provide the lines together with the embodiment composed with 0.47 wt.% Mo.
• the increase in galling events shown in FIGS. 19, 21 and 22 coincides with the elevated average coefficient of friction (COF) shown in FIG. 16.
• FIG. 18 shows only the embodiment composed with 0.47 wt.% Mo and the embodiment composed with 0.1 wt.% Mo.
• FIG. 20 shows only the embodiment composed with 0.47 wt.% Mo and the embodiment composed with 0.75 wt.% Mo.
• FIG. 23 shows only the embodiment composed with 0.47 wt.% Mo and the embodiment composed with 1.50 wt.% Mo.
• FIGS. 18, 20 and 23 depict fewer galling events (i.e., fewer peaks and valleys).
• galling resistance is favorable generally in a range approximately between 0.40 wt.% Mo-0.60 wt.%.
• the method of preparing the cemented carbides includes: first, mixing and/or milling the hard phase and the binder phase; second, pressing the mixture of the hard phase and the binder phase; third, sintering the pressed mixture of the hard phase and the binder phase.
• the sintered product can be ground and coated to obtain a product (e.g., a tool or insert) from the cemented carbides.
• the coating can be provided by chemical vapor deposition (CVD) and/or physical vapor deposition (PVD).
• CVD chemical vapor deposition
• PVD physical vapor deposition
• the cemented carbides can achieve excellent hardness and fracture toughness even without the addition of CrsC2 and/or VC as a grain growth inhibitor. Additionally, the methods of preparing the cemented carbides can proceed to avoid the formation of a cubic Co and Mo phase.
• the cemented carbides of the present application can include ZrC and/or BN as the additive.
• the addition of ZrC or BN helps decrease metal build-up events when machining Ni alloys.
• metal build-up is a critical damage mechanism for cemented carbide tools when machining any metallic alloy. It is usually solved by using a coating on top of standard grades of cemented carbides.
• the cemented carbides of the present application that include ZrC and/or BN as the additive can decrease the adhesion of the machined material to the bulk material when the coating is completely removed from the surface.
• the ZrC and/or BN can be present in an amount of 0.1 wt.% to 0.2 wt.% of the cemented carbide.
• the addition of large amounts of ZrC i.e., over 5 wt.%) is avoided because of the high activity of Zr with oxygen, which can produce highly porous materials.
• the additive can further include a grain growth inhibitor selected from the group consisting of M02C, TiC, TaC, NbC, VC, CrsC2, and mixtures thereof. That is, when the additive is ZrC and/or BN, the cemented carbides can be prepared with and without CrsC2.
• TABLE 3 shows certain embodiments of the cemented carbides of the present application when the additive is ZrC and/or BN and includes the HV30 Vickers hardness and Palmqvist fracture toughness, Kic.
• FIGS. 24-28 show scanning electron microscope images of the grades identified in TABLE 3.
• the reference grade in TABLE 3 refers to a 10% Co grade with submicron WC (i.e. 10Co refers to 10 wt.% Co of the cemented carbide composition).
• the cemented carbides containing ZrC and/or BN have an HV30 Vickers hardness of at least 1500 HV30. In some embodiments, the cemented carbides have an HV30 Vickers hardness in the range of 1500 HV30 to 1650 HV30. In certain embodiments, the cemented carbides have an HV30 Vickers hardness of 1550 HV30 to 1650 HV30. In certain particular embodiments, the cemented carbides have an HV30 Vickers hardness of 1600 HV30 to 1650 HV30. [0082] Additionally, the cemented carbide ZrC and/or BN have a Palmqvist fracture toughness, Kic, of at least 9.9 MPaVm. In certain particular embodiments, the cemented carbides have a Palmqvist fracture toughness, Kic, of 9.9 MPaVm to 10.6 MPaVm.
• FIG. 29 shows that such abrupt changes were not observed for grades of the cemented carbides containing ZrC and/or BN shown in TABLE 3.
• FIG. 29 shows the curves for the friction coefficient against the sliding distance of the reference-grade and grades of the cemented carbides containing ZrC and/or BN shown in TABLE 3.
• FIG. 29 shows that that abrupt changes associated with galling events are not observed on the grades of the cemented carbides containing ZrC and/or BN shown in TABLE 3. Even though the addition of ZrC and/or BN decreases metal build-up, it does not affect hardness and fracture toughness in the range of a common WC-Co material used for machining.
• the present application also includes methods of preparing the cemented carbides.
• the method of preparing the cemented carbides includes: first, mixing and/or milling the hard phase and the binder phase; second, pressing the mixture of the hard phase and the binder phase; third, sintering the pressed mixture of the hard phase and the binder phase.
• the sintered product can be ground and coated to obtain a product (e.g., a tool or insert) from the cemented carbides.
• the coating can be provided by chemical vapor deposition (CVD) and/or physical vapor deposition (PVD).
• Small amounts of ZrC and/or BN can be added to the cemented carbides.
• the small amounts of ZrC and/or BN can be added to the mixture of the hard phase and the binder phase in the methods of preparing the cemented carbides.
• the cemented carbides disclosed herein can be used to prepare tools.
• the present application relates to a tool including the disclosed cemented carbides.
• the tool can be, but is not limited to end mills, inserts, drills or saw tips.
• the tool is an end mill.
• FIG. 30 shows the milling performance on INCONEL 718 of a grade composed of 0.47 wt.% Mo compared to a reference grade.
• the average number of passes is increased by about 35% for the grade composed of 0.47 wt.% Mo in comparison to the reference grade.
• the results demonstrated in FIG. 30 are in alignment with the favorable low coefficient of friction (COF) and a decrease in galling events (i.e. improvement in galling resistance), which were observed for samples generally spanning a range typically between approximately 0.40 wt.% and 0.60 wt.% Mo.
• COF favorable low coefficient of friction
• any two components so associated can also be viewed as being “operably connected”, or “operably coupled,” to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being “operably couplable,” to each other to achieve the desired functionality.
• operably couplable include but are not limited to physically mateable and/or physically interacting components, and/or wirelessly interactable, and/or wirelessly interacting components, and/or logically interacting, and/or logically interactable components.
• one or more components may be referred to herein as “configured to,” “configured by,” “configurable to,” “operable/operative to,” “adapted/adaptable,” “able to,” “conformable/conformed to,” etc.
• configured to can generally encompass activestate components and/or inactive-state components and/or standby-state components, unless context requires otherwise.
• any sequence(s) and/or temporal order of sequence of the system and method that are described herein this disclosure are illustrative and should not be interpreted as being restrictive in nature. Accordingly, it should be understood that the process steps may be shown and described as being in a sequence or temporal order, but they are not necessarily limited to being carried out in any particular sequence or order. For example, the steps in such processes or methods generally may be carried out in various different sequences and orders, while still falling within the scope of the present disclosure.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Mechanical Engineering (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• Powder Metallurgy (AREA)
• Cutting Tools, Boring Holders, And Turrets (AREA)

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• 2022
  • 2022-10-18 MX MX2024006049A patent/MX2024006049A/es unknown
  • 2022-10-18 WO PCT/US2022/078252 patent/WO2023091830A1/en not_active Ceased
  • 2022-10-18 CN CN202280076278.XA patent/CN118202077A/zh active Pending
  • 2022-10-18 KR KR1020247016457A patent/KR20240112838A/ko active Pending
  • 2022-10-18 EP EP22802460.0A patent/EP4433621A1/de active Pending
  • 2022-10-18 JP JP2024529717A patent/JP7788554B2/ja active Active
• 2025
  • 2025-08-28 JP JP2025142041A patent/JP2025179109A/ja active Pending

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