U.S. patent number 3,779,745 [Application Number 05/287,143] was granted by the patent office on 1973-12-18 for carbide alloys suitable for cutting tools and wear parts.
This patent grant is currently assigned to Aerojet-General Corporation. Invention is credited to Erwin Rudy.
United States Patent |
3,779,745 |
Rudy |
December 18, 1973 |
CARBIDE ALLOYS SUITABLE FOR CUTTING TOOLS AND WEAR PARTS
Abstract
This invention relates to refractory metal bonded carbide alloys
for use as cutting tools and in other applications where high
hardness and abrasion resistance are required. The desired
fine-grain, lamellar microstructure is obtained preferably by
casting eutectic, or near-eutectic composition alloys of a Group
IVa metal (titanium, zirconium, hafnium), tungsten and carbon which
may contain certain alloying and inert materials. For selected
applications, the composites may be fabricated by
powder-metallurgical techniques.
Inventors: |
Rudy; Erwin (Beaverton,
OR) |
Assignee: |
Aerojet-General Corporation (El
Monte, CA)
|
Family
ID: |
26964288 |
Appl.
No.: |
05/287,143 |
Filed: |
September 7, 1972 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
802625 |
Feb 26, 1969 |
3690962 |
Sep 12, 1972 |
|
|
Current U.S.
Class: |
420/431; 75/248;
428/539.5; 148/404 |
Current CPC
Class: |
C22C
29/06 (20130101); C30B 21/02 (20130101); C22C
1/1068 (20130101) |
Current International
Class: |
C30B
21/00 (20060101); C30B 21/02 (20060101); C22C
1/10 (20060101); C22C 29/06 (20060101); C22c
027/00 (); C22c 029/00 () |
Field of
Search: |
;75/176,134F,134V,175.5,177 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Rutledge; L. Dewayne
Assistant Examiner: Weise; E. L.
Parent Case Text
This application is a continuation-in-part of copending application
of Erwin Rudy Ser. No. 802,625, filed Feb. 26, 1969, Pat. No.
3,690,962, issued Sept. 12, 1972.
Claims
What is claimed is:
1. A cast carbide quaternary composition of the elemental
formula:
[(Ti.sub.a)(Zr.sub.b)]-- W -- [C.sub.q ]
which consists essentially of Titanium, Zirconium, Tungsten, and
Carbon wherein
a is the At. percent of Ti
b is the At. % of Zr
q is the At.% of C
10 .ltoreq.a + b.ltoreq.40
20.ltoreq.q .ltoreq.30
when the fraction a/(a+b) is equal to or greater than 1/2
and
15.ltoreq.a+b.ltoreq.40
15.ltoreq. q .ltoreq. 30
when the fraction a/(a+b) is less than 1/2
the balance being W when a/(a+b) is equal to, greater than, or less
than 1/2.
2. A cast carbide quaternary composition of the elemental
formula:
[(Hf.sub.a)(Zr.sub.b)]--W--[C.sub.q ]
which consists essentially of Hafnium, Zirconium, Tungsten, and
Carbon wherein
a is the atomic percentage of Hf
b is the atomic percentage of Zr
q is the atomic percentage of C
wherein
15.ltoreq.a+b.ltoreq.40
15.ltoreq.q .ltoreq.30
the balance being tungsten.
3. A cast carbide composition of a higher order than quaternary of
the elemental formula:
[(Ti.sub.a)(Zr.sub.b)]-[(W)(X)(Cr)(R)] --C.sub.q
which consists essentially of at least Titanium, Zirconium,
Tungsten and Carbon wherein
a is the atomic percentage of Titanium
b is the atomic percentage of Zirconium
q is the atomic percentage of Carbon
X is at least 1 element selected from the group consisting of
Molybdenum and Rhenium, said X being present in the range of from 0
to about 20 At. percent;
Cr is present in the range of from 0 to about 10 At. percent
R is at least 1 element selected from the group consisting of
Vanadium, Niobium, and Tantalum, said R being present in the range
of from 0 to about 5 At. percent, wherein
10 .ltoreq. a+b.ltoreq.40
20 .ltoreq. q .ltoreq. 30
when the fraction a/(a+b) is equal to 1/2 or greater than 1/2
and
15.ltoreq. a+b .ltoreq. 40
15.ltoreq. q .ltoreq. 30
when the fraction a/(a+b) is less than 1/2
the balance being w when a/a+b is equal to, greater than, or less
than 1/2; the balance being tungsten. -
4. A cast carbide composition of a higher order than quarternary of
the elemental formula:
[(Hf.sub.a)(Zr.sub.b)] - [(W)(X)(Cr)(R)] - C.sub.q
which consists essentially of at least Hafnium, Zirconium, Tungsten
and Carbon, wherein
a = At. percent of Hf
b = At. percent of Zr
q = At. percent of C
x is at least 1 element selected from the group consisting of
Molybdenum and Rhenium, said X being present in the range of from 0
to about 20 At. percent;
Cr is present in the range of from 0 to about 10 At. percent;
R is at least 1 element selected from the group consisting of
Vanadium, Niobium, and Tantalum, said R being present in the range
of from 0 to about 5 At. percent
and wherein
15.ltoreq.a+b.ltoreq.40 At.%
15.ltoreq.q .ltoreq. 30 At.%
the balance being tungsten.
5. A cast carbide quaternary composition of the elemental
formula
Ti--Zr--W--C
wherein
Ti is present at about 20.5 atomic percent
Zr is present at about 2.5 atomic percent
W is present at about 52 atomic percent
C is present at about 25 atomic percent.
Description
DISCUSSION OF THE PRIOR ART
Modern carbide tooling materials consists of a
mechanically-pulverized, hard carbide phase dispersed in a matrix
(binder) of an iron group metal, usually cobalt or nickel. The
binder phase contributes toughness to the composite and also serves
as an aid in sintering the carbide particles. The loss of strength
of iron metal-based binder phases at relatively low temperatures
can cause thermal wear to become the dominant wear mechanism at
high cutting speeds. The low melting temperatures of these binder
phases also preclude their use as abrasion-resistant composites at
temperature above 800.degree.C. to 1,000.degree.C.
Binderless, cast carbides such as W.sub.2 C + WC eutectics played a
role in the initial development of carbide-based tools and die
materials, but became obsolete with the advent of the tougher,
cobalt-bonded carbides fabricated by powder-metallurgical
techniques.
Despite the attractive features of the casting process, including
its adaptability to low cost manufacturing methods and need for
only moderate capitalization, castable tooling materials of
equivalent performance to the iron group metal bonded carbides were
not developed.
DESCRIPTION OF THE INVENTION
The carbide composite materials of this invention have excellent
thermal and mechanical shock resistance compared to the
conventional cobalt-bonded carbide tool. This is achieved through
the formation of a fine-grain, lamellar microstructure having a
hard monocarbide phase and a tough refractory metal phase.
The carbide composite of this invention, in a preferred embodiment,
comprises a base alloy system of a Group IVa metal (Ti, Zr or Hf),
tungsten and carbon having a fine-grain, lamellar microstructure
which is derived from a pseudobinary eutectic or near-eutectic
composition. The lamellar microstructure possesses a monocarbide
cutting phase and a metal phase with the latter phase being rich in
tungsten and contributing toughness to the composite. The
monocarbide phase contains significant amounts of both the tungsten
and the Group IVa metal. In a preferred embodiment (hypereutectic
composition) of the carbide composite of the invention, grains of
primary carbide are dispersed throughout the lamellar
microstructure. The interspersed primary carbide grains
significantly improve the cutting action of the composite when
employed as a machining tool.
The carbide alloys of the invention are made possible by the
existence of a pesudobinary eutectic (see Table I) in the systems
of Ti--W--C, Zr--W--C, and Hf--W--C. The solidification of the
eutectic liquid provides a refractory metal phase and a monocarbide
phase that are in solid state two-phase equilibria. The
co-existence of the metal phase and the monocarbide phase in the
solid state microstructure is necessary to the concept of the
metal-bonded carbide tool of the invention. The occurrence of
eutectic or near-eutectic-composition reactions provides the means
by which the desired microstructure, which possesses an extremely
fine-grain, lamellar mixture of metal and monocarbide phases, can
be obtained by melting and casting.
Table I shows the exact eutectic compositions and the compositions
of the coexisting component phases of each of the three respective
eutectics in the Ti--W--C, Zr--W--C, and the Hf--W--C systems.
##SPC1##
Alloy compositions from the Ti--W--C systems, even when they are
located somewhat away from the eutectic composition, will still
solidify almost isothermally and thus produce acceptable
micro-structures closely resembling those of the true eutectics.
Hence, there is in this alloy system, considerable latitude in
varying the properties of the composites by changing the overall
composition of the alloys without losing castability or changing
the basic morphology of the cast structure derived from the
pseudobinary eutectic or near-eutectic reaction.
There is considerably less freedom in varying the compositions of
the Zr--W--C and Hf--W--C alloy systems, and in both of the latter
systems it has been found that solidification occurs over a
relatively wide temperature range when the compositions are located
more than approximately 10 atomic percent to the zirconium or
hafnium side away from the pseudobinary eutectic. Hence, the
microstructure of the latter two systems, if provided with too much
zirconium or hafnium, will have a coarser grain structure and the
composites will be less suitable for cutting tool applications.
Other advantages of the invention will be apparent from the
following detailed descriptions and drawings in which:
FIG. 1 is a photomicrograph of a typical Group IVa metal (in this
instance titanium)-tungsten-carbon composition system which
contains (Ti(21)--W(57)--C(22) in atomic percents) taken at a
magnification of 1000X;
FIG. 2 is a photomicrograph at a magnification of 500X of another
Group IVa metal-tungsten-carbon system of somewhat different
composition namely (Ti(23)--W(52)--C(25) atomic percent) wherein
there are grains of primary carbide dispersed throughout the
lamellar microstructure;
FIG. 3 is a graph presenting typical comparative wear curves
obtained in turning Type 347 stainless steel with the cast alloy
tools prepared according to the invention and with top grade C--2
and C--50 type commercial carbide tools.
FIG. 4 is a compositional ternary diagram showing desired
composition areas for Ti--W--C base alloys of the invention;
and
FIG. 5 is a compositional ternary diagram showing desired
composition areas for Zr--W--C and Hf--W--C base alloys of the
invention.
The carbide composites of the invention are preferably prepared by
melting and casting to produce the fine-grain, lamellar
micro-structure of monocarbide phase and refractory metal phase
formed through solidification of an eutectic or
near-eutectic-composition liquid. A typical fine-grain lamellar
microstructure of the invention is illustrated in FIG. 1 where the
metal is dark and the carbide light. The photomicrograph of that
figure, while showing a titanium-tungsten-carbon system, is typical
of the lamellar microstructure of all three base alloy systems,
i.e., Ti--W--C, Hf--W--C, and Zr--W--C of the invention.
For carbide cutting tool applications it has been found desirable
to have grains of primary carbide dispersed throughout the lamellar
microstructure as seen in FIG. 2. The photomicrographs of the
hafnium and zirconium systems show similr microstructures to those
of FIGS. 1 and 2. The presence of the grains of primary carbide in
the lamellar structure significantly improve the use of the carbide
composite for machine tool cutting purposes.
The ternary diagrams of FIGS. 4 and 5 depict base alloy
compositions suitable for producing the carbide composites of the
invention. Referring to FIG. 4, which is concerned with
titanium-tungsten-carbon base alloys, it is seen that the preferred
compositions fall within the inner hatched area E, F, G, H. The
larger area A, B, C, D includes compositions of generally less
suitable composites, but which are acceptable for some
applications. Similarly, the inner hatched area of E, F, G, H of
FIG. 5 dpicts the more desirable compositions of either the hafnium
or zirconium systems. The larger enclosed area A, B, C, D includes
composites generally less suitable, but still of a useful nature.
The lamellar microstructures of the preferred areas E, F, G, H of
FIGS. 4 and 5 include grains of primary carbide dispersed
throughout the microstructure. These primary carbide grains enhance
the cutting characteristics of the composites when used in machine
tools. However, too much of the primary carbide grains promotes
chipping of the machine tool. Compositions falling within the
general areas A, B, C, D graphically above the preferred areas E,
F, G, H will have some tendency to chip. Such is tolerable for some
machine tool applications and not objectionable at all for other
applications where high hardness and abrasive resistance are
required. Below the preferred areas E, F, G, H of FIGS. 4 and 5 but
within the area A, B, C, D there is a tendency for primary metal
grains to form within the lamellar micro-structure. Primary metal
lessens the value of the carbide composite when used as cutting
tools. To the right of the preferred areas E, F, G, H of both FIGS.
4 and 5 and within the general areas A, B, C, D there is a tendency
for subcarbide grains to form within the lamellar micro-structure.
Subcarbides are less hard than monocarbides and, therefore, less
suitable for machining applications. The inner hatched areas E, F,
G, H of FIGS. 4 and 5 contain the primary carbide grains in desired
amounts for most machine tool purposes.
Melting and casting, plasma-arc spraying, as well as
powder-metallurgical methods have been employed in preparing metal
and monocarbide composites based on the alloy systems Ti--W--C,
Zr--W--C, and Hf--W--C of the invention. Melting followed by
casting into chilled molds has produced composites with the best
mechanical properties and performance for cutting tool purposes.
Experience indicates that skull melting, a technique using either a
nonconsumable (tungsten) or a consumable electrode, is the most
efficient and reliable method for obtaining the melts needed for
casting. Melting of the charges in resistively or inductively
heated graphite containers has been proven feasible for Ti--W--C
base alloys, although care has to be exercised to avoid excessive
carbon pick-up upon prolonged exposure of the alloys to
hypereutectic temperatures. Continuous melting of presinerted
compacts in the field of an eddy-current concentrator, or
resistance heating and melting of alloy charges in an arrangement
where the container is formed by a solidified portion of the alloy
to be melted, appear to be promising techniques.
Centrifugal casting of the melt is preferable to casting techniques
employing stationary molds, because the former casting techniques
minimize the problems associated with the formation of shrinkage
pipes and, as the result of the high casting speeds, allows complex
parts to be cast to shape.
Other uses of the alloys of the invention are many including hard
facings for plows, bulldozer blades, bearings, and for penetrator
cores for armor-piercing projectiles. Because of their relatively
low neutron capture cross section, alloys containing zirconium, and
based on the Zr--W--C combination, are thought to find possible use
in nuclear applications. In ceratin instances where small amounts
of Titanium, Hafnium, or both, in quarternary or higher order
combinations such as (Zr, Ti)--W--C, (Zr, Hf)--W--C or
(Zr,Hf,Ti)--W--C are tolerable, multi-Group IVa-metal containing
alloys may be more economical, or may be utilized when an increase
in hardness is desired in spite of the increased neutron capture
cross section.
Application of hard facings to various shaped objects by plasma
melting and spraying of the powdered alloys of the invention, has
been proven feasible. The plasma-arc spraying technique further
holds promise for preparing extremely rapid chilled, and thus
very-fine-grained, alloying powders, which then can be consolidated
into shapes by powder-metallurgical techniques.
It is importaNt in whatever manner of fabrication which is employed
that the eutectic or near-eutectic liquid phase be rapidly cooled
in order to assure the formation of the fine-grained, lamellar
microstructure of the invention.
Dense bodies can also be prepared from powdered material by hot
pressing, and also by cold pressing followed by sintering,
preferably with the addition of sintering aids. The powders may
comprise the desired carbides and metals. The iron group metals or
their alloys, as well as manganese and cooper-containing alloys,
may be used as sintering aids. Among these ,nickel or nickel-iron
alloys seem to afford the best properties in terms of toughness and
shock-resistance, but as cutting tools, the sintered materials are
inferior to the cast alloys.
ALLOYING OF THE GROUP IVa METAL (Ti, Zr, and Hf)--W--C BASE ALLOYS
OF THE INVENTION
The ternary alloys from all three base systems of the invention can
be extensively modified by alloying additions of other metals.
Alloying possibilities were determined by preparing cutting tools
and using these on type 347 stainless steel. However, the
observations are applicable to the composites in general.
1. Ti--W--C base tools had the best cutting performance in terms of
tool life. The optimum composition in this base system lies at, or
near, the composition Ti--W--C(23--52--25 atomic percent) which is
slightly hypereutectic. Hypoeutectic alloys located to the tungsten
side of the pseudobinary eutectic have slightly higher wear rates
than the optimum composition, but also have somewhat higher
edge-stability and cracking resistance, alloys located to the
titanium side of the eutectic have good wear characteristics, but
tend toward chip-welding at high cutting speeds; alloys with more
than 28 atomic percent carbon are hypoeutectic, contain primary
metal-phase, and are subject to high wear.
2. Tungsten may be partially replaced by molybdenum and or Rhenium
(for instance, up to 20 atomic percent of the base alloy system)
without impairing strength or abrasion resistance of the composite.
Small quantities of chromium (up to 10 atomic percent of the base
alloy system) also may be substituted for tungsten, but larger
quantities result in embrittlement of the composites. In certain
embodiments for certain useages all of the tungsten may be replaced
by its alloying substituents. It must be remembered however, that
in any substitution, the fundamental system must be maintained,
namely the three elemental groups titanium and its alloying
materials, tungsten and or its alloying substituents and carbon of
the system. The same is true for the hafnium based systems and the
zirconium based systems.
3. The Group IVa metals (Ti, Hf, and Zr) may be interchanged for
each other in any ratio in their respective base alloy systems, for
most purposes. Low level alloying (1 to 5 atomic percent) of the
Ti--W--C system with Zr or Hf increases the tool life in comparison
with unsubstituted base alloys, still higher concentrations of Hf
or Zr result in a graidual drop-off of cutting performance to the
levels observed for ternary Zr--W--C or Hf--W--C alloys. Generally
speaking, the Hf or Zr will not be substituted in an amount in
excess of 20 atomic percent of the Ti in the base alloy Ti--W--C
system. Ti generally is not substituted in a Zr based system over
20 atomic percent for the Zr.
More typically, the alloying Group IVa metal or metals Hf and Zr
will comprise not more than 5 atomic percent of the base alloy
Ti--W--C system. However, in a Zr--Hf, and in a Hf--Zr based system
a 50:50 ratio of these metals as the Group IVa metal component
would not be uncommon. The 1 to 5 At. percent alloying
substitutions of Zirconium or Hafnium, or mixtures of these two
elements for Titanium in Ti--W--C base alloys significantly improve
cutting tool wear resistance as well as abrasion resistance of
these composites in other applications such as hard facings for
plows, bulldozer blades, bearings and dies. It is believed that the
small Zirconium or Hafnium additions reduce the friction between
cutting tool and work piece leading to lower cutting temperature
which results in greater tool life and improved overall
performance; similarly, advantages in the economics of facings,
bearings and dies are to be expected with the utilization of these
Zirconium or Hafnium containing Ti--W--C composites by virtue of
the improved abrasion resistance. In addition, these small
Zirconium or Hafnium additions are believed to function as grain
refiners of the Ti--W--C base alloy microstructure, presumably
contributing to the overall strength of the composites.
4. Substitution of Group Va metals, such as vanadium for tungsten
or titanium in quantities up to 10 atomic percent of the base alloy
system may be made. In the composites this decreases the cracking
sensitivity, but somewhat impairs abrasion resistnace. In a cutting
tool the addition impairs performance and edge strength.
Up to 5 atomic percent of such Group Va metals as niobium and
tantalum, each alone or in combination, can be added to replace the
Group IVa metal. Edge chipping in a cutting tool is increased if
the noibium-tantalum addition is greater than 5 atomic percent.
Such additions up to and over 5 atomic percent may improve
cratering and chip-welding characteristics in cutting tools.
Overall, the addition of Group Va metals in quantites of more than
5 atomic percent (preferably, not more than 2 atomic percent) is
not recommended for Vanadium, Niobium or Tantalum.
5. No significant change in cutting performance was observed upon
substituting up to 10 atomic percent rhenium for tungsten.
Substitution of rhenium up to 20 atomic percent for tungsten
appears acceptable.
6. Low level additions of iron group metals (Co, Ni, Fe), of
manganese and copper, and of rare earch metals in quantities less
than 3 atomic percent of the carbide composite of the invention
were found to be essentially inert, i.e., to have little or no
effect on the physical and mechanical characterictis of the
composites.
7. Eutectic, or slightly hypereutectic, Zr--W--C and Hf--W--C based
alloys are tougher than Ti--W--C based alloys, but were found to
have higher wear-rates in cutting tool applications.
The base alloy systems of the invention including the added amount
of cutting tool performance improving alloying metals will
typically comprise at least 90 atomic percent of the carbide
composite. Generally speaking, the atomic percent age of inerts is
held to less than 3 to 5 atomic percent of the carbide
composite.
The refractory metal phase of the lamellar microstructure of the
invention will typically have a melting point around 2,700.degree.C
which is a decided improvement over the 1,400.degree.C melting
temperature of the conventional cobalt cutting tool.
The rate of cooling of the alloy of the invention during its
fabrication determines grain size. Desirably, cooling is
accomplished at a rate of at least 20.degree.C per second to obtain
a generally fine grain. Cooling at a slower rate gives a product
with a coarser grain. Preferably, cooling is performed at a rate of
more than 30.degree.per second.
Preliminary test results indicate transverse rupture strength
levels for the cast Ti--W--C eutectic structure in the range of
from 220,000 psi and extending to above 350,000 psi, depending upon
fabrication conditions.
The majority of tests has been carried out in studying the
performance of the alloys as cutting tools in straight turning of
cylindrical test bars on a LeBlonde machineability lathe. For these
tests, the carbide alloys were either machined into inserts
suitable for clamping in standard tool holders, or more or less
irregular shaped bits were brazed onto steel tool holders and then
ground on a K.O. Lee diamond grinder to the desired geometry. The
test material consisted of annealed 347 stainless steel in the form
of 3 inch diameter .times. 18 inch long cylindrical bars. The
surface was removed to a depth of 0.050 inch prior to testing the
experimental alloys. In the standard test, the steel was cut at 400
surface feet per minute (sfm), using a depth of cut of 50 mils and
a feed of 10 mils per revolution. The tool geometry for the
standard test was as follows: back rake, 0.degree.; side rake,
5.degree.; side relief, 5.degree.; end relief, 5.degree.; side
clearance end angle, 25.degree..
A number of representative commercial cutting were evaluated under
machineability test conditions described above. In addition to the
examples below, a selected list of additional tests is contained in
Table II, Infra.
FIG. 3 graphically depicts the comparative wear curves obtained in
the turning of Type 347 stainless steel with the cast alloy tools
prepared according to the invention and with top grade C-2 and C-50
type commercial carbides. It will be seen that the cast alloyed
tools of the invention have equivalent wear resistance to the top
grade wear resistant C-50 tools. In addition, it has been shown
that the tools of the invention have equivalent toughness to that
of the C-2 tools. Therefore, the cast tools of the invention
combine the best qualities of the tough C-2 tools and the wear
resistant C-50 tools.
EXAMPLE I
A button of an alloy Ti--W--C (19-58-23 atomic percent) was
prepared by arc melting in a non-consumable electrode arc furnace
under helium at 1/2 atmosphere pressure; the melt was allowed to
solidify on the water-cooled copper hearth. Metallographic
examination of the alloy showed very small amounts of primary
monocarbide grains in an eutectic lamellar matrix. The average
lamellae width of the eutectic structure was about one micron. The
hardness was R.sub.A = 86. The tool was brazed onto a mild steel
tool holder, ground to the standard tool geometry,, and tested in
turning 347 stainless steel with the standard conditions outlined
above. The tool life, based on a flank wear of 0.016 inch was 45
minutes; the tool showed local wear (crater) of 0.028 inch at the
end of the cutting flank.
EXAMPLE II
An alloy Ti--Zr--W--C (20.5-2.5-52-25 atomic percent) (standard
alloy R1 in FIG. 3) was prepared in the same way as the sample
described under Example I. The composite had a hardness of R.sub.A
= 87, and the metallographic examination showed small amounts of
primary monocarbide in an eutectic matrix (substantially identical
to the microstructure shown in photomicrograph of FIG. 2). The
average lamellae width of the eutectic was about 0.4 microns. The
heterogenous matrix of the photomicrograph of FIG. 2 is an eutectic
of metal plus carbide, and the white or light islands are primary
carbide. A uniform wera rate of 0.07 mils per minute was derived
from a 40-minute turning test of 347 stainless steel with aforesaid
standard conditions, yielding an extrpolated tool life of 190
minutes (0.016 inch flank werar). Cratering of the tool after 40
minutes cutting time was negligible.
EXAMPLE III
An arc cast alloy Hf--W--C (27-51-22 atomic percent) containing a
small amount of primary carbide grains in addition to the eutectic
lamellar microstructure was prepared. Tool life in the standard
test on 347 stainless steel was 15 minutes, with the tool showing
negligible cratering or edge wear at the end of the test.
EXAMPLE IV
The alloy cited under Example II and another arc cast alloy
Ti--Hf--W--C (20.5-2.5-52-25 atomic percent) were tested for edge
stability by gradually increasing the feeds while maintaining a
surface speed of 400 feet/min. and a cutting depth of 0.050 inch.
Both tools performed reliably at feeds up to 0.05. inch per
revolution. At still higher feeds, the tool edges showed signs of
chipping.
EXAMPLE V
The behavior of the cast carbide tooling materials at high depth of
cut were established in another test run using the same alloys as
listed under Example IV with a cutting speed of 400 sfm (surface
feet per minute). A constant cutting depth of 1/4 inch was
maintained in the experiments, while the feed was gradually
increased, starting at 0.005 inch per revolution. No breakdown
occurred at feeds up to 0.030 inch/rev., after which the experiment
had to be stopped for lack of lathe power.
EXAMPLE VI
An arc cast alloy Ti--W-C (19-58-23 atomic percent) was comminuted
to a grain size below 50 microns and thoroughly mixed with 3 weight
percent nickel powder. The mixture was cold-compacted at 4
tons/square inch in steel dies and then sintered for 1 hour at
1,500.degree.C under vacuum. The metallographic examination showed
a dense structure consisting of rounded monocarbide grains embedded
in a metallic matrix. Tool life in the standard turning test on 347
stainless steel was 14 minutes. The tool had a higher crater wear
than the cast alloy of the same composition.
EXAMPLE VII
A composite tool was fabricated by facing one edge of an M-2 tool
steel insert with a 0.080 inch wide .times. 0.20 inch long .times.
0.050 inch thick platelet of the cast standard alloy R1,
Ti--Zr--W--C (20.5-2.5-52-25 atomic percent). The carbide tip was
attached to the steel insert by brazing. The performance of this
composite tool under the standard test condition on 347 stainless
steel was found to be the same as the solid carbide inserts;
however, as a result of the lower thermal conductivity of the tool
steel base compared to the cast carbide alloys, higher tip
temperatures, and, as a consequence, higher wear rates were
observed on the composite insert as the total load on the tool was
increased by either increasing the depth of cut or the feed.
TABLE II
Selected List of Test Data Obtained from Cast Ti(Zr,Hf)-W-C Alloy,
and From Commercial C-2 and C-50 Grade Carbide Cutting Tools, in
Turning Type 347 Stainless Steel
Alloy Composition, Atomic Percent W.sub.B W.sub.B .sub.U T.sub.L
Remarks Ti( 26)-W(51)-C(23 5 3 0.14 65 slight welding tendency
Ti(21)-W(56)-C(23) 4 4 0.25 65 Ti(20)-W(55)-C(25) 3 3 0.13 110
Ti(23)-W(52)-C(25) 3 5 0.16 75 Ti(26)-W(49)-C(25) 4 6 0.09 160
Ti(25)-W(48)-C(27) 4 5 0.06 160 slight chipping tendency
Ti(22)-W(51)-C-27 4 4 0.10 110 Ti(23.5)-Zr(2.5)-W(49)-C(25) 4 5
0.07 160 Ti(17.5)-Zr(2.5)-W(55)-C(25) 4 0.16 75
Ti(20.5)-Zr(2.5)-W52)-C(25) 4 8 0.07 190 alloy R1
Ti(20.5)-Hf(2.5)-W(52)-C(25) 5 8 0.08 130 alloy R2
Ti(23)-Ta(2.5)-W(51.5)-C(23) 7 5 0.19 65 slight chipping tendency
Hf(22)-W(60)-C(18) 6 5 0.44 25 Hf(25)-W(55)-C(20) 4 4 0.25 50
Hf(25)-W(48)-C(27) 4 4 0.25 50 Zr(25)-W(55)-C(20) 7 4 0.70 20
Zr(28)-W(47)-C(28) 6 5 0.30 40 Commerical Alloys Carboloy 370 (C-50
Type) 3 3 0.08 160 Carboloy 883 (C-2 Type) -- 1.10 10 Legend:
W.sub.B -- Break-in wear, mils T.sub.B -- Break-in time, minutes
W.sub.U -- Uniform wear rate, mils per minute T.sub.L --
Extrapolated tool life in minutes for 0.016 inch wear *Data shown
are for specific heats of stainless steel. Results will vary f
o
* * * * *