《复合材料 Composites》课程教学资源（学习资料）第五章 陶瓷基复合材料_brittleness16

JOURNAL OF RARE EARTHS Vol 25, Suppl., Jun. 2007, P. 322 Types, Performance and Application of A2 O3 System Ceramic Cutting Tool Qiu Like(邱立科), Li Xikun(李喜坤), Peng yang(彭阳)3, Ma Weimin(马伟民)3, Qiu guanming(邱关明), Sun yanbin(孙彦彬)5 (I. Jilin Ruid Electrical Technology Development Co, Lid, Jilin 132013, China; 2. Materials Science Engineering College, Shenyang University of Science and Technology, Shenyang 110168, China; 3. Department of Materials Science and Engineering, Shenyang University, Shenyang 110044, China; 4. School of Material and Chemical Engineering, Changchun University of Science and Technology, Changchun 130022, China; 5. Depart- ment of Materials Science and Engineering, Jilin University, Changchun 130026, China) Abstract: Performance and development of traditional Al2O3 ceramics and composite ceramic cutting tool materials with addition of the second phase were described. The composition, additives, strengthening and toughening mechanism, prep- aration technique, brands, mechanical performance, using environment and cutting performance of Al203 system ceramic ride, toughening Al2O3, Z102 toughening-Al2O3-carbide with MnTi, Al2O3-metal-nitride, Al2O3-metal-carbide, Fe3Al(Fe- Al)/Al2O3, Al2O3-TiC-TiB2-ZHO2, A12O3-ZrO2-Y203 and Al2O3 coat Key words: inorganic nonmetal material: Al2 O3 system ceramic; cutting performance CLC number: 0614 33 Document code: A Article ID: 1002-0721(2007)-0322-0 The progress of cutting tool materials has great cess. At present, novel materials of difficult cutting fluence on the civilization development of human be with high-strength, high hardness, corrosion-resistant ing. Before 20000 years B. C, mankind began to abrasion resistance and high temperature resistance use the grinding stone(natural ceramics )as cutting accounts for over 50% of total international processing tool, the progress of cutting materials was adopted as amount. Most of traditional hard alloy tools failed in the division symbol of development of ancient human processing new materials, and the most important history, claiming the history of mankind after that as thing is that the key composition, such as W, Co for Neolithic period", and then Bronze, ancient iron high speed steel and hard alloy cutting tools, is de knife tool were used to divide the stages of develop- clining worldwide so as prices rise. This situation ment in human history more greatly promotes the research and development of ce rom 1850 to present, a great development of cutting ramic cutting tools. On the other hand, the main raw tool materials has been achieved. And there has been materials of ceramic knives, such as Al, Si, are the a very long history in ceramics ed as metal most abundant resources in the earth,s crust. Thus the cutting tools application of advanced ceramic cutting tool in the The emergence of advanced ceramic tool material field of high-speed machining has very broad prospects he first achievement of the technological revolution in the 21st century of using advanced ceramic materials to reform mechan There are three main trends in the research of ce- al machining technique by humans. Back in the ear. ramic materials in the 21st century2, namely the de- ly 20th century, Germany and Britain had been seek velopment from single phase of high purity to multi ing to replace the traditional carbon steel knives with phase composite ceramics, the development from mi- ceramic tools. Modem ceramic cutting tool material, cron level ceramic material to nano level ceramic ma with high abrasion resistance, heat resistance and terial, and computer aided ceramic materials design chemical stability, plays an important role in the area Due to the increase in difficult-to-machine mate of enhancing productivity with high-speed cutting pro and on ncy dur Received date: 2006-10-16; revised date: 2006-11-15 Foundation item: Project supported by the Scientific and Technological Project of Shenyang City (1053090-2-05) Biography Qiu Like(1968-), Male, Bachelor, Senior engineer wCorrespondingauthor(E-mail:sunyanbin1965@163.com

JOURNAL OF RARE EARTHS Vol.25, Suppl., Jun. 2007, p.322 'Jrsrpes , Performance and Application of A1203 System Ceramic Cutting 'Ibol Qiu Like (spa*)', Li Xikun (~-&-hp)2, Peng Yang ($3 Qiu Guanming (sF (I. Jilin Ruid Electrical Technology Development Co. , Ltd. , Jilin 132013, China; 2. Materials Science & Engineering College , Shenyang University of Science and Technology, Shenyang 110168, China ; 3. Department of Materials Science and Engineering , Shenyang University , Shenyang 110044 , China ; 4. School of Material and Chemical Engineering, Changchun University of Science and Technology , Changchun 130022 , China ; 5. Depart￾ment .f Materials Science and Engineering , Jilin University , Changchun 130026, China ) Ma Weimin (-%.1$;€%)3, tfi )" Sun Yanbin (4\B #)5 * Abstract: Performance and development of traditional A1203 ceramics and composite ceramic cutting tool materials with addition of the second phase were described. The composition, additives, strengthening and toughening mechanism, prep￾aration technique, brands, mechanical performance, using environment and cutting performance of A1203 system ceramic materials, such as traditional pure A1203, A1203-carbide, A1203-carbide-meta1, Al,O,-with additives of nitride and bo￾ride, toughening A1203, ZrO2 toughening-A1203-carbide with MnTi , A1203-metal-nitride, A1203-metal-carbide, Fe3A1( Fe￾Al)/A1203, A1203-TiC-TiBz-Zr02, A1203-Zr02-Y203 and A1203 coating, were outlined. Key words: inorganic nonmetal material ; A1203 system ceramic ; cutting performance CLC number : 0614.33 Document code : A Article ID : 1002 - 072 1 ( 2007 ) - 0322 - 05 The progress of cutting tool materials has great in￾fluence on the civilization development of human be￾ing. Before 20000 years B. C., mankind began to use the grinding stone (natural ceramics) as cutting tool, the progress of cutting materials was adopted as the division symbol of development of ancient human history, claiming the history of mankind after that as "Neolithic period " , and then Bronze, ancient iron knife tool were used to divide the stages of develop￾ment in human history"]. During more than 150 years from 1850 to present, a great development of cutting tool materials has been achieved. And there has been a very long history in ceramics being used as metal cutting tools. The emergence of advanced ceramic tool material is the first achievement of the technological revolution of using advanced ceramic materials to refom mechan￾ical machining technique by humans. Back in the ear￾ly 20th century, Germany and Britain had been seek￾ing to replace the traditional carbon steel knives with ceramic tools. Modem ceramic cutting tool material, with high abrasion resistance, heat resistance and chemical stability, plays an important role in the area of enhancing productivity with high-speed cutting pro￾cess. At present, novel materials of difficult cutting, with high-strength , high hardness, corrosion-resistant , abrasion resistance and high temperature resistance, accounts for over 50% of total international processing amount. Most of traditional hard alloy tools failed in processing new materials, and the most important thing is that the key composition, such as W, Co for high speed steel and hard alloy cutting tools, is de￾clining worldwide so as prices rise. This situation greatly promotes the research and development of ce￾ramic cutting tools. On the other hand, the main raw materials of ceramic knives, such as Al, Si, are the most abundant resources in the earth's crust. Thus the application of advanced ceramic cutting tool in the field of high-speed machining has very broad prospects in the 21st century. There are three main trends in the research of ce￾ramic materials in the 21st century"], namely the de￾velopment from single phase of high purity to multi￾phase composite ceramics, the development from mi￾cron level ceramic material to nano level ceramic ma￾terial, and computer aided ceramic materials design. Due to the increase in difficult-to-machine mate￾rials, and on the demand of improving efficiency dur￾Receiveddate: 2006-10-16; reviseddate: 2006-11-15 Foundation item: Project supported by the Scientific and Technological Project of Shenyang City (1053090-2-05) Biography: Qiu Like (1968 - 1, Male, Bachelor, Senior engineer * Corresponding author (E-mail : sunyanhinl965 @ 163. corn)

Qiu L K et al. Types, Performance and Application of AlyO3 323 ing machining process and reducing costs, it is neces- particles of 20%60%dispersed in Al203 matrix is sary to develop new ceramic cutting tools. At present, prepared by hot pressing method at 1450-1600C in there have been 5%-10% of ceramic cutting tools in gra e ave proportion to all kinds of cutting tools. According to hot pressing ceramics can reach to 93. 5-94 5HRA the latest statistics, there is a market scale of 100 mil- bending strength is 0.9-1.0 GPa, Kic=4.5 MPa.m lion usd in the United States(700-1000 50, 000/ elastic module 420 MPa, thermal expansion coefficient year),about 70 million USD in Europe, about 60 mil- 8.3 x 10-6K-. This kind of cutting tool can be used lion USD in Japan. The Geramtec company in Germa n processing cast iron of abrasion resistance, hard ny is the major European manufacturers of new ceram- ened steel and high strength steel and other difficult- is very expens ting tool is its main product, the price to-machine materials. The bending strength of Al20, ive(in average, ten or more USD), an- TiC ceramics is better than that of pure AL, ceramics nual sales amounts to tens of millions of dollars not only at room tempura, but also at high tempera- Ceramic knives are currently used in more than ture. And at high temperature(above 1000C),the 20 industries, such as machine building, metallurgy decrease of bending strength is slow. The hardness of automobiles, transportation, mine and energy sources, Al, 0-Tic is higher than that of pure Al O, ceramics at low temperature. Ceramic cutting tool of Al2O3(Ti pumps, etc. the application of ceramic cutting tools W)C system: in which, crack expansion is hindered saves a lot of electric power, costs of cutting tools and by wC, TiC phase, framework intersect combination working hours for users with each other with dense phases, its particle size 1 Ceramic Cutting Tools of A,2O3 0.5-1.5 Am; and subgrains of 0. 1-0. 2 um in size Matrix can be found; HV=2600(93-95HRA), K, is about 5-6 MPam, 0=800-1100 MPa; it is suitable 1.1 Tradition ceramic cutting tools of for machining iron and steel materials of high hardness pure Al2O3 of 55-65HRC, also is suitable for machining or cut ting cast iron, brittleness materials, high density alloy Back to 1905, Germans began to study Al2O3ce- of W-based; and can perform continuous or interrupt mics as cutting tool. The first British patent of alu- ed milling and cutting with fine or crude precision mina ceramic tool was conferred in 1912. It is the first generation of ceramic cutting tool. In this kind of ce- 1.3 AL2O3carbide-metal ceramic cutting ramic cutting tool materials, the content of Al2O3 is tools ore then 99%. They are prepared by hot pressing Besides carbides, a small amount of metal(such method with a small amount of sintering agent( such as Ni, Ti. Mo, Cr, Co, w) was added in this kind of as MgO, Nio, Cr20,, TiO2)(namely white porce- a-A1,0,(<0. 5 m) ceramics to improve the lain). Pure Al2 0, ceramic cutting tools are of low strength with carbide and performance.A1,O,-carbide bending strength(700 MPa, Kic=4. 3 MPa.m metal ceramic cutting tools can be used to process elastic module 400 MPa, thermal expansion coefficient hardened steel, alloy steel, Mn-steel, chilled cast 8.2 x")and poor impact resistance, but they iron, Ni-based and Co-based alloy and nonmetal mate- are suitable to be used in machining cast iron of hard- rials(such as fiber glass, plastic sandwich materials ness lower than HB235 with semi precision and small etc. ) It is the best material for finished machining feeding rate, and carbide steel of hardness lower thar roller of chilled cast iron. Because of improvement of HRC38 and alloy steel because of their low costs, impact resistance, it can be used in situation of dis- abrasion resistance at high temperature. Cutting tools continuous cutting and fluid cutting of pure A1, 0, are usually used to process parts of grey 1.4 AL2O3 ceramic cutting tools with cast iron in automobile industry additives of nitride and boride 1.2 Al2O3-carbide ceramic cutting tool Thermal shock resistance is improved by adding The strength and impact resistance of Al2O3 nitride to Al2O3. Performance and machining scope of bide ceramic cutting tools were improved by adding a the Al2O3-nitride cutting tools is almost the same as certain amount of carbide (such as TiC, wC, TaC, that of Al2O3-carbide-metal cutting tools, they are NbC, Mo2C, Cr3 C2).The most widely used additive more suitable for discontinuous cutting, but their TiC, ceramics of AlO3-TiC with hard and fine Tic bending strength ( Krc =5. 7-7. 2 MPa. m)and

Qiu L K et a1 . Types , Performance and Application of A1203 323 ing machining process and reducing costs, it is neces￾sary to develop new ceramic cutting tools. At present, there have been 5% - 10% of ceramic cutting tools in proportion to all kinds of cutting tools. According to the latest statistics, there is a market scale of 100 mil￾lion USD in the United States (700 - 1000 50,000 / year), about 70 million USD in Europe, about 60 mil￾lion USD in Japan. The Geramtec company in Germa￾ny is the major European manufacturers of new ceram￾ics, ceramic cutting tool is its main product, the price is very expensive (in average, ten or more USD) , an￾nual sales amounts to tens of millions of dollars. Ceramic knives are currently used in more than 20 industries, such as machine building, metallurgy, automobiles , transportation, mine and energy sources, housing stock, mining, precision instruments, water pumps, etc . the application of ceramic cutting tools saves a lot of electric power, costs of cutting tools and working hours for users 1 Ceramic Cutting Tools of A1,0, Matrix 1.1 Tradition ceramic cutting tools of pure 403 Back to 1905, Germans began to study AlzO, ce￾ramics as cutting tool. The first British patent of alu￾mina ceramic tool was conferred in 1912. It is the first generation of ceramic cutting tool. In this kind of ce￾ramic cutting tool materials, the content of A1203 is more then 99%. They are prepared by hot pressing method with a small amount of sintering agent (such as MgO, NiO, Cr203, TiO,) ( namely white porce￾lain). Pure A1203 ceramic cutting tools are of low bending strength (700 MPa, Klc = 4. 3 MPa * m”’, elastic module 400 MPa , thermal expansion coefficient 8.2 x K-’) and poor impact resistance, but they are suitable to be used in machining cast iron of hard￾ness lower than HB235 with semi precision and small feeding rate, and carbide steel of hardness lower than HRC38 and alloy steel because of their low costs, abrasion resistance at high temperature. Cutting tools of pure A1203 are usually used to process parts of grey cast iron in automobile industry. 1.2 A1203-carbide ceramic cutting tools The strength and impact resistance of Alz03-car￾bide ceramic cutting tools were improved by adding a certain amount of carbide (such as TIC, WC, TaC, NbC, Mo2C, Cr3Cz). The most widely used additive is TIC, ceramics of A1203-TiC with hard and fine Tic particles of 20% - 60% dispersed in A1203 matrix is prepared by hot pressing method at 1450 - 1600 “c in graphite moulds. At present, the average hardness of hot pressing ceramics can reach to 93.5 - 94.5HRA , bending strength is 0.9- 1.0 GPa, Klc =4.5 i”a*m’/2, elastic module 420 MPa , thermal expansion coefficient 8.3 x K-’. This kind of cutting tool can be used in processing cast iron of abrasion resistance, hard￾ened steel and high strength steel and other difficult￾to-machine materials. The bending strength of &o3- TIC ceramics is better than that of pure A1203 ceramics not only at room tempura, but also at high tempera￾ture. And at high temperature (above 1000 T), the decrease of bending strength is slow. The hardness of A1203-TiC is higher than that of pure A120, ceramics at low temperature. Ceramic cutting tool of A1203-( Ti, W)C system: in which, crack expansion is hindered by WC , TIC phase, framework intersect combination with each other with dense phases, its particle size is 0.5-1.5pm; andsubgrains ofO.l-0.2pminsize can be found ; HV = 2600( 93 - 95HRA) , Klc is about 5 - 6 MPa.m‘/’, CT~ = 800 - 1100 MPa; it is suitable for machining iron and steel materials of high hardness of 55 - 65HRC, also is suitable for machining or cut￾ting cast iron, brittleness materials, high density alloy of W-based; and can perform continuous or intenupt￾ed milling and cutting with fine or crude precision. 1.3 A1203-carbide-metal ceramic cutting tools Besides carbides, a small amount of metal (such as Ni , Ti, Mo, Cr, Co, W) was added in this kind of a-A1203 ( < 0. 5 pm) ceramics to improve the joint strength with carbide and performance. A1203-carbide￾metal ceramic cutting tools can be used to process hardened steel, alloy steel, Mn-steel , chilled cast iron, Ni-based and Co-based alloy and nonmetal mate￾rials ( such as fiber glass, plastic sandwich materials, etc. ) . It is the best material for finished machining roller of chilled cast iron. Because of improvement of impact resistance, it can be used in situation of dis￾continuous cutting and fluid cutting. 1.4 A1203 ceramic cutting tools with additives of nitride and boride Thermal shock resistance is improved by adding nitride to A1203. Performance and machining scope of the Alz03-nitride cutting tools is almost the same as that of A1203-carbide-metal cutting tools, they are more suitable for discontinuous cutting, but their bending strength ( KIc = 5.7 - 7.2 MPa m”’ ) and

JOURNAL OF RARE EARTHS, Vol 25, Suppl ., Jun. 2007 hardness are lower than that of Al2 O]-TiC-Metal ce- 1.6 AL, O, ceramic cutting tools toughened ramie cutting tools. Ceramic knives with additive TiB, as adhesive in Al2O, matrix, because its composition is by Zroz phase with Mn, Ti oxide fine grains of Al,, and TiB2 of continuous adhesive A certain amount of ZrO2 can play an effect of hase,the three dimension continuity of boride is pre- toughening in A2 0-MnO-TiO2 system. With the in- served, so it has excellent impact resistance and abra- crease of ZrO2 content, toughness improved obviousl sion resistance and no peak. But total amount of MnO and TiO2 1.5 Toughening A1,O, ceramic cutting tool should be lower than 4. 5%o. These kind ceramic cut Toughening ALOy ceramics is prepared by adding high toughness and certain abrasion resistance toughening or strengthening materials to Al203 matrix 1.7 AL2O3metal-nitride ceramic cutting Now, the common used toughening method is ZrO tools Toughened and strengthened by nitrides(nitride The mechanism of ZrO2 phase change toughening is of Ti, Zr, Hf, Ta, Nb or their mixture, lubricant that phase change takes place at 1150 C in ZHO 2 lead- and metals(Ni, Mo, W), ceramics of this kind are of ing to volume change and inducing many cracks high abrasion resistance (low fiction coefficient )and matrix so as to absorb most of energy in tips of cracks heat conductivity, high strength, high toughness, red Kicisabout5-7Mpa'm.compactfinegrainscan hardness and excellent cutting performance. They are be prepared by Hot Isostatic Pressing technique. The suitable for machining quenching steel of high hard- cutting speed can reach to 60 m's. It can process ness, high quality steel of high strength, stainless loy with cutting speed of 4-5 times higher than hard are also suitable for machining normal cast iron, al g) Inconel Hastalloy and Rene high temperature super alloy cutting tools. (2)The mechanism of grain fiber cast iron of high hardness. With the bending strength toughening is that the fibers play the role of strength of 1200- 1300 MPa, hardness of 1800-1900 HV ening rod, grain fibers act as obstacle to block off fracture toughness KIc of 5-6 MPa.m",this kind cracks or to change the extending direction of cracks ceramic cutting tools can be used for continuously or so as to improve fracture toughness and to enhance im- discontinuously exact or coarse cutting and exact mill- pact resistance. It can also prevent built-up edge ing. This kind of ceramics with fine particles, well (BUE )during machining. The normally used fibers proportioned structure and no holes, can be prepared are SiC fibers and Si, N4 fibers. Sic fibers not only by wet milling mixture of Al2O,, nitride(for example can strengthen Al2O3 matrix, but also can disperse TiN )and metals, then hot pressing in vacuum at stress in the matrix. or is about 600-900 MPa, and 1600-1900C with pressure of 27. 6 MPa for less KIc is about 8-10 MPa.". So cutting tools tough ened with grain fibers are suitable for processing Ni- Table 1 shows the brand and mechanic properties based heat resistance alloy, hardened steel, nonmetal of some typical ceramic cutting tool 4) brittleness materials and high hardness cast iron with 1.8 Al,O3metal-carbonnitrides w machining speed. Thermal impact resistance can e improved by adding Si,N. fibers to Al2O,matrix AlO3-Metal-carbonnitrides composite has advan KIc=5-7 MPa m. This kind of ceramics is suit tage of abrasion resistance (low friction coefficient able for cutting heat resistant alloy of Ni-Cr-Fe with thermal conductivity, high strength, red hardness and hardness of HRC45. Its cutting speed is 10 times big toughness. Their cutting performance is excellent They are suitable for cutting and machining hardened ger than that of hard alloy cutting tools, its using life steel of big hardness, fine steel with high strength is 10-15 times longer that that of hard alloy cutting stainless steel, alloy steel, carbon steel, normal cast tools. Dispersion of the second phase particles tough ening is to hinder the slide and climb of dislocation by iron and cast iron alloy of high hardness. Its mechani- the dispersed particles of the second phase. The crack cal properties: or= 1200- 1300 MPa, HV= 1800 deflection or crack pinning aroused by the residual 1900, KIc=5-6 MPa.m2, so this kind of materials stress field around particles of the second ph crease fracture toughness of materials so as to im cutting with fine or rough precision the toughness of Al2O3 Ceramics greatly

324 JOURNAL OF RARE EARTHS, Vol. 25, Suppl. , Jun . 2007 hardness are lower than that of A1203-TiC-Metal ce￾ramic cutting tools. Ceramic knives with additive TiBz as adhesive in A1203 matrix, because its composition is fine grains of A1203 and TiB2 of continuous adhesive phase, the three dimension continuity of boride is pre￾served, so it has excellent impact resistance and abra￾sion resistance. 1.5 Toughening A1203 ceramic cutting tool Toughening A1203 ceramics is prepared by adding toughening or strengthening materials to A1203 matrix. Now, the common used toughening method is Zr02 phase transform toughening, grain fiber toughening and dispersion of the second phase particles, etc . ( 1 ) The mechanism of ZrO, phase change toughening is that phase change takes place at 1150 “c in ZrOz lead￾ing to volume change and inducing many cracks in matrix so as to absorb most of energy in tips of cracks, KIc is about 5 - 7 MPa. m112. Compact fine grains can be prepared by Hot Isostatic Pressing technique. The cutting speed can reach to 60 m * s-l. It can process Inconel Hastalloy and Rene high temperature super al￾loy with cutting speed of 4 - 5 times higher than hard alloy cutting tools. (2) The mechanism of grain fiber toughening is that the fibers play the role of strength￾ening rod, grain fibers act as obstacle to block off cracks or to change the extending direction of cracks so as to improve fracture toughness and to enhance im￾pact resistance. It can also prevent built-up edge (BUE) during machining. The normally used fibers are Sic fibers and Si3N4 fibersL3’. Sic fibers not only can strengthen A1203 matrix, but also can disperse stress in the matrix. cf is about 600 - 900 MPa, and KIc is about 8 - 10 MPa . m112. So cutting tools tough￾ened with grain fibers are suitable for processing Ni￾based heat resistance alloy, hardened steel, nonmetal brittleness materials and high hardness cast iron with low machining speed. Thermal impact resistance can be improved by adding Si3N4 fibers to Al2O3 matrix, KIc = 5 - 7 MPa . ml”. This kind of ceramics is suit￾able for cutting heat resistant alloy of Ni-Cr-Fe with hardness of HRC45. Its cutting speed is 10 times big￾ger than that of hard alloy cutting tools, its using life is 10- 15 times longer that that of hard alloy cutting tools. Dispersion of the second phase particles tough￾ening is to hinder the slide and climb of dislocation by the dispersed particles of the second phase. The crack deflection or crack pinning aroused by the residual stress field around particles of the second phase in￾crease fracture toughness of materials so as to improve the toughness of A1203 Ceramics greatly. 1.6 A1203 ceramic cutting tools toughened by ZrOz phase with Mn, Ti oxide A certain amount of ZrO2 can play an effect of toughening in A1203-Mn0-Ti02 system. With the in￾crease of Zr02 content, toughness improved obviously, and no peak. But total amount of MnO and Ti02 should be lower than 4.5 % . These kind ceramic cut￾ting tools are of high application value because of their high toughness and certain abrasion resistance. 1. 7 A1203-metal-nitride ceramic cutting tools Toughened and strengthened by nitrides (nitride of Ti, Zr, Hf, Ta, Nb or their mixture, lubricant) and metals (Ni , Mo, W) , ceramics of this kind are of high abrasion resistance (low fiction coefficient) and heat conductivity, high strength, high toughness, red hardness and excellent cutting performance. They are suitable for machining quenching steel of high hard￾ness, high quality steel of high strength, stainless steel and various alloy steel and carbon steel. They are also suitable for machining normal cast iron, alloy cast iron of high hardness. With the bending strength of 1200 - 1300 MPa, hardness of 1800 - 1900 HV, fracture toughness KIc of 5 - 6 MPa m112, this kind ceramic cutting tools can be used for continuously or discontinuously exact or coarse cutting and exact mill￾ing. This kind of ceramics with fine particles, well￾proportioned structure and no holes, can be prepared by wet milling mixture of A1203, nitride (for example, TIN) and metals, then hot pressing in vacuum at 1600 - 1900 “c with pressure of 27. 6 MPa for less than 5 min. Table 1 shows the brand and mechanic properties of some typical ceramic cutting . 1.8 Al,03-metal-carbonnitrides A1203-Metal-carbonnitrides composite has advan￾tage of abrasion resistance ( low friction coefficient ) , thermal conductivity, high strength, red hardness and toughness. Their cutting performance is excellent. They are suitable for cutting and machining hardened steel of big hardness, fine steel with high strength, stainless steel, alloy steel, carbon steel, normal cast iron and cast iron alloy of high hardness. Its mechani￾cal properties: of = 1200 - 1300 MPa, HV = 1800 - 1900, KIc = 5 - 6 MPa*m1’2, so this kind of materials is suitable for uninterrupted or interrupted milling and cutting with fine or rough precision

Qiu L K et al. Types, Performance and Application of A12O3 325 Table 1 Brand and mechanic properties of some typical ceramic cutting tool Brand (HRA) Coun strength/GPa Al2O,+(W, Ti)C 94.5-94.8 AlO3+(W, Ti)C 94.7-95.3 AlO,+ SiC Al2O+TiC Mo+ Ni 93.794.8 1.0~1.2 At6 Al203+TiC +Metal 93.5~94.5 0.88~0.93 China Al2O, AlgO+ TiC 0.80 AlO3+Ti(Nt 94.5 FDI2 AlO,+TiC 0.85 PI (≥965) 0.4~0.5 China O2 Al,Oa+irl 0.7~0.8 Al203+ TiC ZrO (≥96.5) 09-1.0 1203+ TiC (≥96.5~97) ≥96.5-97)0.8-0.9 Al2O3+ Carbide+ Metal (≥96.5-97) 0.9-1.15 A12O3+ Carbide+Metl(≥96.5~97)08~0.95 AlO,+ Carbide+ Metal (≥96.5-97) 0.8-1.05 CC650 93.5-94.5 Sweden CC670 Al2O3, SiC whisker KY2500 Al O3, SiC whisker 93.5-94.0 Al2O3-ZrO2 94 203-TC 94.5 990(HV) 0.62 Al2O3-TiC 2150(Hv) WG300 Al2O3- SiCw 2100(HV Al2O3 980(Hv Al2O3-zrO2 2000(HV) Germany CEW100 Al2 O3 1.9 FeaAl( FeAI)/Al203 ceramic composite time, the using life of YB415 type hard alloy knives (with cube boron nitride coating) is 2/5 of that of AF cutting tools knives, and cost of aF knives is only 1/3 of that of The intermetallic compound Fe, Al has special YB415 knives. Technical performance specification of physical, chemical and mechanical properties, partic- the production 6:(1)Red hardness: working temper ular deformation behavior and room temperature brit- ature can reach to 1200 C(HRA >72);(2)HRA tleness. called semi ceramic materials. It is a new 91-94.5;(3)KIc=6.0-8.35 MPa m";(4)At high temperature material with properties between high room temperature, or =850 MPa;(5)Production temperature alloy and ceramics. Fe3 Al and Al2O3 have cost =7. 62 RMB/pcs, it is reduced 65 of the cost preferable adaptive properties. There is no chemical of normal ceramic cutting tool reaction at the interface of the composite, no new in- 1.10 AL,O3-TiC-TiB2-ZrO2 ceramic cutting terface phase produced. It has better interface joint strength. This kind of cutting tool materials shows per fect characteristics during machining cast iron and Ceramic cutting tools of Al2O3-TiC system: TiC is prospect with their low costs, high power efficiencyGon added to pure Al20, ceramic cutting tool to improve its middle carbon steel; they are of broad toughness(KIc=4.2-4.5 MPa", dispersed TiC The cutting amount of AF cutting tool (Fe-Al 14.5%) hard phase plays a role of pinning to cracks to make is 0.075-0.09 million meters at one blade abrading crack deflect so as to hinder the expansion of cracks)

@u L K et a1 . Qpes, Pedonnance and Application of A1,0, 325 Table 1 Brand and mechanic properties of some typical ceramic cutting tool Brand Composition Hardness (HRA) Bending strength/GPa Country SG3 sG4 SG5 LT3 5 LT55 JX-1 AT6 HDM4 AG2 FD22 FDlO FD12 P1 I?? n M16 M4 M5 M6 M8-1 CC650 CC670 KY2500 460 VRlOO GEM 1 GEM2 WG300 CAOlO NBWS SN80 A1203 + (W, Ti)C A1203 + SIC A1203 +Tic + Mo + Ni A1203 + Tic + Mo + Ni A12O3, Sic whisker A1203 + Tic + Metal A1203 matrix A1203 + Tic AI2O3 +Ti(NC) Az 03 A1203 +TIC A1203 A1203 + ZrO2 A1203 + Tic + Zr02 A1203 +TIC A1203 + Carbide + Metal A1203 + Carbide + Metal A1203 + Carbide + Metal A1203 + Carbide + Metal A1203 + Ti(NC) A1203, Sic whisker A1203, Sic whisker A1203-zfi2 A1203-TiC A1203 A1203-TiC A1203-SiCW A1203 A1203-TiC A1203-Zd2 A19 0, 94.5-94.8 94.7 - 95.3 94 93.5-94.5 93.7 - 94.8 94 - 95 93.5 - 94.5 93 93.5 - 95.0 94.5 93 94 (296.5) (296.5) (396.5) ( 296.5 - 97) ( 296.5 - 97) ( 296.5 - 97) ( 296.5 - 97) ( 296.5 - 97) 93.5 - 94.5 94.0 - 94.5 93.5 - 94.0 94 94.5 1990 ( HV ) 2150(HV) 2100(HV) 1980( HV ) 3000(HV) 2000(HV) 0.825 China 0.79 0.70 0.9-1.1 1.0-1.2 0.70 0.88 - 0.93 China 0.80 China 0.80 China 0.85 China 0.80 0.85 0.4-0.5 China 0.7 -0.8 0.9 - 1 .O 0.8-0.95 0.8-0.9 0.9-1.15 0.8 -0.95 0.8 - 1.05 Sweden USA 0.86 USA 0.90 0.62 0.76 0.69 0.69 Japan 0.95 0.60 GelTlany CEWlOO -I ~ _I 93.5 0.84 Sweden 1.9 Fe3Al ( FeAl ) /A1203 ceramic composite cutting tools The intermetallic compound Fe3Al has special physical, chemical and mechanical properties, partic￾ular deformation behavior and room temperature brit￾tleness, called semi ceramic materials. It is a new high temperature material with properties between high temperature alloy and ceramics. Fe3A1 and A1203 have preferable adaptive properties. There is no chemical reaction at the interface of the composite, no new in￾terface phase produced. It has better interface joint strength. This kind of cutting tool materials shows per￾fect characteristics during machining cast iron and middle carbon steel; they are of broad application prospect with their low costs, high power efficiency[51 . The cutting amount of AF cutting tool (Fe-A1 14.5 % ) is 0.075 - 0.09 million meters at one blade abrading time, the using life of YB415 type hard alloy knives (with cube boron nitride coating) is 2/5 of that of AF knives, and cost of AF knives is only 1/3 of that of YB415 knives. Technical performance specification of the production[61 : ( 1 ) Red hardness : working temper￾ature can reach to 1200 "c (HRA > 72) ; (2) HRA = 91-94.5; (3) KIc=6.0-8.35 MPa-m"'; (4) At room temperature, of = 850 MPa; (5 ) Production cost = 7.62 RMB/pcs , it is reduced 65% of the cost of normal ceramic cutting tool. 1.10 A1203-TiC-TiB2-Zr02 ceramic cutting tool Ceramic cutting tools of A1203-TiC system: Tic is added to pure A1,03 ceramic cutting tool to improve its toughness ( KIc = 4.2 - 4.5 MPa * ml'*, dispersed TIC hard phase plays a role of pinning to cracks to make crack deflect so as to hinder the expansion of cracks)

JOURNAL OF RARE EARTHS, Vol, 25, Suppl., Jun. 200 bue the read hardness of pure alumina ceramics is re- (1)To study raw materials, especially prep ion will take place when cuttin tion of super fine powder with super high purity sys at 1200 C. European patent 013386Al shows a kind tematically in order to make super fine and nano pow of Al203-TIC-TiB2-Z102 ceramic cutting tool. It con- der of a-Al2O3 with high purity; (2)To design and It has better thermal conductivity, good impact resis- structure to improve toughness; (3)To design of a va tance, high toughness and low interface abrasion than riety of means of interaction to play a synergistic A1203-TiC. It has been successfully used and shows toughening effect;(4) To analyze the effect of grains good cutting performance and wide mechanic mach whiskers, fibers and matrix to tough Ing area and develop technique of high dispersed grains, whis kers and fiber of high strength, high elastic modulus 1.11 Al2O3-ZrO2"Y2O3 cutting tool high aspect ratio and good performance at high temper European patent 011902882A2 shows a kind of ature to match the matrix, to adjust composition of the cutting tool with high hardness and high toughness. It interface, to find out the best bonding strength so as to is suitable for high speed cutting of cast iron, and al make ar, Kic reach their maximum at the same time loys. It contains ZO2 of no more than 60%, Y20, (5) Addition of rare earth oxide can improve tough 0.5%-4.5%. It is prepared by hot pressing under ness, fine composition and reduce sintering tempera sintering temperature of strict control 1. 12 Al,O3 ceramic coated cutting tool References Al2O, powder is a perfect thermal insulator due to [1] Miao Hezhuo. Development and applications of new its chemical stability at high temperature. Al2O3 coal types of ceramic cutting tools [JI. Chinese Journal of g has the advantage of dense structure, good heat re Nonferrous Metals (in Chin. ) 2004, 14(5):237 sistance, high hardness and toughness, good impact 2] Zhong Jinbao, Huang Chuanzhen, Yu Jinwei, et al.The resistance and abrasion resistance. Using life of alloy present status of research on materials [J]. Shandong Machinery(in Chin),2006 cutting tool with Al2O, coating is increased 2 times 173(4):17 the thicker of coating, the longer of using life. The us- [3] Ding Yanhong, Yang Yang. Sic whisker/particle ing life of hard alloy with Al2O, coating can be rmet for cutting tool [J]. Jor urnal of Zhuzhou creased 3 times longer. Its cutting speed is improved wute of Technology (in Chin. ) 2006, 20(4):60 about 20%. Al2O, coated cutting tool has been widely [4] Zhou Bin. Development and application of alumina ce- amic tools [J]. Mechanical Management and develop AlO, coated cutting tool is about 5% of total output of ment,2004,78(3):37 5] Zhang Yujun, Yin Yansheng, Wang Deyun. FeAl inter- hard alloy and ceramic cutting tools 2 Developing Trend of Al2O3 System material [J]. Materials for Mechanical Engineering 2000,24(2):30. Ceramic Cutting Tools [6] Yin Yansheng, Zhang Jingde. Alumina Ceramics and With the development of Al2O3 coated cutting Complex Material [M]. Beijing: Chemical Industry Press in Chin), 200 tools with better performance there are many problems merged. The following is some recommendation

326 JOURNAL OF RARE EARTHS, Vol. 25, Suppl. , Jun . 2007 bue the read hardness of pure alumina ceramics is re￾duced. Interface abrasion will take place when cutting at 1200 “c . European patent 013386A1 shows a kind of .41203-TiC-TiBz-Zr02 ceramic cutting tool. It con￾tains ZrO, of 0.1% - lo%, Tic-TiB, of 10% - 40%. It has better thermal conductivity, good impact resis￾tance, high toughness and low interface abrasion than A1203-TiC. It has been successfully used and shows good cutting performance and wide mechanic machin￾ing area. 1.11 A1203-Zr02-Y203 cutting tool European patent 01 1902882A2 shows a kind of cutting tool with high hardness and high toughness. It is suitable for high speed cutting of cast iron, and al￾loys. It contains Zr02 of no more than 60%, Y203 0.5 % - 4.5 % . It is prepared by hot pressing under sintering temperature of strict control. 1.12 A1203 ceramic coated cutting tool A1203 powder is a perfect thermal insulator due to its chemical stability at high temperature. A1203 coat￾ing has the advantage of dense structure, good heat re￾sistance, high hardness and toughness, good impact resistance and abrasion resistance. Using life of alloy cutting tool with A1203 coating is increased 2 times, the thicker of coating, the longer of using life. The us￾ing life of hard alloy with A1203 coating can be in￾creased 3 times longer. Its cutting speed is improved about 20%. A1203 coated cutting tool has been widely used as the western hob, shaper knives. In Japan, A1203 coated cutting tool is about 5% of total output of hard alloy and ceramic cutting tools. 2 Developing Trend of A1,0, System Ceramic Cutting Tools With the development of A1203 coated cutting tools with better performance there are many problems emerged. The following is some recommendation : (1 ) To study raw materials, especially prepara￾tion of super fine powder with super high purity sys￾tematically in order to make super fine and nano pow￾der of a-A1203 with high purity; (2) To design and control of microstructure and nano-submicroscopic structure to improve toughness; (3) To design of a va￾riety of means of interaction to play a synergistic toughening effect ; (4) To analyze the effect of grains, whiskers, fibers and matrix to toughening, to study and develop technique of high dispersed grains, whis￾kers and fiber of high strength, high elastic modulus, high aspect ratio and good performance at high temper￾ature to match the matrix, to adjust composition of the interface, to find out the best bonding strength so as to make of, KIc reach their maximum at the same time; (5) Addition of rare earth oxide can improve tough￾ness, fine composition and reduce sintering tempera￾ture. References : [ 11 Mia0 Hezhuo. Development and applications of new types of ceramic cutting tools [ J] . Chinese Journal of Nonferrous Metals (in Chin. ) , 2004, 14( 5) : 237. [ 21 Zhong Jinbao, Huang Chuanzhen, Yu Jinwei, et al. The present status of research on nano-composite ceramic tool materials [ J] . Shandong Machinery (in Chin. ) , 2006, 173(4): 17. Sic whiskedparticle tough￾ened cermet for cutting tool [ J] . Journal ofZhuthou insti￾tute of Technology (in Chin. ) , 2006, 20(4) : 60. Development and application of alumina ce￾ramic tools [ J] . Mechanical Management and Develop￾ment, 2004, 78(3): 37. FeAl inter￾metallic cornpounds/Al2O3 composites-a new ceramic tool material [ J ] . Materials for Mechanical Engineering, 2000, 24(2): 30. [6] Yin Yansheng, Zhang Jingde. Alumina Ceramics and Complex Material [ M] . Beijing: Chemical Industry Press (in Chin. ) , 2001. [3] Ding Yanhong, Yang Yang. [4] Zhou Bin. [5] Zhang Yujun, Yin Yansheng , Wang Deyun