Ford Motor Company Limited

Iscar, Ltd.

Iscar Ceramics, Inc.

David Moskowitz

Leslie L Terner

Charles W Phillips

Duane J Schmatz

Reuven Porat

David W Hoffman

Roy L Van Alsten

Andre Ezis

Krishnamoorthy Subramanian

Shyam K Samanta

James C Uy

A composition for a ceramic cutting tool which enjoys long tool life at high speed machining of ferrous alloys. The composition consists essentially of 60-80% alpha aluminum oxide (Al.sub.2 O.sub.3) having a hexagonal crystal structure and the remainder of titanium carbonitride (TiCN). The titanium carbonitride has a mixture of 30-70% titanium carbide and the remainder titanium nitride. The mixture is compacted and hot pressed, sintered or pressure sintered to form the tool.

Ceramic cutting tool

A ceramic cutting tool is disclosed in which the cutting tool consists essentially of a hot pressed composition of alumina and 6 to 30% by weight of aluminum nitride. This ceramic cutting tool is particularly advantageous for cutting ferrous materials, especially cast iron.

The wear life of a high-speed tool steel cutting bit is increased by (a) cleansing the bit by subjection to an ion beam; (b) while preventing the temperature of said cleansed from rising above 350.degree. C., coating the cleansed bit by condensing sputtered atoms of titanium and boron thereonto, the condensation being carried out to provide a coating thickness of 2-6 microns. An argon or krypton beam of ions is accelerated to 1300-1800 volts as a broad-beam ion source to sputter a titanium diboride target arranged as a cathode. The sputtering is carried out for 5-10 minutes while the bit is heated to about 200.degree. C., and a soft vacuum of about 4-6 milli-torr is used during the process.

Method of increasing useful life of tool steel cutting tools

Methods are disclosed of making and of using a high density high strength titanium diboride comprising material. The method of making comprises (a) compacting a mixture of titanium diboride, 5-20% by weight of a metal group binder, and up to 1% oxygen and up to 2% graphite, the mixture having a maximum particle size of 5 microns, and (b) sintering the compact to substantially full density. The TiB.sub.2 may be replaced by up to 10% TiC. The method of use is as a cutting tool at relatively high speeds against aluminum based materials.

Titanium diboride composite body

Method of making and using a titanium diboride comprising body

Method of cutting using a titanium diboride body

The wear life of a high-speed tool steel cutting bit is increased by (a) cleansing the bit by subjection to an ion beam; (b) while preventing the temperature of said cleansed from rising above 350.degree. C., coating the cleansed bit by condensing sputtered atoms of titanium and boron thereonto, the condensation being carried out to provide a coating thickness of 2-6 microns. An argon or krypton beam of ions is accelerated to 1300-1800 volts as a broad-beam ion source to sputter a titanium diboride target arranged as a cathode. The sputtering is carried out for 5-10 minutes while the bit is heated to about 200.degree. C. and a soft vacuum of about 4-6 milli-torr is used during the process.

A method of machining cast iron by using a ceramic cutting tool of specific composition at specified removal rates which results in increased tool life.

Method of cutting cast iron with Si.sub.3 N.sub.4 composite cutting tool

This application discloses a new powder composition which may be plasma sprayed onto the surface of an article to provide a protective coating therefor. The protective coating may be resistant to heat, wear, and corrosion. The coating may also provide a thermal or radiation barrier. In particular, the coating composition for arc plasma spraying consists of finely divided silicon carbide mixed with finely divided silicon. This coating composition is applied to a substrate by developing a plasma spray, feeding the coating composition to the plasma spray and directing the plasma spray at an exposed surface of the substrate so that the exposed substrate is coated with a coating which consists essentially of beta silicon carbide and silicon. The new article of manufacture disclosed in this application, is a substrate with a tightly adherent coating thereon consisting essentially of beta silicon carbide and silicon. The substrate may be any material, either metallic or non-metallic, to which the coating adheres. The coating may provide the substrate with wear resistant characteristics as, for example, if the substrate is to be used for machining metals or as a valve seat in an aluminum engine. The substrate, with the coating thereon, may be used to withstand severe temperatures as, for example, in rocket nozzles and other areas where a substrate would be subjected to extreme temperatures.

Article coated with beta silicon carbide and silicon

A method of making Si.sub.3 N.sub.4 based cutting tools (and the resulting product) is disclosed. A mixture is formed of three powders: a first powder of at least 75% crystalline Si.sub.3 N.sub.4, a second powder selected from the group Y.sub.2 O.sub.3, MgO, CeO.sub.2 and ZrO.sub.2, and a third powder selected from the group consisting of Al.sub.2 O.sub.3, WC, Wsi.sub.2, W and TiC. The mixture is cold pressed to a density of 50-70% of theoretical and then sintered to full density without the application of pressure.

Process for producing Si.sub.3 N.sub.4 base articles by the cold press

A method of making cemented titanium carbide base cutting tools with increased tool life is disclosed. Substantially unoxidized carbide and binder metal powders are ground to a sub-micron particle size in the presence of a low-boiling oxidation-inhibiting ingredient covering the particles of said powders. A low-boiling pressing aid is added. The ground powders are then subjected to air drying to evaporate said oxidation inhibiting liquid ingredient and the pressing aid consisting preferably of polyethylene glycol. After compacting the waxed ground particles to a predetermined configuration, the compact is first heated to volatize the wax at an appropriate temperature and critically in the presence of a nitrogen based atmosphere which may contain 0-10% H.sub.2. The dewaxed compact is then heated to a higher second temperature level for effecting sintering in the presence of a vacuum.

Method of improving tool life of TiC base tools

Novel spraying composition, method of applying the same and article

A hard sintered carbide composition and the method of making such composition for use as a cutting material or for use as wear parts or dies and the like, is disclosed. The composition consists essentially of a titanium carbide phase bound together by a binding alloy principally composed of molybdenum and nickel; the titanium carbide contains controlled amounts of dissolved vanadium carbide and/or titanium nitride. The binding alloy is characterized by the addition of aluminum in controlled amounts and chromium may be added to the binding alloy as a partial substitute for some of the aluminum. The presence of the dissolved vanadium carbide and/or titanium nitride produces a grain refinement in the carbide phase and the presence of the aluminum tends to form a nickel aluminide in the binding alloy which is of a finely divided character. The presence of two or more of the elements; vanadium carbide, titanium nitride and aluminum produce an unprecedented improvement in the deformation resistance of a TiC--Ni--Mo composition. The method requires that the binding alloy powder and the carbide powders be selected as to size (about 3-4 microns) be milled with the additive powders and the compacted charge then be sintered at about 1400.degree. C in closed graphite trays in a furnace evacuated to less than 1 micron of mercury pressure.

Cemented titanium carbide tool for intermittent cutting application

A hard sintered carbide composition and the method of making such composition for use as a cutting material or for use as wear parts or dies and the like, is disclosed. The composition consists essentially of a titanium carbide phase bound together by a binding alloy principally composed of molybdenum and nickel; the titanium carbide contains controlled amounts of dissolved vanadium carbide and/or titanium nitride. The binding alloy is characterized by the addition of aluminum in controlled amounts and chromium may be added to the binding alloy as a partial substitute for some of the aluminum. The presence of the dissolved vanadium carbide and/or titanium nitride produces a grain refinement in the carbide phase and the presence of the aluminum tends to form a nickel aluminide in the binding alloy which is of a finely divided character. The presence of two or more of the elements: vanadium carbide, titanium nitride and aluminum produce an unprecedented improvement in the deformation resistance of a TiC-Ni-Mo composition. The method requires that the binding alloy powder and the carbide powders be selected as to size (about 3-4 microns) be milled with the additive powders and the compacted charge then be sintered at about 1400.degree. C in closed graphite trays in a furnace evacuated to less than 1 micron of mercury pressure.

An apex seal element for a rotary internal combustion engine is described which is comprised of a cemented carbide having a binder constituted of nickel and molybdenum carbide and a controlled addition of excess free carbon (or equivalent lubricating agent).

Growing community of inventors

Southfield, MI, United States of America

David Moskowitz