Cutting Insert of a Cermet Having a Co-Ni-Fe-Binder

The present invention pertains to a cutting tool such as, for example, a milling insert or a cutting insert, comprising a flank face, a rake face, and a cutting edge at the intersection of the flank and rake faces, for chip form machining of workpiece materials. In the case of a milling insert, such a cutting tool has been typically used to mill workpiece materials. In the case of a cutting insert, such a cutting tool has been used to chip form machine workpiece materials.

For the most part when made from a cermet, cutting tools are comprised of tungsten carbide cermets (WC-cermets), also known as cobalt cemented tungsten carbide and WC-Co. Here, a cobalt binder (Co-binder) cements tungsten carbide particles together. Although WC-cermets have achieved successful results as a cutting tool, there are some drawbacks.

One drawback is that up to about 45 percent of the world's primary cobalt production is located in politically unstable regions (e.g., political regions that have experienced either armed or peaceful revolutions in the past decade and could still experience additional revolutions). About 15 percent of the world's annual primary cobalt market is used in the manufacture of hard materials including WC-cermets. About 26 percent of the world's annual primary cobalt market is used in the manufacture of superalloys developed for advanced aircraft turbine engines--a factor contributing to cobalt being designated a strategic material. These factors not only contribute to the high cost of cobalt but also explain cobalt's erratic cost fluctuations. Consequently, cobalt has been relatively expensive, which, in turn, has raised the cost of WC-cermet inserts which in turn has raised the cost of cutting tools. Such an increase in the cost of cutting tools has been an undesirable consequence of the use a Co-binder for WC-cermet inserts. Therefore, it would be desirable to reduce cobalt from the binder of cermets.

Furthermore, because of the principal locations of the largest cobalt reserves, there remains the potential that the supply of cobalt could be interrupted due to any one of a number of causes. The unavailability of cobalt would, of course, be an undesirable occurrence.

Cutting inserts may operate in environments that are corrosive. While WC-cermets having a Co-binder have been adequate in such corrosive environments, the development of a cutting tool that has improved corrosion resistance without losing any of the chip form machining performance remains an objective.

While the use of WC-cermets having a Co-binder for cutting tools has been successful, there remains a need to provide a material that does not have the drawbacks, i.e., cost and the potential for unavailability, inherent with the use of cobalt set forth above. There also remains a need to develop a cutting tool for use in corrosive environments that possess improved corrosion resistance without losing any of the cutting performance characteristics of cutting inserts made of WC-cermets having a Co-binder.

An improved cermet comprising a cobalt-nickel-iron binder (Co--Ni--Fe-binder) having unexpected metal cutting performance, mechanical properties, and physical properties over the prior art has been discovered. The discovery is surprising in that the Co--Ni--Fe-binder comprises a composition that is contrary to the teaching of the prior art. More particularly, the inventive cermet for cutting tools comprises about 2 weight percent (wt. %) to about 19 wt. % Co--Ni--Fe-binder (a more typical range comprises about 5 wt. % to about 14 wt. % and a narrower typical range comprises about 5.5 wt. % to about 11 wt. %) and about 81 wt. % to about 98 wt. % hard component. The hard component comprises at least one of borides, carbides, nitrides, oxides, silicides, their mixtures, their solid solutions, and combinations of the preceding. Preferably, the hard component comprises at least one of carbides and carbonitrides, for example, such as tungsten carbide and/or titanium carbonitride optionally with other carbides (e.g., TaC, NbC, TiC, VC, Mo.sub.2 C, Cr.sub.2 C.sub.3) present as simple carbides and/or in solid solution.

Cutting tools for the chip forming machining of workpiece materials, such as metals, metal alloys, and composites comprising one or more of metals, polymers, and ceramics, are composed of the foregoing compositions. The cutting tools in accordance with the present invention have a flank face and a rake face over which chips, formed during chip forming machining, flow. At a juncture of the rake face and flank face, a cutting edge is formed for cutting into workpiece materials to form chips.

The invention illustratively disclosed herein may suitably be practiced in the absence of any element, step, component, or ingredient which is not specifically disclosed herein.

These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings where:

FIG. 1 shows an embodiment of a cutting tool in accordance with the present invention; and

FIG. 2 shows an embodiment of a cutting tool with chip control surfaces integrally molded in the tool in accordance with the present invention.

In accordance with the present invention, FIG. 1 shows an embodiment of an indexable cutting insert 2 composed of a cermet having a cobalt-nickel-iron-binder (Co--Ni--Fe-binder). The cutting insert 2 is used in the chip forming machining (e.g. turning, milling, grooving and threading) of workpiece materials including metals, polymers, and composites having a metallic or polymeric matrix. This invention is preferably used in the machining of metallic workpiece materials (see e.g., KENNAMETAL Lathe Tooling Catalog 6000 and KENNAMETAL Milling Catalog 5040), and is particularly useful in roughing and interrupted cutting of these workpiece materials where a combination of high toughness and high wear resistance is required. The cutting insert 2 has a rake face 4 over which chips, formed during high speed machining of workpiece materials, flow. Joined to the rake surface 4 are flank faces 6. At the juncture of the rake face 4 and the flank faces 6 is formed a cutting edge 8 for cutting into the workpiece materials. The cutting edge 8 may be in either a sharp, honed, chamfered or chamfered and honed condition depending on application requirements. The hone may be any of the style or sizes of hones used in the industry. The cutting insert may also be made in standard shapes and sizes (for example SNGN-434T, SNGN-436T, SPGN-633T, SPGN-634T, inserts may also be made with holes therein as well).

For example, as depicted in FIG. 2, the substrate may comprise an indexable cutting insert 10 comprising a polygonal body with a top surface 12, a bottom surface 14, and a peripheral wall with sides 16 and corners 18 extending from the top surface 12 to the bottom surface 14. At an intersection of the peripheral wall and the top surface 12 is a cutting edge 20. The top surface 12 comprises a land area 22 joining the cutting edge 20 and extending inwardly toward the center of the body. The land area 22 is comprised of corner portion land areas 24 and side portion land areas 22. The top surface 12 also comprises a floor 28 between the land area 22 and the center of the body, which is disposed at a lower elevation than the land area 22. The top surface 12 may further comprise sloping wall portions 30 inclined downwardly and inwardly from the land area 22 to the floor 28. A plateau or plateaus 32 may be disposed upon the floor 28 spaced apart from the sloping wall portions 30 and having sloped sides ascending from the floor 28. Furthermore, the bottom surface 14 of the body may have features similar to those described for the top surface 12. Regardless of its shape, the cermet 34 comprising an indexable cutting insert 10 may be at least partially coated with a coating scheme 36 and preferably in portions that contact the material to be machined and/or that has been machined

A cutting tool of the present invention may be advantageously used at cutting speeds, feeds, and depths of cut (DOC) that are compatible with achieving the desired results. Furthermore, the cutting tools of the present invention may be used either with or without a cutting or cooling fluid.

The cermet from which the cutting insert 2 of FIG. 1 or the hard insert 10 of FIG. 2 are made of a cermet comprising a cobalt-nickel-iron binder and at least one hard component. The Co--Ni--Fe-binder is unique in that even when subjected to plastic deformation, the binder maintains its face centered cubic (fcc) crystal structure and avoids stress and/or strain induced transformations. Applicants have measured strength and fatigue performance in cermets having Co--Ni--Fe-binders up to as much as about 2400 megapascal (MPa) for bending strength and up to as much as about 1550 MPa for cyclic fatigue (200,000 cycles in bending at about room temperature). Applicants believe that substantially no stress and/or strain induced phase transformations occur in the Co--Ni--Fe-binder up to those stress and/or strain levels that leads to superior performance.

Applicants believe that in the broadest sense the Co--Ni--Fe-binder comprises at least about 40 wt. % cobalt but not more than 90 wt. % cobalt, at least about 4 wt. % nickel, and at least about 4 wt. % iron. Applicant believes that the Co--Ni--Fe-binder comprising not more than about 36 wt. % Ni and not more than about 36 wt. % Fe is preferred. A preferred Co--Ni--Fe-binder comprises about 40 wt. % to 90 wt. % Co, about 4 wt. % to 36 wt. % Ni, about 4 wt. % to 36 wt. % Fe, and a Ni:Fe ratio of about 1.5:1 to 1:1.5. A more preferred Co--Ni--Fe-binder comprises about 40 wt. % to 90 wt. % Co and a Ni:Fe ratio of about 1:1. An other more preferred Co--Ni--Fe-binder comprises a cobalt:nickel:iron ratio of about 1.8:1:1.

It will be appreciated by those skilled in the art that the Co--Ni--Fe-binder may also comprise at least one secondary alloying element either in place of one or both of nickel and iron and/or in a solid solution with the Co--Ni--Fe-binder and/or as discrete precipitates in the Co--Ni--Fe-binder. Such at least one secondary alloying element may contribute the physical and/or mechanical properties of the cermet. Whether or not the at least one secondary alloying element contributes to the properties of the cermet, the least one secondary alloying element may be included in the Co--Ni--Fe-binder to the extent that the least one secondary alloying element does not detract from the properties and/or performance of the cutting tool.

The range of the Co--Ni--Fe-binder in the cermet comprises about 2 wt. % to about 19 wt. %. A more preferred range of Co--Ni--Fe-binder comprises about 5 wt. % to about 14 wt. %. An even more preferred range of the Co--Ni--Fe-binder in the cermet comprises about 5.5 wt. % to about 11 wt. %.

The hard component of the cermet of the present invention may comprise borides(s), carbide(s), nitride(s), oxide(s), silicide(s), their mixtures, their solid solutions (e.g., carbonitride(s), borocarbide(s), oxynitride(s), borocarbonitride(s) . . . etc.), or any combination of the preceding. The metal of these may comprise one or more metals from International Union of Pure and Applied Chemistry (IUPAC) groups 2, 3 (including lanthanides and actinides), 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, and 14. Preferably the hard component comprises one or more of carbide(s), nitride(s), carbonitride(s), their mixture(s), their solid solution(s), or any combination of the preceding. The metal of the carbide(s), nitride(s), and carbonitrides(s) may comprise one or more metal from IUPAC groups 3 (including lanthanides and actinides), 4, 5, and 6; preferably, one or more of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, and W; and more preferably one or more of Ti, Ta, Nb, and W.

In this context, the inventive cermets may be referred to by the composition making up a majority of the hard component. For example, if a majority of the hard component comprises a carbide, the cermet may be designated a carbide-cermet. If a majority of the hard component comprises tungsten carbide (WC), the cermet may be designated a tungsten carbide cermet or WC-cermet. In a like manner, when a majority of the hard component comprises a carbonitride, the cermet may also be designated a carbonitride-cermet. For example, when a majority of the hard component comprises titanium carbonitride, the cermet may be designated a titanium carbonitride-cermet or TiCN-cermet.

The grain size of the hard component comprises a broadest range of about 0.1 micrometers (.mu.m) to 40 .mu.m. A mediate range for the grain size of the hard component comprises about 0.5 .mu.m to 10 .mu.m. Another mediate range for the grain size of the hard component comprises about 1 .mu.m and 5 .mu.m. Applicants believe that the above ranges of hard component grain size are particularly applicable to WC-cermets having a Co--Ni--Fe-binder.

Applicants contemplate that every increment between the endpoints of ranges disclosed herein, for example, binder content, binder composition, Ni:Fe ratio, hard component grain size, hard component content, . . . etc. is encompassed herein as if it were specifically stated. For example, a binder content range of about 2 wt. % to 19 wt. % encompasses about 1 wt. % increments thereby specifically including about 2 wt. %, 3 wt. %, 4 wt. %, . . . 17 wt. %, 18 wt. % and 19 wt. % binder. While for example, for a binder composition the cobalt content range of about 40 wt. % to 90 wt. % encompasses about 1 wt. % increments thereby specifically including 40 wt. %, 41 wt. %, 42 wt. %, . . . 88 wt. %, 89 wt. %, and 90 wt. % while the nickel and iron content ranges of about 4 wt. % to 36 wt. % each encompass about 1 wt. % increments thereby specifically including 4 wt. %, 5 wt. %, 6 wt. %, . . . 34 wt. %, 35 wt. %, and 36 wt. %. Further for example, a Ni:Fe ratio range of about 1.5:1 to 1:1.5 encompasses about 0.1 increments thereby specifically including 1.5:1, 1.4:1, . . . 1:1, . . . 1:1.4, and 1:1.5). Furthermore for example, a hard component grain size range of about 0.1 .mu.m to about 40 .mu.m encompasses about 1 .mu.m increments thereby specifically including about 0.1 .mu.m, 1 .mu.m, 2 .mu.m, 3 .mu.m, . . . 38 .mu.m, 39 .mu.m, and 40 .mu.m.

A cermet cutting tool of the present invention may be used either with or without a coating. If the cutting tool is to be used with a coating, then the cutting tool is coated with a coating that exhibits suitable properties such as, for example, lubricity, wear resistance, satisfactory adherence to the cermet, chemical inertness with workpiece materials at material removal temperatures, and a coefficient of thermal expansion that is compatible with that of the cermet (i.e., compatible thermo-physical properties). The coating may be applied via CVD and/or PVD techniques.

Examples of the coating material, which may comprise one or more layers of one or more different components, may be selected from the following, which is not intended to be all-inclusive: alumina, zirconia, aluminum oxynitride, silicon oxynitride, SiAlON, the borides of the elements for IUPAC groups 4, 5, and 6, the carbonitrides of the elements from IUPAC groups 4, 5, and 6, including titanium carbonitride, the nitrides of the elements from IUPAC groups 4, 5, and 6 including titanium nitride, the carbides of the elements from IUPAC groups 4, 5, and 6 including titanium carbide, cubic boron nitride, silicon nitride, carbon nitride, aluminum nitride, diamond, diamond like carbon, and titanium aluminum nitride.

The significant advantages of the present invention are further indicated by the following examples which are intended to be purely illustrative of the present invention.

As summarized in Table 1, a WC-cermet having a Co--Ni--Fe-binder of this invention and a comparative conventional WC-cermet were produced using conventional powder technology as decried in, for example, "World Directory and Handbook of HARDMETALS AND HARD MATERIALS" Sixth Edition, by Kenneth J. A. Brookes, International Carbide DATA (1996); "PRINCIPLES OF TUNGSTEN CARBIDE ENGINEERING" Second Edition, by George Schneider, Society of Carbide and Tool Engineers (1989); "Cermet-Handbook", Hertel AG, Werkzeuge+Hartstoffe, Fuerth, Bavaria, Germany (1993); and "CEMENTED CARBIDES", by P. Schwarzkopf & R. Kieffer, The Macmillan Company (1960)-the subject matter of which is herein incorporated by reference in it entirety. In particular, Table 1 presents a summary of the nominal binder content in weight percent (wt. %), the nominal binder composition, and the hard component composition and amount (wt. %) for a composition of this invention and a comparative prior art composition. That is, commercially available ingredients that had been obtained for each of the inventive and the conventional composition as described in Table 1 were combined independent attritor mills with hexane for homogeneous blending over a period of 12 hours. After each homogeneously blended mixture of ingredients was appropriately dried, green bodies having the form of cutting inserts and plates for properties evaluation were pressed . The green bodies were densified by pressure-sintering (also known as sinter-HIP) at about 1450.degree. C. for about 1.5 hours (during the last 10 minutes at about 1450.degree. C. the furnace pressure was raised to about 4 MPa). After densification, the sintered bodies were processed by, for example, cutting, grinding, and honing, to prepare specimens for properties and cutting tool evaluation.

Table 2 presents a summary of the results of properties evaluation including the density (g/cm.sup.3), the magnetic saturation (0.1 .mu.Tm.sup.3 /kg), the coercive force (Oe, measured substantially according to International Standard ISO 3326: Hardmetals--Determination of (the magnetization) coercivity), the hardness (Hv.sub.30, measured substantially according to International Standard ISO 3878: Hardmetals--Vickers hardness test), the transverse rupture strength (MPa, measured substantially according to International Standard ISO 3327/Type B: Hardmetals--Determination of transverse rupture strength) and the porosity (measured substantially according to International Standard ISO 4505: Hardmetals--Metallographic determination of porosity and uncombined carbon) for the inventive and the conventional compositions of Table 1.

As noted above, the inventive and conventional WC-cermets of Table 1 were produced in the form of cutting inserts. In particular, the cutting insert style comprised CNMG120412 (based on International Standard ISO 1832: Indexable inserts for cutting tool--Designation). Some cutting inserts made from each of the inventive and the conventional WC-cermets were tested using an interrupted cutting procedure that provided an evaluation of comparative toughness in use. This interrupted cutting procedure (Leistendrehtest performed as substantially disclosed by W. Konig, K. Gerschwiler, R. v. Haas, H. Kunz, J. Schneider, G. Kledt, R. Storf, and A. Thelin in "Beurteilung des Zahigkeitsverhaltens von Schneidstoffen im unterbrochenen Schnitt" VDI BERICHTE NR. 762 (1989) starting at page 127 available from Verlag des Deutscher Ingenieure Dusseldorf, Germany) involved using a workpiece material with clamped bars so that the cutting insert experienced interrupted cutting under the conditions summarized in Table 3. The test was performed so that the feed rate was increased from about 0.40 mm/rev. to 0.90 mm/rev. at increments of about 0.1 mm/rev. after the cutting insert experienced about 100 impacts at the designated feed rate. Five cutting insert of each WC-cermet were tested. All of the tested cutting inserts of both the inventive and the WC-cermet reached the feed rate of about 0.90 mm/rev. without catastrophically failing.

Additionally, cutting inserts comprising the inventive and the conventional WC-cermets were coated with a first about 4 .mu.m titanium carbonitride (TiCN) layer followed by a second about 8 .mu.m aluminum oxide (Al.sub.2 O.sub.3) layer, both of which were applied by commercially known conventional chemical vapor deposition (CVD). Five CVD TiCN/CVD Al.sub.2 O.sub.3 coated cutting inserts of each WC-cermet were subjected to the comparative toughness test summarized in Table 3. As with the uncoated cutting inserts, the feed rate was increased until the cutting inserts failed. The average feed rate at failure for the CVD TiCN/CVD Al.sub.2 O.sub.3, coated cutting inserts comprising the WC-cermet having the Co--Ni--Fe-binder was about 0.76 mm/rev. The average feed rate at failure for the CVD TiCN/CVD Al.sub.2 O.sub.3 coated cutting inserts comprising the WC-cermet having the Co-binder was about 0.74 mm/rev.

Five CVD TiCN/CVD Al.sub.2 O.sub.3 coated cutting inserts of each WC-cermet were subjected to a comparative toughness endurance test as summarized in Table 4, in which one cutting insert edge was subjected to about 18,000 impacts. All of the CVD TiCN/CVD Al.sub.2 O.sub.3 coated cutting inserts of both WC-cermets survived about 18,000 impacts without catastrophically failing.

As summarized in Table 5, TiCN-cermets having a Co--Ni--Fe-binder of the invention and a comparative TiCN-cermet having a Co--Ni-binder were produced using conventional powder technology as described by, for example, K. J. A. Brookes; G. Schneider; and P.

Schwarzkopf et al.--mentioned above. In particular, Table 5 presents a summary of the nominal binder content in weight percent (wt. %), the nominal binder composition, and the hard component composition and amount (wt. %) for a TiCN-cermet of this invention and a comparative prior art composition. That is, commercially available ingredients that had been obtained for each of the inventive and the conventional composition as described in Table 1 were combined in independent attritor mills with hexane for homogeneous blending over a period of about 13 hours. After each homogeneously blended mixture of ingredients was appropriately dried, green bodies having the form of a cutting inserts and plates for properties evaluation were pressed. The green bodies were densified by pressure-sintering (also known as sinter-HIP) a about 1435.degree. C. for about 1.5 hours (during the last 10 minutes at about 1435.degree. C. the furnace pressure was raised to about 4 MPa). After densification, the sintered bodies were processed by, for example, cutting, grinding, and honing, to prepare specimens for properties and cutting tool evaluation.

Table 6 presents a summary of the results of properties evaluation including density (g/Cm.sup.3), magnetic saturation (0.1 .mu.Tm.sup.3 /kg), coercive force (Hc, oersteds), Vickers Hardness (HV30), transverse rupture strength (TRS in megapascal (MPa)) and porosity for the inventive and the conventional TiCN-cermets of Table 5.

As noted above, the inventive and conventional TiCN-cermets of Table 5 were produced in the form of cutting inserts. In particular, the cutting insert style comprised CNMG120408 (based on International Standard ISO 1832: Indexable inserts for cutting tool--Designation). Some cutting inserts made from each of the inventive and the conventional TiCN-cermets were tested using an interrupted cutting procedure that provided an evaluation of comparative toughness in use. This interrupted cutting procedure involved using a workpiece material with clamped bars so that the cutting insert experienced interrupted cutting under the conditions summarized in Table 7. The test was performed so that the feed rate was increased from about 0.10 mm/rev. to breakage at increments of about 0.05 mm/rev. after the cutting insert experienced about 100 impacts at the designated feed rate. Five cutting insert of each composition were tested. Additional cutting inserts were tested in a turning test in which the cutting speed was continually increased up to the failure of the inserts.

The patents and other documents identified herein, including U.S. patent application Ser. No. 08/918,993 entitled, "A CERMET HAVING A BINDER WITH IMPROVED PLASTICITY", by Hans-Wilm Heinrich, Manfred Wolf, Dieter Schmidt, and Uwe Schleinkofer (the applicants of the present patent application) which was filed on the same date as the present patent application and assigned to Kennametal Inc. (the same assignee as the assignee of the present patent application), are hereby incorporated by reference herein.

Other embodiments of the invention will be apparent to those skilled in the art from a consideration of the specification or practice of the invention disclosed herein. It is intended that the specification and examples be considered as illustrative only, with the true scope and spirit of the invention being indicated by the following claims.