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    • 专利摘要:
    AB STRACT In one aspect, cemented carbide bodies are provided. A cemented carbide body described herein, comprises: 5 to 15 percent by Weight of binder phase comprising at 1east one metal of the iron group or an a11oy thereof; cubic carbides of zirconium and niobium,(Zr,Nb)C, comprising in percent by Weight:0.5-1.5 Nb,03-1 Zr; and ba1ance WC apart from impurities. 23
    公开号:SE537387C2
    申请号:SE1251487
    申请日:2012-12-21
    公开日:2015-04-14
    发明作者:Guenter Roder；Anders Petersson；Charles Mcnerny；Pankaj Mehrotra
    申请人:Kennametal Inc；
    IPC主号:
    专利说明:

    CEMENTED CARBIDE BODY AND APPLICATIONS THEREOF FIELD The present invention relates to cemented carbide bodies and, in particular, tocemented carbide bodies comprising metals from Groups IVB, VB and VIB of thePeriodic Table.
    BACKGROUND Cutting tools comprising cemented carbide bodies have been used in both coatedand uncoated conditions for machining various metals and alloys. lncreasing cutting toolresistance to Wear and failure modes, including thermal deforrnation, fracture andchipping, remains an intense area of research and development. To that end, significantresources have been assigned to the development of Wear resistant refractory coatings forcutting tools. TiC, TiCN, TiOCN, TiN and Al2O3, for example, have been applied tocemented carbides by chemical vapor deposition (CVD) as Well as physical vapordeposition (PVD).
    Moreover, the properties of the underlying cutting tool substrate have beeninvestigated. Cutting tool manufacturers have examined compositional changes tocemented carbide bodies and the resulting effects on cemented carbide propertiesincluding, but not limited to, hardness, Wear resistance, therrnal deformation resistance,toughness, density and various magnetic properties. Enhancement of one cementedcarbide property, however, often results in the concomitant deterioration of anothercemented carbide property. For example, increasing the resistance of a cemented carbidebody to deformation can result in decreased toughness and thermal conductivity of thebody. Japanese patent application publication JP 2002-356734A recognizes such aproblem and describes a cemented carbide body having plastic deformation resistanceand increased hardness and therrnal conductivity. According to JP 2002-356734A, theseobjectives are achieved by incorporating into the cemented carbide body several differingsolid solution phases of carbides, nitrides and carbonitrides of metals selected from Groups IVB, VB and VIB.
    NeVertheless, improvements to cemented carbide substrates are necessary to meetthe eVolVing demands of metal Working applications, and a careful balance betweencompeting properties is required When making compositional changes to cemented carbide bodies in efforts to proVide cutting tools With improVed performance.
    SUMMARY In one aspect, cemented carbide bodies are described herein Which, in someembodiments, can demonstrate improVed resistance to Wear and/or one or more failuremodes. In some embodiments, for example, a cemented carbide body described hereindisplays increased resistance to thermal deformation Without a substantial loss of toughness.
    A cemented carbide body described herein, in some embodiments, comprises:- 5 to l5 percent by Weight of a binder phase comprising at least one metal ofthe iron group or an alloy thereof;- cubic carbides of zirconium and niobium,(Zr,Nb)C, comprising in percent byWeight:0.5-1.5 Nb,0.3-l Zr; and - balance WC apart from impurities.
    In some embodiments, the cemented carbide body comprises cubic carbides in an amountranging from 0.5 Volume percent to 6 Volume percent. In some embodiments, thecemented carbide body comprises cubic carbides in an amount ranging from l Volumepercent to 5.5 Volume percent. The cemented carbide body, in some embodiments,comprises cubic carbides in an amount greater than 2 Volume percent to 5 Volumepercent. A cemented carbide body described herein, in some embodiments, furthercomprises a coating deposited thereon by physical Vapor deposition (PVD), chemicalVapor deposition (CVD) or a combination thereof. In some embodiments, the coatingcomprises one or more metallic elements selected from the group consisting of metallic elements of Groups IVB, VB and VIB of the Periodic Table and aluminum and one or more non-metallic elements selected from the group consisting of non-metallic elementsof Groups IIIA, IVA and VIA of the Periodic Table. Groups of the Periodic Tabledescribed herein are identified according to the CAS designation. In some embodiments,the coating is a single layer coating. AltematiVely, in some embodiments, the coating is amulti-layer coating.
    In some embodiments, a cemented carbide body described herein has the shape ofa cutting tool for one or more metal Working applications. A cemented carbide body, insome embodiments, comprises a rake face and a flank face intersecting the rake face toform a cutting edge.
    In another aspect, methods making cemented carbide bodies are described herein.The method of making a cemented carbide body comprises providing a powder mixturecomprising: - 5 to l5 percent by Weight of a binder comprising at least one metal of the iron group or an alloy thereof; - a solid solution of cubic carbides of zirconium and niobium,(Zr,Nb)C,comprising in percent by Weight::0.5-1.5 Nb,0.3-l Zr; and- balance WC apart from impurities.
    A green compact is formed of the mixture and sintered to provide the cemented carbidebody comprising a tungsten carbide phase, a binder phase, a solid solution phase of(Zr,Nb)C and cubic carbides in an amount ranging from 0.5 Volume percent to 6 Volumepercent.In another aspect, methods of cutting metal are described herein. In some embodiments,a method of cutting metal comprises proViding a metal Workpiece and cutting the metalWorkpiece With a cutting tool, the cutting tool comprising a cemented carbide bodycomprising: - 5 to l5 percent by Weight of a binder phase comprising at least one metal of the iron group or an alloy thereof;- cubic carbides of zirconium and niobium,(Zr,Nb)C, comprising in percent byWeight:0.5-1.5 Nb, 0.3-1 Zr; and- balance WC apart from impurities.
    In some embodiments of methods of cutting metal, the cemented carbide bodyfurther comprises a coating deposited thereon by physical vapor deposition (PVD),chemical vapor deposition (CVD) or a combination thereof. In some embodiments, thecoating comprises one or more metallic elements selected from the group consisting ofmetallic elements of Groups IVB, VB and VIB of the Periodic Table and aluminum andone or more non-metallic elements selected from the group consisting of non-metallicelements of Groups IIIA, IVA and VIA of the Periodic Table. In some embodiments, thecoating is a single layer coating. Altematively, in some embodiment, the coating is amulti-layer coating.
    These and other embodiments are described in greater detail in the detailed description that follows.
    BRIEF DESCRIPTION OF THE FIGURES Figure 1 illustrates a cemented carbide body having the shape of a cutting toolaccording to one embodiment described herein.
    Figure 2 illustrates results of deformation testing of a cemented carbide bodyaccording to one embodiment described herein in view of comparative cemented carbidebodies.
    Figure 3 illustrates results of toughness testing of a cemented carbide bodyaccording to one embodiment described herein in view of comparative cemented carbidebodies.
    Figure 4 illustrates results of interrupted cut testing of a cemented carbide bodyaccording to one embodiment described herein in view of comparative cemented carbidebodies.
    Figure 5 illustrates results of interrupted cut testing of a cemented carbide bodyaccording to one embodiment described herein in view of comparative cemented carbidebodies.
    Figure 6 illustrates results of milling testing of a cemented carbide body according to one embodiment described herein in view of a comparative cemented carbide body.
    DETAILED DESCRIPTION Embodiments described herein can be understood more readily by reference to thefollowing detailed description and examples and their previous and followingdescriptions. Elements, apparatus and methods described herein, however, are notlimited to the specific embodiments presented in the detailed description and examples.lt should be recognized that these embodiments are merely illustrative of the principles ofthe present invention. Numerous modif1cations and adaptations Will be readily apparentto those of skill in the art Without departing for the spirit and scope of the invention.
    In one aspect, cemented carbide bodies are described herein Which, in someembodiments, can demonstrate improved resistance to Wear and/or one or more failuremodes. In some embodiments, for example, a cemented carbide body described hereindisplays increased resistance to thermal deformation Without a substantial loss oftoughness.
    A cemented carbide body described herein, comprises - 5 to l5 percent by Weight of a binder phase comprising at least one metal of the iron group or an alloy thereof; - cubic carbides of zirconium and niobium,(Zr,Nb)C, comprising in percent by Weight:0.5-l.5 Nb,0.3-l Zr; and - balance WC apart from impurities.
    The cubic carbides is preferably in an amount ranging from 0.5 volume percent to 6volume percent.
    Tuming now to components of a cemented carbide body, a cemented carbidebody described herein comprises a solid solution phase of carbides of zirconium andniobium (Zr,Nb)C. ln being formed of carbides of zirconium and niobium, the solidsolution phase,does not comprise one or more additional metallic elements in excess oftrace or impurity amounts. Moreover, the solid solution phase of (Zr,Nb)C is the solesolid solution phase of the cemented carbide body. Therefore a cemented carbide bodydescribed herein does not comprise one or more additional solid solution phases of carbides, nitrides and/or carbonitrides of metals of Groups IVB, VB and VIB of the Periodic Table, for example, a cemented carbide body described herein does not include asolid solution phase comprising a carbide, nitride and/ or carbonitride of titanium,hafi1ium, Vanadium, tantalum, tungsten, molybdenum or chromium or mixtures thereof.
    Niobium is present in a cemented carbide body described herein in an amountranging from 0.5 mass percent to 1.5 mass percent. Niobium, in some embodiments, ispresent in an amount ranging from 0.7 mass percent to 1.3 mass percent. In someembodiments, niobium is present in an amount ranging from 0.8 mass percent to 1 masspercent. Additionally irconium is present in the cemented carbide body in an amountranging from 0.3 mass percent to 1 mass percent. In some embodiments, zirconium ispresent in an amount ranging from 0.5 mass percent to 0.7 mass percent. A cementedcarbide body, in some embodiments, has a mass ratio of Nb/(NbJrZr) 2 0.5. In someembodiments, the foregoing mass ratio is greater than or equal to 0.6. The mass ratio, insome embodiments, is greater than or equal to 0.7.
    A cemented carbide body described herein also comprises cubic carbides in anamount ranging from 0.5 Volume percent to 6 Volume percent. In some embodiments,cubic carbides are present in the cemented carbide body in an amount ranging from 1Volume percent to 5 Volume percent. In some embodiments, cubic carbides are present inan amount ranging from greater than 2 Volume percent to 5 Volume percent. In someembodiments, cubic carbides are present in an amount ranging from 2.5 Volume percentto 4 Volume percent.
    A cemented carbide body described herein also comprises cubic carbides of(Zr,Nb)C in an amount ranging from 0.8 Weight percent to 2.8 Weight percent. Possibleranges of(Zr,Nb)C includes 0.9-2.2, 1.0-1.9, 1.2-1.8, 1.4-1.7.
    The cubic carbides of the cemented carbide body consist of the carbides ofniobium and zirconium of the solid solution phase (Zr,Nb)C. Therefore-cubic carbides ofthe cemented carbide body do not comprise one or more additional metals of GroupsIVB, VB and VIB of the Periodic Table in excess of trace or impurity amounts. Forexample, cubic carbides of the cemented carbide body do not comprise titanium, tantalumor mixtures thereof in more than trace or impurity amounts.
    A cemented carbide body described herein also comprises a tungsten carbide (WC) phase. In some embodiments, particles of the tungsten carbide phase demonstrate a grain size distribution ranging from 1 pm to 12 pm. In some embodiments, theparticles of the tungsten carbide phase have a particle size distribution ranging from 2 pmto 10 pm. The average grain size is preferably in the range of 2 pm to 10 pm. Possibleranges of the average grain size includes 3-5 pm, 3-10 pm, 4-9 pm, and 6-10 pm. ASTME112 may be used to determine the average grain size.
    MoreoVer, the binder phase of a cemented carbide body described hereincomprises at least one metal of the iron group or an alloy thereof. In some embodiments,for example, the binder phase comprises cobalt. In some embodiments, the binder phasecomprises a cobalt-nickel alloy or a cobalt-nickel-iron alloy. Additional alloyingelements, such as chromium and/or tungsten, can be included in the binder phase. Thebinder phase, is present in the cemented carbide body in an amount ranging from 5 masspercent to 15 mass percent. In some embodiments, the binder phase is present in anamount ranging from 7 mass percent to 13 mass percent. In some embodiments, thebinder phase is present in an amount ranging from 9 mass percent to 12 mass percent.
    A cemented carbide body described herein, in some embodiments, does notcomprise a binder enriched zone including, but not limited to, a binder enriched surfacezone. In some embodiments, for example, a cemented carbide body does not comprise abinder enriched surface zone being free or substantially free of cubic carbides and/or the(Zr,Nb)C solid solution phase.
    A cemented carbide body described herein, in some embodiments, furthercomprises a coating deposited thereon by physical Vapor deposition (PVD), chemicalVapor deposition (CVD) or a combination thereof. In some embodiments, the coatingcomprises one or more metallic elements selected from the group consisting of metallicelements of Groups IVB, VB and VIB of the Periodic Table and aluminum and one ormore non-metallic elements selected from the group consisting of non-metallic elementsof Groups IIIA, IVA and VIA of the Periodic Table. In some embodiments, for example,the coating comprises one or more carbides, nitrides, carbonitrides, oxides or borides of ametallic element selected from the group consisting of metallic elements of Groups IVB,VB and VIB of the Periodic Table and aluminum.
    Additionally, in some embodiments, the coating is a single layer coating.
    AltematiVely, in some embodiments, the coating is a multi-layer coating. In some embodiments, for example, a multi-layer coating comprises a TiCN layer adjacent to thecemented carbide body followed by an outer layer of alumina (AlgOg). In someembodiments, the TiCN layer is a medium temperature (MT) TiCN layer While thealumina layer is an ot-alumina layer, K-alumina layer or mixture thereof. Further, in someembodiments, a single layer coating or multi-layer coating can be subjected to one ormore post-coat treatment processes such as post-coat blasting. In some embodiments, apost-coat blasting treatment is administered in accordance With the disclosure of UnitedStates Patent 6,869,334, Which is incorporated herein by reference in its entirety.
    A cemented carbide body described herein, in some embodiments, has a hardness(HV30) ranging from 1200 to 1600, Wherein HV30 refers to Vickers Hardness using a30 kilogram-force load. In some embodiments, a cemented carbide body has a hardnessranging from 1200 to 1500 HV30 or from 1200 to 1460 HV30. In some embodiments,a cemented carbide body has a hardness ranging from 1250 to 1400 HV30. A cementedcarbide body, in some embodiments, has a hardness ranging from 1280 to 1380 HV30.Vickers hardness Values recited herein are deterrnined according to ASTM E 384,“Standard Method for Knoop and Vickers Hardness of Materials,” ASTM Intemational.
    MoreoVer, in some embodiments, a cemented carbide body described herein has acoerciVity ranging from 120 Oe to 170 Oe. In some embodiments, a cemented carbidebody has a coerciVity ranging from 130 Oe to 160 Oe. A cemented carbide body, insome embodiments, has a coerciVity ranging from 135 Oe to 150 Oe. CoerciVity Valuesrecited herein are deterrnined according to ASTM B887, “Standard Test Method forDetermination of CoerciVity (Hcs) of Cemented Carbides,” ASTM Intemational.
    In some embodiments, a cemented carbide body described herein has a magneticsaturation (Ms) ranging from 75% to 95%. A cemented carbide body, in someembodiments, has a magnetic saturation ranging from 79% to 89%. In someembodiments, a cemented carbide body has a magnetic saturation ranging from 80% to85%. Magnetic saturation Values recited herein are deterrnined according to ASTM B886, “Standard Test Method for Deterrnination of Magnetic Saturation (Ms) of CementedCarbides,” ASTM International. As known to one of skill in the art, magnetic saturationValues may be converted from percentages to uTm3 /kg based on comparison to a nominally pure Co binder phase. For example, see Roebuck, B. Magnetic Moment (Saturation) Measurements on Hardmeta1s, Int. J. Refractory Metals & Hard Materials,14 (1996) 419-424.
    Additiona11y, a cemented carbide body described herein has a density rangingfrom 12.5 g/cm3 to 15.0 g/cm3. In some embodiments, a cemented carbide body has adensity ranging from 13.0 g/cm3 to 14.5 g/cm3. In some embodiments, a cementedcarbide body has a density ranging from 14.1 g/cm3 to 14.4 g/cm3.
    A cemented carbide body described herein can have any combination of theforegoing properties. For example, a cemented carbide body can comprise any Value ofhardness, coercivity, magnetic saturation and density recited herein.
    In some embodiments, a cemented carbide body has the shape of a cutting too1. Acemented carbide body, in some embodiments, comprises a rake face and a flank faceintersecting With the rake face to form a cutting edge. Figure 1 i11ustrates a cementedcarbide body having the shape of a cutting too1 according to one embodiment describedherein. As i11ustrated in Figure 1, the cemented carbide body (10) comprises a flank face(12) and a rake face (14), Wherein the flank (12) and rake (14) faces intersect to provide acutting edge (16). The cemented carbide body (10) a1so comprises an aperture (18)operab1e to secure the body (10) to a too1 ho1der.
    In another aspect, methods of making cemented carbide bodies are describedherein. In some embodiments, a method of making a cemented carbide body comprisesproviding a mixture comprising a tungsten carbide powder, binder powder comprising at1east one meta1 from the iron group or an a11oy thereof and a poWdered so1id so1ution ofcarbides of zirconium and niobium (Zr,Nb)C. A green compact is formed of the mixtureand sintered to provide the cemented carbide body comprising a tungsten carbide phase, abinder phase, a so1id so1ution phase of (Zr,Nb)C and cubic carbides in an amount rangingfrom 0.5 vo1ume percent to 6 vo1ume percent. The tungsten carbide phase, binderphase, so1id so1ution phase of (Zr,Nb)C and cubic carbides can have any of the propertiesrecited hereinabove for such phases. The so1id so1ution of phase of (Zr,Nb)C is the so1eso1id so1ution phase of the cemented carbide body as described herein. Moreover, thecubic carbides, consist of the carbides of niobium and zirconium of the so1id so1ution phase .
    In some embodiments of methods described herein, metals of the powderedmixture are provided in amounts commensurate with their desired compositionalpercentages of the sintered cemented carbide body. For example, binder powdercomprising at least one metal from the iron group or an alloy thereof is provided to themixture in an amount ranging from 5 mass percent to 15 mass percent. Binder powder,in some embodiments, is provided to the mixture in an amount ranging from 7 masspercent to 13 mass percent. In some embodiments, binder powder is provided to themixture in an amount ranging from 9 mass percent to 12 mass percent.
    Moreover, the solid solution powder of carbides of niobium and zirconium(Zr,Nb)C is added to the mixture in an amount suff1cient to provide a niobium contentranging from 0.5 mass percent to 1.5 mass percent and a zirconium content rangingfrom 0.3 mass percent to 1 mass percent. ln some embodiments, (Zr,Nb)C solidsolution powder is added to the mixture in an amount sufficient to provide a niobiumcontent ranging from 0.7 mass percent to 1.3 mass percent and a zirconium contentranging from 0.5 mass percent to 0.7 mass percent. A (Zr,Nb)C solid solution powderfor use in some embodiments of methods described herein has a mass ratio Nb/(Nb+Zr) 20.5. In some embodiments, the foregoing mass ratio is greater than or equal to 0.6. Themass ratio, in some embodiments, is greater than or equal to 0.7.
    Tungsten carbide powder,-serves as the balance of the mixture used to formcemented carbide bodies described herein.
    The green compact can be sintered under any conditions not inconsistent with theobjectives of the present invention to provide a cemented carbide body described herein.ln some embodiments, for example, the green compact is vacuum sintered or sintered-hotisostatic press (HIP) at a temperature ranging from 1400°C to 1560°C. In someembodiments, the green compact is sintered for a time period ranging from 15 minutes to120 minutes. ln some embodiments, the green compact is sintered for a time periodranging from 15 minutes to 90 minutes or from 30 minutes to 75 minutes.
    A method of making a cemented carbide body, in some embodiments, furthercomprises depositing a coating on the cemented carbide body by PVD, CVD or acombination thereof In some embodiments, the coating comprises one or more metallic elements selected from the group consisting of metallic elements of Groups IVB, VB and VIB of the Periodic Table and aluminum and one or more non-metallic elements selectedfrom the group consisting of non-metallic elements of Groups IIIA, IVA and VIA of thePeriodic Table. In some embodiments, for example, the coating comprises one or morecarbides, nitrides, carbonitrides, oxides or borides of a metallic element selected from thegroup consisting of metallic elements of Groups IVB, VB and VIB of the Periodic Tableand aluminum. Additionally, in some embodiments, the coating is a single layer coating.AltematiVely, in some embodiments, the coating is a multi-layer coating.
    In another aspect, methods of cutting metal are described herein. In someembodiments, a method of cutting metal comprises proViding a metal Workpiece andcutting the metal Workpiece With a cutting tool, the cutting tool comprising a cementedcarbide body comprising: - 5 to l5 percent by Weight of a binder phase comprising at least one metal of the iron group or an alloy thereof; - cubic carbides of zirconium and niobium,(Zr,Nb)C, comprising in percent by Weight: 0.5-1.5 Nb,0.3-l Zr; and- balance WC apart from impurities.
    The cubic carbides preferably being in an amount ranging from 0.5 Volume percent to 6Volume percent. In some embodiments of methods of cutting metal, the cementedcarbide body can have any of the properties described herein for a cemented carbidebody. MoreoVer, in some embodiments, the cemented carbide body further comprises acoating as described herein.
    In some embodiments, the metal Work piece comprises plain and alloyed steel,stainless steel, gray cast iron, gray cast iron With nodular graphite and Various hightemperature alloys.
    These and other embodiments are filrther illustrated by the following non-limiting examples. ll EXAMPLE lCemented Carbide BodiesPowder mixture (A), in accordance with one embodiment described herein, 5 having the metal compositional parameters provided in Table I was pressed to forrn agreen compact having an ANSI standard geometry of CNMGl20408 RP. As provided inTable I, (ZrNb)C solid solution powder was added to the mixture in an amount sufficientto provide a niobium content of 0.93 mass percent and a zirconium content of 0.62 masspercent. Tungsten carbide (WC) powder constituted the balance of mixture after the 10 addition of 10.6 mass percent cobalt. The green compact was vacuum sintered at atemperature ranging from l400°C-l560°C for a time period of 30-60 minutes to provide acemented carbide body.
    Table I~ Powder Mixtiire of Cemented Carbide Body (mass percent) Example Cob alt Chromium Tantalum Ni obiurn/ Zirc onium* Tungsten(TaC) (WC)A 10.6 0.93 / 0.62 Balance * AS (ZrNb)C Solid Solution with mass ratio Nb/(Nb+Zr) 2 0.5l 5 Powder mixtures (B-E) having the metal compositional parameters provided in Table IIwere also pressed to form green compacts of insert geometry CNMGl20408 RP andsintered in a manner consistent with that of powder mixture A to provide comparative cemented carbide bodies. 20 Table II ~ Powder Mixtures of Comparative Cemented Carbide Bodies (mass percent) Example Cob alt Chromium Tantalum Ni obium Zirconium Tungsten(TaC)* (NbC)* (ZrC) (WC)B 11.5 0.40 _ _ _ BalanceC 10.0 0.35 _ _ _ BalanceD 10.5 _ 1.7 0.83 _ BalanceE 10.5 1.1 0.27 Balance * Provides a (TaNb)C solid solution powder l2 As provided in Table II, (TaNb)C solid solution powder in Examples D and E was addedto the mixture in an amount suff1cient to provide the tantalum and niobium masspercents. WC powder constituted the balance of the powder mixture after the addition of10.5 mass percent cobalt. For examples B and C, WC powder also constituted thebalance of the mixture after the addition of the cobalt and chromium mass percents.Cemented carbide body examples A-E were provided a multilayer coatingconsisting of a titanium carbonitride (TiCN) inner layer and an ot-alumina outer layerdeposited by chemical vapor deposition (CVD), wherein the coating thickness for eachexample is provided in Table III below. Cemented carbide body examples A-E weresubsequently subjected to the various ASTM testing procedures recited herein, the results of which are also provided in Table III.Table III ~ Properties of Cemented Carbide Bodies Example Density Magnetic Coercivity Hardness Coating(g/cnf) samfanon (oe) (Hvso) Thicimess(oi ttTnf fkg) (um)A 14.10 181 143 1331 7.0B 14.19 191 146 1316 7.7C 14.33 167 143 1351 7.7D 14.22 179 147 1321 8.8E 14.35 181 148 1327 8.3EXAMPLE 2 Deformation T estíng Cemented carbide bodies made in accordance with examples A-E of Example 1were subjected to a deformation tuming test under the following conditions:Workpiece - 42CrMo4 (1 .7225) Cutting Speed- 270, 285, 300, 315 and 330 m/minCutting time - 5 seconds per cutting speedFeed rate - 0.3 mn1/rev. 13 Depth ofCut - 2.5 mm Coolant - none Cutting Insert Holder - MCLNL3225P12 The average nose Wear (mm) of cemented carbide body examples A-E at a cutting speed of 315 m/min over three repetitions is provided in Table IV. The cutting speed of315 n1/min Was reached after the cemented carbide body examples A-E progressedthrough cutting speeds 270, 285 and 300 m/min. In some cases, a cemented carbidecutting tool reached end of life (EOL) prior to or during application of the 315 m/mincutting speed. EOL Was determined by plastic deformation resulting from therrnal overloading as demonstrated by nose Wear 2 0.6 mm and/or coating flaking.
    Table IV ~ Average Nose Wear (mm) at Cutting Speed of 315 m/min Example REPl REP2 REP3 AverageA 0.295 0.293 0.364 0.320B EOL 0.520 EOL > 0.5C 0.438 0.361 0.327 0.380D 0.247 0.347 0.357 0.320E 0.417 0.360 0.433 0.400 As provided in Table IV, the cemented carbide bodies of example A, havingcompositional parameters and properties described herein, demonstrated the highestresistance to nose Wear, thereby exceeding comparative examples B, C and E Whilematching the performance of comparative example D.
    Furthermore, the cemented carbide bodies of example A demonstrated desirableresistance to therrnal deformation in view of the comparative examples. As illustrated inFigure 2, the cemented carbide body of example A displayed significantly less therrnaldeformation in comparison With examples B and C at the cutting speed of 285 m/min.Coating flaking, for example, Was significant for examples B and C While substantially non-existent for example A. 14 EXAMPLE 3Toughness TestingCemented carbide bodies made in accordance with examples A-E of Example 1 were subjected to a toughness turning test under the following conditions: Workpiece - CK60 (1 .1221) Cutting Speed - 100 rn/min Feed rate - 0.4, 0.5, 0.6, 0.7, 0.8 mm/reV Impacts per feed rate - 100 Depth ofCut - 2.5 mm Coolant - none Cutting Insert Holder - MCLNL3225P12 The results of the toughness testing of cemented carbide body examples A-E oVer two repetitions is provided in Figure 3. The criteria for EOL were cemented carbidebody breakage and/or plastic deformation resulting from therrnal oVerloading asdemonstrated by nose wear 2 0.6 mm and/or coating flaking. As displayed in Figure 3,cemented carbide bodies of example A demonstrated comparable toughness to comparatiVe examples B-E.
    EXAMPLE 4interrupted Cut T estíngCemented carbide bodies made in accordance with examples A-E of Example 1 were subjected to an interrupted cut turning test under the following conditions:Workpiece - 42CrMo4 (1 .7225) Cutting Speed - 160 rn/min Cutting time - Up to 4 minutes or until tool failure Feed rate - 0.3 mn1/rev for 3 minutes, 0.35 mm/reV from 3-4 minutes Depth ofCut - 3 mm Coolant - yes Cutting Insert Holder - MCLNL3225P12 Figure 4 illustrates results of the interrupted cut testing, Wherein the bestperformance taken from five repetitions for each of examples A-E is provided. The EOLcriteria Were nose Wear > 0.4 mm and/or plastic deformation resulting from thermaloverloading as evidenced by coating flaking in conjunction With the nose Wear > 0.4 mm.As illustrated in Figure 4, the cemented carbide body of Example A demonstrated thehighest resistance to Wear. Figure 5 further illustrates the enhanced Wear resistantcharacteristics of the cemented carbide body of example A in comparison With examples B and C.
    EXAMPLE 5Millíng TestingPowder mixtures (A) and (B-E) provided in Tables I and II of Example 1 Wereeach pressed to form a green compact having an ANSI standard geometry ofSEKN1203AFSN3 and vacuum sintered at a temperature ranging from 1400°C-1560°Cfor a time period of 30-60 minutes to provide cemented carbides body examples A-E.Cemented carbide body examples A-E Were provided a multi-layer coating consisting of a TiCN inner layer and an ot-alumina outer layer, Wherein the thickness ofthe coating for each example Was 9 um. The cemented carbide body examples A-E Weresubsequently subjected to a face milling test having the following conditions:Workpiece - 42CrMo4V Cutting Speed - 250 n1/min Feed per tooth - 0.3 mm Axial Depth of Cut - 2.0 mm Radial Depth of Cut - 120 mm Coolant - None Machine - Heller PFH 12-1400 Tooling Adapter - SK 50 The average cutting length until EOL of cemented carbide body examples A-E over three repetitions is provided in Table V. EOL criteria Were flank Wear greater than0.3 mm and/or plastic deformation by therrnal overloading as evidenced by coating flaking in conjunction With flank Wear greater than 0.3 mm. 16 Table V ~ Average Cutting Length (mm) Prior to EOL Example REP 1 REP 2 REP 3 Stdev AverageA 1009 800 962 110 924B 118 115 125 5 119C 365 370 360 5 365D 669 903 800 117 794E 790 738 800 33 776 As provided in Table V, the cemented carbide bodies of example A, havingcompositional parameters described herein, had the longest cut length, therebydemonstrating increased resistance to therrnal deformation Without a loss in toughnessunder the foregoing severe milling conditions. Figure 6 filrther illustrates the enhancedperformance of the cemented carbide body of example A in comparison to thecomparative cemented carbide body of example E. At approximately equal cuttinglengths of 800 mm, the cemented carbide body of example E displayed significantcoating flaking on the rake face, crater Wear and deformation in comparison to the Wear of example A. 17 EXAMPLE 6Míllíng Testing The milling test of Example 5 Was repeated Wherein the only deviation Was an5 alteration of the cutting speed from 250 rn/min to 200 rn/min. The results of the testingare provided in Table VI.
    Table VI ~ Average Cutting Length (mm) Prior to EOL Example REP 1 REP 2 REP 3 Stdev Average A 4000 4000 4800 462 4267 932 485 400 286 606C 1600 2800 2000 611 2133D 2800 2800 4400 924 3333E 2800 2800 4000 693 3200 10 As provided in Table VI, the cemented carbide bodies of example A, havingcompositional parameters described herein, had the longest cut length, therebydemonstrating increased therrnal deformation resistance Without a loss in toughness underthe foregoing severe milling conditions.
    Various embodiments of the invention have been described in fialfillment of the 15 various objects of the invention. It should be recognized that these embodiments aremerely illustrative of the principles of the present invention. Numerous modif1cations andadaptations thereof Will be readily apparent to those skilled in the art Without departing from the spirit and scope of the invention. 20 That Which is claimed is: 18
    权利要求:
    Claims (26)
    [1] 1. A cernented carbide body cornprising: 5 to 15 percent by Weight of a binder phase cornprising at 1east one rneta1 ofthe iron group or an a11oy thereof; cubic carbides of zirconiurn and niobiurn,(Zr,Nb)C, cornprising in percent by Weight:0.5-1.5 Nb,0.3-1 Zr; and balance WC apart from irnpurities.
    [2] 2. The cernented carbide body of c1airn 1, Wherein the cubic carbides are present inan arnount ranging frorn 0.5 vo1urne percent to 6 vo1urne percent, preferab1y the cubic carbides are present in an arnount greater than 2 vo1urne percent to 5 vo1urne percent.
    [3] 3. The cernented carbide body of c1airn 1, Wherein the binder phase is present in an arnount ranging frorn 7 rnass percent to 13 rnass percent.
    [4] 4. The cernented carbide body of c1airn 1, Wherein the binder phase cornprises coba1t, a coba1t-nicke1 a11oy or a coba1t-nicke1-iron a11oy.
    [5] 5. The cernented carbide body of c1airn 1, Wherein the body does not cornprise a binder enriched zone.
    [6] 6. The cernented carbide body of c1airn 1, having a hardness ranging frorn -1200 to 1600 HV30.
    [7] 7. The cernented carbide body of c1airn 1 having a hardness ranging frorn 1280 to1380 HV30.
    [8] 8. The cernented carbide body of c1airn 1 having a coercivity (Hcg) ranging frorn 120Oe to 170 Oe. 19
    [9] 9. The cemented carbide body of c1aim 1 having a coercivity ranging from 130 Oe to 160 Oe.
    [10] 10. The cemented carbide body of c1aim 1, Wherein Nb is present in an amount ranging from 0.7 mass percent to 1.3 mass percent.
    [11] 11. The cemented carbide body of c1aim 1, Wherein Zr is present in an amount ranging from 0.5 mass percent to 0.7 mass percent.
    [12] 12. The cemented carbide body of c1aim 1 having a mass ratio of Nb/(Nb+Zr) 2 0.6.
    [13] 13. The cemented carbide body of c1aim 1 further comprising a coating deposited byphysica1vapor deposition (PVD), chemica1vapor deposition (CVD) or a combinationthereof, the coating comprising one or more carbides, nitrides, carbonitrides, oxides orborides of a meta11ic e1ement se1ected from the group consisting of a1uminum and meta11ic e1ements of Groups IVB, VB and VIB of the Periodic Tab1e.
    [14] 14. The cemented carbide body of c1aim 1 having the shape of a cutting too1.
    [15] 15. The cemented carbide body of c1aim 14, Wherein the body comprises a rake face and a flank face intersecting With the rake face to form a cutting edge.
    [16] 16. A method of making a cemented carbide body comprising:a) providing a powder mixture comprising:5 to 15 percent by Weight of a binder comprising at 1east one meta1 of the iron group or an a11oy thereof; a so1id so1ution of cubic carbides of zirconium and niobium,(Zr,Nb)C,comprising in percent by Weight:0.5-1.5 Nb,0.3-1 Zr; and ba1ance WC apart from impurities; b) forrning a green compact of the mixture; and c) sintering the green compact to provide the cemented carbide body
    [17] 17. The method of claim 16, wherein sintering comprises Vacuum sintering or sinter- hot isostatic press (HIP).
    [18] 18. The method of claim 16, wherein the cubic carbides are present in an amountranging from 0.5 Volume percent to 6 Volume percent, preferably greater than 2 Volume percent to 5 Volume percent.
    [19] 19. The method of claim 16, wherein the cubic carbides consist of the carbides of Zrand Nb.
    [20] 20. The method of claim 16, wherein binder powder comprises cobalt powder, nickel powder, iron powder or mixtures thereof
    [21] 21. The method of claim 16, wherein the binder powder is present in the mixture in an amount ranging from 7 mass percent to 13 mass percent.
    [22] 22. The method of claim 16, wherein Nb is present in an amount ranging from-0.7 mass percent to 1.3 mass percent.
    [23] 23. The method of claim 16, wherein Zr is present in an amount ranging from 0.5 mass percent to 0.7 mass percent.
    [24] 24. The method of claim 16, wherein the powdered solid solution has a mass ratio ofNb/(NbJrZr) 2 0.6.
    [25] 25. The method of claim 16, wherein the green compact is sintered at a temperature ranging from l400°C to l560°C. 21
    [26] 26. The method of claim 16 further comprising depositing a coating on the cementedcarbide body by PVD, CVD or a combination thereof, the coating comprising one ormore carbides, nitrides, carbonitrides, oxides or borides of a metallic element selectedfrom the group consisting of aluminum and metallic elements of Groups IVB, VB and VIB of the Periodic Table. 22
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