US20140305045A1 - Self-renewing cutting surface, tool and method for making same using powder metallurgy and densification techniques - Google Patents
Self-renewing cutting surface, tool and method for making same using powder metallurgy and densification techniques Download PDFInfo
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- US20140305045A1 US20140305045A1 US14/317,495 US201414317495A US2014305045A1 US 20140305045 A1 US20140305045 A1 US 20140305045A1 US 201414317495 A US201414317495 A US 201414317495A US 2014305045 A1 US2014305045 A1 US 2014305045A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
- B24D3/04—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
- B23B27/14—Cutting tools of which the bits or tips or cutting inserts are of special material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B2222/00—Materials of tools or workpieces composed of metals, alloys or metal matrices
- B23B2222/28—Details of hard metal, i.e. cemented carbide
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B2228/00—Properties of materials of tools or workpieces, materials of tools or workpieces applied in a specific manner
- B23B2228/10—Coatings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B2228/00—Properties of materials of tools or workpieces, materials of tools or workpieces applied in a specific manner
- B23B2228/28—Soft
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B2228/00—Properties of materials of tools or workpieces, materials of tools or workpieces applied in a specific manner
- B23B2228/56—Two phase materials
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- Y10T428/24372—Particulate matter
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- Y10T428/24372—Particulate matter
- Y10T428/24413—Metal or metal compound
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- Y10T428/24372—Particulate matter
- Y10T428/24421—Silicon containing
Definitions
- the present invention relates generally to the field of cutting tools and cutting elements and, more specifically, to self-renewing cutting tools and elements for cutting hard materials such as metals or metallic structures that may be in aqueous environments.
- Conventional cutting tools and elements for cutting metals and other tough surfaces may be made of a superhard material such as tungsten carbide. While conventional cutting tools and elements provide good performance under normal operating conditions and loads, they may not be suitable for applications in which harsh environmental conditions are present or high loads must be applied to cut large and or very complex structures. For example, in certain large scale demolition operations, it is often desirable or necessary to cut completely through a large objects comprised at least in part of metal or other difficult to cut surfaces in order to section them into more manageable sized to effect removal.
- conventional cutting tools Under normal operating conditions, conventional cutting tools will wear and eventually become dull or damaged which, in turn, reduces cutting performance. Under difficult operating conditions or sustained high loads (or both), conventional cutting tools tend to wear at an accelerated rate, leading to increased downtime to replace worn or broken tools.
- the basic geometries of conventional cutting tools may not be appropriate or effective for cutting objects that are massive and/or complex (e.g., an object made of multiple materials and/or systems, or a submerged structure).
- one known approach to cutting massive and/or complex objects is to braze pieces of a superhard material, such as tungsten carbide, to a surface of a tool. That approach suffers from at least one major disadvantage. Because brazing does not provide a sufficiently strong bond between and among the pieces of superhard material, the braze material and the tool surface, the pieces of superhard material become dislodged during cutting operations. The loss of superhard pieces, in turn, degrades the performance of the tool thereby necessitating more frequent repair or replacement.
- a superhard material such as tungsten carbide
- a self-renewing cutting tool or cutting element is formed by forming or bonding an overcoat, cladding or layer including superhard, very durable constituents on a surface of a substrate or load-bearing element.
- the cutting layer is a composite structure and includes appropriately sized, multi-edged pieces of a superhard material, such as tungsten carbide, interspersed with a bonding material which produces high strength bonds between and among the pieces and the substrate or load-bearing element and forms an integral composite of the plurality of materials.
- a superhard material such as tungsten carbide
- the cutting layer may be formed from a combination of superhard pieces and one or more powder materials having appropriate bonding characteristics.
- a hot isostatic pressing (HIP) process the combination is densified and diffusion bonded between and among the superhard pieces, the bonding material and the substrate or load-bearing element.
- densification and related terms refer to a process in which the mass density of a body or aggregation increases as a result of the controlled application of temperature and/or pressure.
- the cutting layer may be formed from a combination of superhard pieces and one or more powder metals having appropriate bonding characteristics.
- SPS spark plasma sintering
- the cutting layer may be formed on almost any substrate or load-bearing element geometry, as desired for a particular application including but not limited to planar, spherical, elliptical, conical, polyhedral, and cylindrical geometries.
- a substrate or load-bearing element may include one or more features which are specially adapted or arranged to accommodate the cutting layer.
- the cutting layer material may be formed in a desired pattern, as opposed to a continuous layer, on a substrate or load-bearing element.
- the superhard pieces may be formed by crushing or fracturing recycled (used) tungsten carbide machine tool inserts.
- FIG. 1 is a cross section of a finished cutting element having a cutting layer bonded to a substrate or load bearing element in accordance with a preferred embodiment of the present invention
- FIGS. 2A and 2B are an enlarged cross section of the cutting layer of FIG. 1 showing a typical dispersion of superhard pieces bearing cutting edges within the cutting layer;
- FIG. 3 is a cross section of an assembly of a load bearing element, located within a can, to which a cutting layer will be applied;
- FIG. 4 is a cross section of the assembly of FIG. 3 in which a metal powder and superhard pieces have been introduced in preparation for a hot isostatic pressing;
- FIG. 5 is a cross section of the assembly of FIG. 4 following the application of hot isostatic pressing and prior to removal of the can;
- FIG. 6 is a cross section of a load bearing element which includes a recessed area or feature in which a cutting layer is disposed;
- FIG. 7 is a schematic diagram of a spark plasma sintering system which may alternatively be used to form the cutting layer of FIG. 1 ;
- FIG. 8 is an enlarged schematic view of the central portion of FIG. 7 ;
- FIG. 9 is a cross section of a finished cutting element having a cutting layer bonded to selected portions of a substrate or load bearing element.
- a structure 10 serviceable as a cutting element includes a substrate or load-bearing element 20 on which a layer 26 is formed of particles or pieces 32 of a first material embedded in or bonded to a continuous second material 38 .
- Layer 26 represents a substantially fully dense overcoat, cladding or cutting layer bonded to substrate 20 .
- the thickness of second material 38 may vary from point to point on substrate 20 , and may conformally coat pieces 32 .
- second material 38 may comprise an alloy or a material comprising more than one type of compound.
- substrate 20 and superhard pieces 32 may be fabricated from any number of materials and methods, provided that they will bond among and between themselves when interspersed with or dispersed within second material 38 .
- Cutting and abrading are different mechanisms of removing material. Cutting is a shearing action where a chip of the material to be removed is formed. Abrading is the wearing away of material through the use of friction. As used herein, the terms “cut” and “cutting” and their derivatives should be understood to include cutting or abrading or both.
- pieces 32 are of a superhard material (>12 GPa Vickers) and provide multiple respective cutting edges 44 shown in FIGS. 2A-2B .
- superhard materials include, but are not limited, to tungsten carbide, zirconium oxide, silicon carbide, cubic boron nitride and polycarbonate diamond. Alternatively, somewhat softer but appropriate material such as tool steel may be used.
- Pieces 32 are generally dispersed throughout or interspersed with second material 38 . One or more of pieces 32 may protrude from second material 38 such that cutting edges 44 are typically randomly oriented and, in aggregate, provide a highly effective cutting surface. Alternatively, pieces 32 may be oriented in a preferential manner to better expose cutting edges 44 and provide a more effective cutting surface.
- Layer 26 is so constituted such that cutting edges 44 of those pieces 32 lying beneath the cutting surface of layer 26 are gradually exposed upon wearing of the second material 38 .
- structure 10 may be adapted (e.g., secured to an appropriate fixture and power source) to cut an object worked against the cutting surface of layer 26 with continual self-renewal of the cutting surface.
- pieces 32 are of irregular and nonuniform shape but characterizable in terms of an average of the shortest diameters of respective pieces 32 , which may be up to several inches.
- a powder used to prepare second material 38 may be, e.g., spherical or dendritic in morphology and has an average longest particle diameter of respective particles of the powder.
- the average longest particle diameter of the powder form of second material 38 before densification may be on the order of 0.05, 0.005, or 0.00005 times the average shortest diameter of pieces 32 or less.
- pieces 32 may have average shortest diameter on the order of up to several inches, whereas the average longest particle diameter may be several thousandths of an inch to tenths of inches.
- second material 38 has a hardness that is less than 1 ⁇ 2 the hardness of the first material of which pieces 32 are made.
- the strength of the bonds between a given one of pieces 32 and second material 38 in structure 10 is preferably greater than the strength of an individual one of pieces 32 , so that under stress layer 26 loses pieces 32 more readily by breaking a piece 32 or removing a portion of the second material 38 than by detachment of the second material 38 from one of the pieces 32 .
- the continuous second material 38 is configured to transfer load, during contact between layer 26 and an object to be cut or abraded from cutting edges 44 to substrate 20 .
- the material for substrate 20 of structure 10 is selected for its preferred properties, including but not limited to its ability to bear load, strength, resistance to corrosion in relevant environments, expense or other considerations.
- substrate 20 may be a steel such as 4340 alloy steel.
- substrate 20 may be metallic in nature.
- pieces 32 are of a material that is at least three times, five times, or ten times as hard as second material 38 .
- Tungsten carbide is a superhard material available commercially as recycled fragments (Dynalloy Industries, Inc., Tomball, Tex.) having sharp cutting edges and suitable for pieces 32 .
- the second material 38 in layer 26 is illustratively a metallic alloy, for example having the composition of a powder such as B27 (Carpenter Powder Products, Inc., Bridgeville, Pa.) which includes nickel, silicon, boron and carbon.
- Layer 26 is illustratively formed by placing a powder substantially identical in composition to second material 38 in intimate contact between and among pieces 32 and between pieces 32 and substrate 20 and then subjecting substrate 20 , pieces 32 and the powder form of second material 38 to a densification process such as HIP.
- a can 50 alternatively designated a skin or encapsulation, as is used to contain pieces 32 and the powder form of second material 38 during HIP, is disposed over a surface 56 on substrate 20 .
- Can 50 is spaced apart from surface 56 of substrate 20 to form a cavity 62 .
- Inert material 68 for example alumina, may be disposed upon or applied to an interior surface 58 to prevent interior surface 58 of can 50 from bonding to pieces 32 , and to facilitate removal of can 50 from substrate 20 later in the method.
- a material that does not bond with pieces 32 or the powder for example a piece of carbon paper such as Grafoil® (Graftech International Holdings, Inc., Parma, OH) whose thickness is selected based on the desired characteristics may be used.
- Grafoil® Grafoil® (Graftech International Holdings, Inc., Parma, OH) whose thickness is selected based on the desired characteristics may be used.
- Grafoil® Grafoil® (Graftech International Holdings, Inc., Parma, OH) whose thickness is selected based on the desired characteristics
- FIG. 4 shows can 50 holding the mixture which substantially fills the volume between neighboring ones of pieces 32 and between the pieces and can 50 and surface 56 .
- Substrate 20 , pieces 32 and powder 74 thus assembled constitute a precursor to the final structure 10 ( FIG. 1 ).
- the mixture is illustratively created in cavity 56 stepwise by first loading pieces 32 into the cavity from its top end and then pouring powder 74 to appropriately fill remaining space between can 50 and surface 56 .
- pieces 32 may occupy about 40% to 60% of cavity 62 .
- powder 74 may occupy the volume in the cavity 62 not occupied by the pieces 32 at the tap density of powder 74 .
- Cavity 62 is then evacuated, sealed, placed in a hot isostatic press and heated under isostatic pressure, as understood by those skilled in the art.
- the operating parameters of the hot isostatic pressing operation are selected in view of the physical and sintering properties of the materials of which substrate 20 , pieces 32 and powder 74 are made to consolidate the powder 74 and pieces 32 and substrate 20 , as known to those skilled in the art.
- typical process temperatures are 0.9 to 0.95 times the melting temperature of powder 74 with typical pressures around 10 to 30 Ksi.
- particles of powder 74 FIG. 4
- consolidate into a continuous phase 38 FIGS. 2A-2B
- substrate 20 and pieces 32 need not densify during HIP.
- FIG. 5 shows the assembly of FIG. 4 after densification of powder 74 , with commensurate reduction of the volume it occupies following HIP.
- Can 50 has assumed a conformal profile accommodating the relatively reduced volume of second material 38 and pieces 32 protruding therefrom due to the HIP process. Removal of can 50 by, e.g., a mechanical or chemical process exposes protruding portions of pieces 32 illustratively bearing cutting edges 44 as shown in FIGS. 2A-2B .
- a cutting layer, overcoat or cladding similar in composition to layer 26 may be formed on a wide variety of substrate or load-bearing element geometries including planar, spherical, elliptical, conical, polyhedral and cylindrical.
- FIG. 6 shows an alternative configuration of substrate 20 in which a concavity 80 is disposed.
- Concavity 80 is substantially filled with the mixture of pieces 32 and powder 74 as described above.
- concavity 80 is sealed by can 50 .
- a concavity 80 may be combined with a specifically configured can 50 to provide for the formation of custom layer 26 profiles.
- spark plasma sintering may be used to provide densification in order to form a structure like structure 10 ( FIG. 1 ).
- SPS may be employed to fabricate layer 26 using similar, if not identical materials as those described above.
- powder 74 and superhard pieces 32 are disposed in a volume within tooling 100 between an upper press platen 110 and a lower press platen 120 .
- An appropriate volume of respective superhard pieces 32 and powder 74 of appropriate ratios are placed within the tooling volume. Densification and sintering takes place under mechanical pressure that is applied by lowering upper press platen 110 and/or raising lower press platen 120 in opposition.
- the necessary temperature is produced by passing a pulsed high electrical current from a power source 140 through the tooling, as well as the powder and/or superhard pieces, thereby generating heat from the electrical resistance.
- a layer of electrically conductive powder 130 such as carbon powder, is placed in contact with an electrode, tooling, powder 74 and pieces 32 , to accommodate the rough surface morphology of powder 74 and pieces 32 .
- powder 74 is at tap density and there are points of contact between and among powder particles, substrate and other powder particles. In some instances it may be necessary or desirable to mechanically compress powder 74 and pieces 32 prior to the application of the electrical current.
- FIG. 9 shows a cross section of a structure 140 which includes a substrate or load-bearing element 20 similar that described above.
- substrate 20 does not have a continuous composite cutting layer bonded to it.
- powder manufacturing techniques allow for patterning or selective application of a cutting layer to substrate 20 .
- Material 26 a - 26 c which is similar in composition to layer 26 described above, is preferentially disposed on substrate 20 , leaving at least one untreated area 142 .
- Such material may be applied in any number of more complex patterns or shapes including a simple, substantially uniform layer 26 a disposed over a portion of the substrate 20 , a layer with varying thickness 26 b, or a more complex feature, such as a cone, rail, or ridge 26 c.
- the composition of material 26 a - 26 c may also change as a function of its depth, depending on the desired properties.
- powder manufacturing techniques make it possible to use various materials for pieces 32 , powder 74 , second material 38 or substrate 20 , as long as the materials will bond to and among each other.
- ceramics, intermetallics, stellites, diamond, alumina, silicon carbides, titanium nitrides, may be used for each of the above mentioned elements.
Abstract
In one embodiment, a self-renewing cutting tool includes a substrate and a layer bonded to the substrate forming a composite cladding. The layer includes a plurality of pieces of a first material having irregular, non-uniform shapes, the irregular, non-uniform shapes forming cutting edges, and a second material in which the plurality of first pieces are embedded. The second material is bonded to both the plurality of pieces of the first material and the substrate by densification of the plurality of pieces of a first material and a powder of the second material. At least some cutting edges of the first material lie beneath a surface of the second material and are exposable by wear of the second material.
Description
- This application is a continuation of U.S. patent application Ser. No. 13/068,969 filed on May 25, 2011 by Gerhard B. Beckmann, for a “Self-Renewing Cutting Surface, Tool and Method for Making Same Using Powder Metallurgy and Densification Techniques”, the contents of which are incorporated by reference herein in their entirety.
- 1. Field of the Invention
- The present invention relates generally to the field of cutting tools and cutting elements and, more specifically, to self-renewing cutting tools and elements for cutting hard materials such as metals or metallic structures that may be in aqueous environments.
- 2. Background Information
- Conventional cutting tools and elements for cutting metals and other tough surfaces may be made of a superhard material such as tungsten carbide. While conventional cutting tools and elements provide good performance under normal operating conditions and loads, they may not be suitable for applications in which harsh environmental conditions are present or high loads must be applied to cut large and or very complex structures. For example, in certain large scale demolition operations, it is often desirable or necessary to cut completely through a large objects comprised at least in part of metal or other difficult to cut surfaces in order to section them into more manageable sized to effect removal. Depending upon the environment in which the demolition takes place, including the orientation and balance of the object(s) to be cut, as well as the size and hardness of the object being cut or abraded, it may be impractical or unsafe to perform such cutting other than by tools which can be actuated some distance from the point of the cut.
- Under normal operating conditions, conventional cutting tools will wear and eventually become dull or damaged which, in turn, reduces cutting performance. Under difficult operating conditions or sustained high loads (or both), conventional cutting tools tend to wear at an accelerated rate, leading to increased downtime to replace worn or broken tools. In addition, the basic geometries of conventional cutting tools may not be appropriate or effective for cutting objects that are massive and/or complex (e.g., an object made of multiple materials and/or systems, or a submerged structure).
- As shown in the literature, one known approach to cutting massive and/or complex objects is to braze pieces of a superhard material, such as tungsten carbide, to a surface of a tool. That approach suffers from at least one major disadvantage. Because brazing does not provide a sufficiently strong bond between and among the pieces of superhard material, the braze material and the tool surface, the pieces of superhard material become dislodged during cutting operations. The loss of superhard pieces, in turn, degrades the performance of the tool thereby necessitating more frequent repair or replacement.
- In brief summary, a self-renewing cutting tool or cutting element is formed by forming or bonding an overcoat, cladding or layer including superhard, very durable constituents on a surface of a substrate or load-bearing element. The cutting layer is a composite structure and includes appropriately sized, multi-edged pieces of a superhard material, such as tungsten carbide, interspersed with a bonding material which produces high strength bonds between and among the pieces and the substrate or load-bearing element and forms an integral composite of the plurality of materials. When the cutting layer is initially formed, portions of at least some of the superhard pieces typically protrude from a wear surface of the layer and are thus available to remove material wear surface is worked against an object. As the wear surface is worked, the bonding material of the cutting layer may gradually wear away exposing additional edges of pieces and additional pieces of the superhard materials in a self-renewing cycle.
- In accordance with another aspect of the invention, the cutting layer may be formed from a combination of superhard pieces and one or more powder materials having appropriate bonding characteristics. Through application of a hot isostatic pressing (HIP) process, the combination is densified and diffusion bonded between and among the superhard pieces, the bonding material and the substrate or load-bearing element. As used herein, densification and related terms refer to a process in which the mass density of a body or aggregation increases as a result of the controlled application of temperature and/or pressure.
- In accordance with another aspect of the invention, the cutting layer may be formed from a combination of superhard pieces and one or more powder metals having appropriate bonding characteristics. Through the application of spark plasma sintering (SPS), the combination is densified and diffusion bonded to the substrate or load-bearing element.
- In accordance with another aspect of the invention, the cutting layer may be formed on almost any substrate or load-bearing element geometry, as desired for a particular application including but not limited to planar, spherical, elliptical, conical, polyhedral, and cylindrical geometries. In order to meet the requirements of a particular application, a substrate or load-bearing element may include one or more features which are specially adapted or arranged to accommodate the cutting layer. Similarly, the cutting layer material may be formed in a desired pattern, as opposed to a continuous layer, on a substrate or load-bearing element.
- In accordance with another aspect of the invention, the superhard pieces may be formed by crushing or fracturing recycled (used) tungsten carbide machine tool inserts.
- The invention description below refers to the accompanying drawings, of which:
-
FIG. 1 is a cross section of a finished cutting element having a cutting layer bonded to a substrate or load bearing element in accordance with a preferred embodiment of the present invention; -
FIGS. 2A and 2B are an enlarged cross section of the cutting layer ofFIG. 1 showing a typical dispersion of superhard pieces bearing cutting edges within the cutting layer; -
FIG. 3 is a cross section of an assembly of a load bearing element, located within a can, to which a cutting layer will be applied; -
FIG. 4 is a cross section of the assembly ofFIG. 3 in which a metal powder and superhard pieces have been introduced in preparation for a hot isostatic pressing; -
FIG. 5 is a cross section of the assembly ofFIG. 4 following the application of hot isostatic pressing and prior to removal of the can; -
FIG. 6 is a cross section of a load bearing element which includes a recessed area or feature in which a cutting layer is disposed; -
FIG. 7 is a schematic diagram of a spark plasma sintering system which may alternatively be used to form the cutting layer ofFIG. 1 ; -
FIG. 8 is an enlarged schematic view of the central portion ofFIG. 7 ; and -
FIG. 9 is a cross section of a finished cutting element having a cutting layer bonded to selected portions of a substrate or load bearing element. - With reference to
FIG. 1 , astructure 10 serviceable as a cutting element includes a substrate or load-bearingelement 20 on which alayer 26 is formed of particles orpieces 32 of a first material embedded in or bonded to a continuoussecond material 38.Layer 26 represents a substantially fully dense overcoat, cladding or cutting layer bonded tosubstrate 20. The thickness ofsecond material 38 may vary from point to point onsubstrate 20, and may conformally coatpieces 32. Those skilled in the art will understand thatsecond material 38 may comprise an alloy or a material comprising more than one type of compound. Those skilled in the art will further understand thatsubstrate 20 andsuperhard pieces 32 may be fabricated from any number of materials and methods, provided that they will bond among and between themselves when interspersed with or dispersed withinsecond material 38. - As is understood by those skilled in the art, cutting and abrading are different mechanisms of removing material. Cutting is a shearing action where a chip of the material to be removed is formed. Abrading is the wearing away of material through the use of friction. As used herein, the terms “cut” and “cutting” and their derivatives should be understood to include cutting or abrading or both.
- Illustratively,
pieces 32 are of a superhard material (>12 GPa Vickers) and provide multiplerespective cutting edges 44 shown inFIGS. 2A-2B . Examples of superhard materials include, but are not limited, to tungsten carbide, zirconium oxide, silicon carbide, cubic boron nitride and polycarbonate diamond. Alternatively, somewhat softer but appropriate material such as tool steel may be used.Pieces 32 are generally dispersed throughout or interspersed withsecond material 38. One or more ofpieces 32 may protrude fromsecond material 38 such thatcutting edges 44 are typically randomly oriented and, in aggregate, provide a highly effective cutting surface. Alternatively,pieces 32 may be oriented in a preferential manner to better exposecutting edges 44 and provide a more effective cutting surface.Layer 26 is so constituted such thatcutting edges 44 of thosepieces 32 lying beneath the cutting surface oflayer 26 are gradually exposed upon wearing of thesecond material 38. Thus,structure 10 may be adapted (e.g., secured to an appropriate fixture and power source) to cut an object worked against the cutting surface oflayer 26 with continual self-renewal of the cutting surface. - In general,
pieces 32 are of irregular and nonuniform shape but characterizable in terms of an average of the shortest diameters ofrespective pieces 32, which may be up to several inches. A powder used to preparesecond material 38, as described below, may be, e.g., spherical or dendritic in morphology and has an average longest particle diameter of respective particles of the powder. The average longest particle diameter of the powder form ofsecond material 38 before densification may be on the order of 0.05, 0.005, or 0.00005 times the average shortest diameter ofpieces 32 or less. For example,pieces 32 may have average shortest diameter on the order of up to several inches, whereas the average longest particle diameter may be several thousandths of an inch to tenths of inches. Ilustratively,second material 38 has a hardness that is less than ½ the hardness of the first material of whichpieces 32 are made. - The strength of the bonds between a given one of
pieces 32 andsecond material 38 instructure 10 is preferably greater than the strength of an individual one ofpieces 32, so that understress layer 26 losespieces 32 more readily by breaking apiece 32 or removing a portion of thesecond material 38 than by detachment of thesecond material 38 from one of thepieces 32. Thus, the continuoussecond material 38 is configured to transfer load, during contact betweenlayer 26 and an object to be cut or abraded from cuttingedges 44 tosubstrate 20. - The material for
substrate 20 ofstructure 10 is selected for its preferred properties, including but not limited to its ability to bear load, strength, resistance to corrosion in relevant environments, expense or other considerations. Illustratively, where strength is a veryimportant consideration substrate 20 may be a steel such as 4340 alloy steel. There is no requirement thatsubstrate 20 be metallic in nature. Illustratively,pieces 32 are of a material that is at least three times, five times, or ten times as hard assecond material 38. Tungsten carbide is a superhard material available commercially as recycled fragments (Dynalloy Industries, Inc., Tomball, Tex.) having sharp cutting edges and suitable forpieces 32. Thesecond material 38 inlayer 26 is illustratively a metallic alloy, for example having the composition of a powder such as B27 (Carpenter Powder Products, Inc., Bridgeville, Pa.) which includes nickel, silicon, boron and carbon. -
Layer 26 is illustratively formed by placing a powder substantially identical in composition tosecond material 38 in intimate contact between and amongpieces 32 and betweenpieces 32 andsubstrate 20 and then subjectingsubstrate 20,pieces 32 and the powder form ofsecond material 38 to a densification process such as HIP. In an illustrative method for forming structure 10 (FIG. 1 ), with reference toFIG. 3 , acan 50, alternatively designated a skin or encapsulation, as is used to containpieces 32 and the powder form ofsecond material 38 during HIP, is disposed over asurface 56 onsubstrate 20. Can 50 is spaced apart fromsurface 56 ofsubstrate 20 to form acavity 62.Inert material 68, for example alumina, may be disposed upon or applied to aninterior surface 58 to preventinterior surface 58 ofcan 50 from bonding topieces 32, and to facilitate removal ofcan 50 fromsubstrate 20 later in the method. Alternatively, a material that does not bond withpieces 32 or the powder, for example a piece of carbon paper such as Grafoil® (Graftech International Holdings, Inc., Parma, OH) whose thickness is selected based on the desired characteristics may be used. Those skilled in the art will recognize that it may be preferable to fabricate can 50 from a material that does not bond withpieces 32 orsecond material 38. - A substantially uniform mixture of pieces 32 (
FIG. 1 ) and the powder to be densified intosecond material 38 is introduced intocavity 62.FIG. 4 shows can 50 holding the mixture which substantially fills the volume between neighboring ones ofpieces 32 and between the pieces and can 50 andsurface 56.Substrate 20,pieces 32 andpowder 74 thus assembled constitute a precursor to the final structure 10 (FIG. 1 ). - Returning to
FIG. 4 , the mixture is illustratively created incavity 56 stepwise byfirst loading pieces 32 into the cavity from its top end and then pouringpowder 74 to appropriately fill remaining space betweencan 50 andsurface 56. Preferably,pieces 32 may occupy about 40% to 60% ofcavity 62. Preferably,powder 74 may occupy the volume in thecavity 62 not occupied by thepieces 32 at the tap density ofpowder 74. -
Cavity 62 is then evacuated, sealed, placed in a hot isostatic press and heated under isostatic pressure, as understood by those skilled in the art. The operating parameters of the hot isostatic pressing operation are selected in view of the physical and sintering properties of the materials of whichsubstrate 20,pieces 32 andpowder 74 are made to consolidate thepowder 74 andpieces 32 andsubstrate 20, as known to those skilled in the art. By way of illustration, and not limitation, typical process temperatures are 0.9 to 0.95 times the melting temperature ofpowder 74 with typical pressures around 10 to 30 Ksi. During HIP, particles of powder 74 (FIG. 4 ) consolidate into a continuous phase 38 (FIGS. 2A-2B ) which is diffusion bonded topieces 32 andsubstrate 20. Illustratively,substrate 20 andpieces 32 need not densify during HIP. -
FIG. 5 shows the assembly ofFIG. 4 after densification ofpowder 74, with commensurate reduction of the volume it occupies following HIP. Can 50 has assumed a conformal profile accommodating the relatively reduced volume ofsecond material 38 andpieces 32 protruding therefrom due to the HIP process. Removal ofcan 50 by, e.g., a mechanical or chemical process exposes protruding portions ofpieces 32 illustratively bearing cuttingedges 44 as shown inFIGS. 2A-2B . - Using the method described above, a cutting layer, overcoat or cladding similar in composition to layer 26 may be formed on a wide variety of substrate or load-bearing element geometries including planar, spherical, elliptical, conical, polyhedral and cylindrical.
-
FIG. 6 shows an alternative configuration ofsubstrate 20 in which aconcavity 80 is disposed.Concavity 80 is substantially filled with the mixture ofpieces 32 andpowder 74 as described above. In preparation for a HIP process,concavity 80 is sealed bycan 50. Those skilled in the art will recognize that aconcavity 80 may be combined with a specifically configured can 50 to provide for the formation ofcustom layer 26 profiles. - As an alternative to HIP, spark plasma sintering (SPS) may be used to provide densification in order to form a structure like structure 10 (
FIG. 1 ). SPS may be employed to fabricatelayer 26 using similar, if not identical materials as those described above. With reference now toFIGS. 7 and 8 , in the SPS process,powder 74 andsuperhard pieces 32 are disposed in a volume withintooling 100 between anupper press platen 110 and alower press platen 120. An appropriate volume of respectivesuperhard pieces 32 andpowder 74 of appropriate ratios are placed within the tooling volume. Densification and sintering takes place under mechanical pressure that is applied by loweringupper press platen 110 and/or raisinglower press platen 120 in opposition. The necessary temperature is produced by passing a pulsed high electrical current from apower source 140 through the tooling, as well as the powder and/or superhard pieces, thereby generating heat from the electrical resistance. In SPS a layer of electricallyconductive powder 130, such as carbon powder, is placed in contact with an electrode, tooling,powder 74 andpieces 32, to accommodate the rough surface morphology ofpowder 74 andpieces 32. - Initially,
powder 74 is at tap density and there are points of contact between and among powder particles, substrate and other powder particles. In some instances it may be necessary or desirable to mechanically compresspowder 74 andpieces 32 prior to the application of the electrical current. - Once pressure is applied these contacts are effected and any oxide layers that may have been present may be broken down. The electric current produces high heating rates (>300° C./min are attainable) and heat is generated internally as opposed to being provided from the outside. Substantial densification results and cycle times on the order of minute(s) are possible. Custom tool designs can provide a wide range of desired post SPS tool geometries.
-
FIG. 9 shows a cross section of astructure 140 which includes a substrate or load-bearing element 20 similar that described above. In contrast to structure 10 ofFIG. 1 , however,substrate 20 does not have a continuous composite cutting layer bonded to it. Instead, as those skilled in the art will recognize, powder manufacturing techniques allow for patterning or selective application of a cutting layer tosubstrate 20.Material 26 a-26 c, which is similar in composition to layer 26 described above, is preferentially disposed onsubstrate 20, leaving at least oneuntreated area 142. Such material may be applied in any number of more complex patterns or shapes including a simple, substantiallyuniform layer 26 a disposed over a portion of thesubstrate 20, a layer with varyingthickness 26 b, or a more complex feature, such as a cone, rail, or ridge 26 c. In addition, the composition ofmaterial 26 a-26 c may also change as a function of its depth, depending on the desired properties. - Those skilled in the art will recognize that powder manufacturing techniques make it possible to use various materials for
pieces 32,powder 74,second material 38 orsubstrate 20, as long as the materials will bond to and among each other. In particular ceramics, intermetallics, stellites, diamond, alumina, silicon carbides, titanium nitrides, may be used for each of the above mentioned elements.
Claims (20)
1. A self-renewing cutting tool comprising:
a substrate; and
a layer bonded to the substrate forming a composite cladding, the layer including
a plurality of pieces of a first material having irregular, non-uniform shapes, the irregular, non-uniform shapes forming cutting edges, and
a second material in which the plurality of pieces of the first material are embedded, the second material bonded to both the plurality of pieces of the first material and the substrate by densification of the plurality of pieces of the first material and a powder of the second material,
wherein at least some cutting edges of the plurality of pieces of the first material lie beneath a surface of the second material and are exposable by wear of the second material.
2. The self-renewing cutting tool of claim 1 , wherein the cutting edges are randomly oriented.
3. The self-renewing cutting tool of claim 1 , wherein the plurality of pieces of the first material are fragments of crushed machine tool inserts.
4. The self-renewing cutting tool of claim 1 , wherein the plurality of pieces of the first material have an average shortest diameter, the powder of the second material has an average longest particle diameter, and the average longest particle diameter is less than 0.05 times the average shortest diameter.
5. The self-renewing cutting tool of claim 1 , wherein the plurality of pieces of the first material have an average shortest diameter, the powder of the second material has an average longest particle diameter, and the average longest particle diameter is less than 0.005 times the average shortest diameter.
6. The self-renewing cutting tool of claim 1 , wherein the plurality of pieces of the first material have an average shortest diameter, the powder of the second material has an average longest particle diameter, and the average longest particle diameter is less than 0.00005 times the average shortest diameter.
7. The self-renewing cutting tool of claim 1 , wherein a bonding force between the plurality of pieces of the first material and the second material is greater than a strength of the plurality of pieces of the first material, such that under stress pieces of the first material more readily break than detach from the second material.
8. The self-renewing cutting tool of claim 1 , wherein the second material has a hardness that is less than a hardness of the first material.
9. The self-renewing cutting tool of claim 1 , wherein the first material comprises tungsten carbide.
10. The self-renewing cutting tool of claim 1 , wherein the first material comprises silicon carbide, cubic boron nitride, diamond, zirconium oxide or tool steel.
11. A self-renewing cutting tool comprising:
a plurality of pieces of a first material having cutting edges, and
a second material in which the plurality of pieces of the first material are embedded, the second material having a hardness that is less a hardness of the first material, the second material bonded to the plurality of pieces of the first material by densification of the plurality of pieces of the first material and a powder of the second material,
wherein at least some cutting edges of the plurality of pieces of the first material lie beneath a surface of the second material and are exposable by wear of the second material.
12. The self-renewing cutting tool of claim 11 , wherein the cutting edges of the plurality of pieces of the first material are randomly oriented.
13. The self-renewing cutting tool of claim 11 , wherein the cutting edges of the plurality of pieces of the first material are oriented in predetermined directions.
14. The self-renewing cutting tool of claim 11 , wherein the plurality of pieces of the first material each have an irregular, non-uniform shape.
15. The self-renewing cutting tool of claim 11 , wherein a bonding force between the plurality of pieces of the first material and the second material is greater than a strength of the plurality of pieces of the first material, such that under stress pieces of the first material more readily break than detach from the second material.
16. A self-renewing cutting tool comprising:
a substrate; and
a layer bonded to the substrate, the layer including
a plurality of pieces of a first material having cutting edges, the plurality of pieces of the first material having an average shortest diameter, and
a second material in which the plurality of pieces of the first material are embedded, the second material bonded to both the plurality of pieces of the first material and the substrate by densification of the plurality of pieces of a first material and a powder of the second material, the powder of the second material having an average longest particle diameter,
wherein the average longest particle diameter is less than 0.05 times the average shortest diameter.
17. The self-renewing cutting tool of claim 16 , wherein the plurality of pieces of the first material each have an irregular, non-uniform shape.
18. The self-renewing cutting tool of claim 16 , wherein at least some cutting edges of the plurality of pieces of the first material lie beneath a surface of the second material and are exposable by wear of the second material.
19. The self-renewing cutting tool of claim 16 , wherein the average longest particle diameter is less than 0.005 times the average shortest diameter.
20. The self-renewing cutting tool of claim 16 , wherein the average longest particle diameter is less than 0.00005 times the average shortest diameter.
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US13/068,969 US8778259B2 (en) | 2011-05-25 | 2011-05-25 | Self-renewing cutting surface, tool and method for making same using powder metallurgy and densification techniques |
US14/317,495 US20140305045A1 (en) | 2011-05-25 | 2014-06-27 | Self-renewing cutting surface, tool and method for making same using powder metallurgy and densification techniques |
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US14/317,495 Abandoned US20140305045A1 (en) | 2011-05-25 | 2014-06-27 | Self-renewing cutting surface, tool and method for making same using powder metallurgy and densification techniques |
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EP3838447A1 (en) * | 2019-12-18 | 2021-06-23 | Commissariat à l'énergie atomique et aux énergies alternatives | Method for manufacturing a tool part by hot isostatic pressing |
FR3105040A1 (en) * | 2019-12-18 | 2021-06-25 | Commissariat A L'energie Atomique Et Aux Energies Alternatives | Manufacturing process by hot isostatic compression of a tool part |
Also Published As
Publication number | Publication date |
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US20120301675A1 (en) | 2012-11-29 |
WO2012161742A1 (en) | 2012-11-29 |
US8778259B2 (en) | 2014-07-15 |
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