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How can we reduce the high processing cost of heat resistant alloys?
Recently, with the market growth of superalloys, manufacturers of heat-resistant alloys have gradually increased, but as the competition in the market has intensified, the processing cost has become an urgent demand. Due to the processing properties of superalloys, processing has become a problem. The time is extremely long, the tool loss is also large, and the processing cost is high. For this, Kyocera proposes to use ceramic blades for high-speed machining to reduce the processing time and reduce the processing cost of superalloy.
figure 1
Superalloys are mainly used for machining parts in the automotive industry, aerospace and energy industries because of their high temperature and corrosion resistance. Because of its oxidation resistance, it is also widely used in the processing of marine parts.
figure 2
In recent years, the demand for high-performance alloys including superalloys has gradually increased due to the improvement of environmental concepts. As shown in the figure below, the market expectation growth rate is 1.3 times as of 2020.
image 3
Figure 4
However, since the heat resistant alloy contains a large amount of Ni and Cr, heat resistance and wear resistance are very high relative to ordinary steel and stainless steel, but in turn, chip strength due to improvement in strength, heat resistance and toughness. It also became very poor. The right side of the chart is a representative superalloy inconel718. Compared to ordinary steel parts, the machinability index is less than 10, which means that none of the steel parts are processed.
The table below shows the processing temperature effect of S50C steel and inconel718. It can be seen that the temperature of inconel718 exceeds 800 °C when the line speed is 80m/min.
Figure 5
Generally speaking, the hardness of the tool during machining is recommended to be more than three times that of the workpiece. Therefore, there is no major problem when processing according to the general parameters, but if high-speed machining parameters are used, the super-hard coating may be The hardness will be greatly reduced due to the high temperature, and the ceramic can maintain the hardness at high temperatures, so ceramic blades are recommended for high speed machining.
Image 6
Among the materials of ceramic inserts, we recommend SiAION, which has the highest heat resistance and hardness.
Figure 7
There are not many blade manufacturers that can make SiAION materials all over the world. Kyocera is one of the representatives. The model of Kyocera's SiAION ceramic blade is KS6030. Hardness and oxidation resistance are higher than previous ceramic products.