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Fig 27: Microstructure of the Kennametal grade KC9110 showing the cross-section of the tool nose [10]
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The post-coat polish can resist chip hammering, microchipping, and built-up edge The fine-grained thick alumina can resist crater wear The tough substrate can handle increased feeds Hafnium carbide coated tools, manufactured based on an MIT process, have been in limited use in the US These tools are reported to be able to resist edge wear better than either TiC or TiN coated carbide tools [11] Aluminium oxide coated tools have been recommended for use on cast iron Some grades can cut steel too Figure 28 (a) shows an optical micrograph of a GE aluminium oxide coated tool and Figure 28 (b) a scanning electron micrograph of a Sandvik tool Wear resistance of a coating on a substrate in a coated carbide tool depends not only on the type of coating material but also on the quality of the coating The quality of the coating in turn considerably depends on the substrate material on which the coating material is deposited The
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Fig 28: (a) An aluminium oxide coated carbide insert (GE) and (b) a SEM picture showing an extremely finegrained Al2O3 coating on the fine-grained TiC layer on a tungsten carbide substrate (Courtesy: Sandvik)
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quality of bonding between the coating and the substrate, which may be either due to a chemical reaction or diffusion, is also affected by the substrate on which the coating is deposited TiC coated cemented titanium carbide [12] is a new tool material developed to provide a quality TiC coating on a better performing substrate Figure 29 shows the microstructure of a TiC coated cemented titanium carbide tool in which fine grains are observed in the coating For the TiC coating on cemented titanium carbide, eta phase
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Fig 29: (a) An optical micrograph of the novel TiC coated cemented titanium carbide in which pores are absent
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but the carbide grains can be clearly seen (b) A SEM photograph showing the presence of horizontal pores, but no grains can be seen
Tool Materials for Precision Machining
and cracks are absent, but pores are present in the coating [13 15] Thus, the bonding between the substrate and the coating was observed to be better compared to that of TiC coating on WC tools The coating is removed occasionally by adhesion Coating titanium carbide on cemented titanium carbide tools reduces grooving wear and chip notching There is no white layer formed on these tools when machining steel This may be due to the absence of a binding material and the presence of cracks in the coating The surface finish produced by these tools is extremely good (Ra= 05 m), but their resistance to chipping is reduced [16]
400 m 100 m
Fig 210: (a) Uncoated carbide showing all forms of wear and (b) coated cemented titanium carbide in which
the crater recedes when a coating is present, leading to the development of a wider stagnant zone [16]
In these tools, crater wear begins at a distance from the coating edge [Figure 210 (b)], and the wear moves towards the cutting edge with further machining [17] A small width of the cutting edge with the crater front is maintained even after a long period of machining The retention of the sharp front lip at the cutting edge provides a longer tool life But as the crater depth increases, the front lip becomes weak, which may lead to chipping of the cutting edge due to the high brittleness of the coating
223 Coating of the First Generation of TiC (Cermets)
The credit for the first coating and the only one to be reported goes to Venkatesh [12, 18] (Figure 211) in association with Widia (India) in Bangalore This concept was put forward by W S Sampath, a student of IIT, where coating was taught It made him wonder as to why a TiC coating could not be applied onto a TiC substrate to get a crack-free coating
224 Coating of the Second Generation of TiC (Cermets)
The technique of applying a thin refractory hard coating on cermet tools has also been used to enhance the performance of metal cutting tools Unlike coated tungsten carbide tools, however, not
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