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There are many ways to improve the performance of coated products: fine-tuning the chemical composition in the coating furnace, more careful structural control of the coatings, fine grinding of the top and bottom of the coated blades, and even the cutting edge after coating Polishing, all of which is good for the end user.
In addition to these improvements over the past few years, Seco has attempted to adopt a relatively more basic approach to improve coating performance. For example, the industry is one of the reasons for the polishing of some material grades in a more basic way, and this is one of the measures used by Seco to remove the flaws in the coating itself. Polishing can improve smoothness, residual stress state and reduce cutting friction. But what happens when these flaws are not the first factor? This problem has led Seco to work to improve the structural integrity of the various coatings.
If we start from the original place, there are two different forms of alumina applied to the coating: kappa and alpha. The difference between the two lies in the difference in crystal structure. For example, ceramic sinks and rubies are made of alumina. The difference between the two is in the way the atoms are arranged.
Turning product expert Don Graham explains: “When used as a tool material, we prefer to use alpha phase alumina. However, the kappa phase is easier to deposit, so we first deposit the kappa phase and then heat treat the coating in the furnace. It is converted to the alpha phase. In this process, volume shrinkage occurs, and the direct consequence is that cracks are inevitably generated. Until Seco's coating experts solved how to directly deposit alpha phase alumina, the structure is free of cracks. â€
The analogy of diamonds "we can use another analogy. We all know that diamond is the hardest material known to man, and can be opened relatively easily from a certain crystal direction," continues Don Graham. "Diamond can resist very well." Any form of breakage or wear. By carefully adjusting the coating cycle, Seco's R&D team already knows how to control the crystal structure of these coatings to improve toughness and wear resistance. This is the 'Duratomic' process we have named. I hope it reflects our idea of ​​controlling the coating to make it more durable through atomic processes. By introducing another direction of crystallization into the cut, we increase the toughness and wear resistance of the product.†Product Manager Roger Granström added Road: “The Seco research and development team is doing a chemical change in the crystal structure of the alumina (Al2O3) layer to create a coating that provides longer tool life and improved cutting capabilities. We believe this will be complete. Change the performance expectations of future material grade developments. Development of coatings with Duratomic technology can be used with any different matrix Together, create a new generation of applications have peak performance and a wide range of material grades. "
The hardness of the conventional alumina coating is about 27.5 GPa. Duratomic's hardness is about 30.5GPa, an increase of 10% to 15%. The increase in hardness translates directly into an increase in wear resistance and, therefore, tool life. In a typical application, the coating's operating temperature is also reduced from 915 degrees Celsius to 880 degrees Celsius, which is sufficient to greatly improve the resistance to crater wear.
The material grade is caused by an adhesive that bonds alumina to the underlying titanium carbonitride layer. Ti(C,N) is very hard and wear resistant. Below it is a brand new matrix that is considered to be an ideal partner for this coating and also features a cobalt-rich zone, which means that cobalt is transferred from the core of this structure to the surface.
There is no doubt that Seco has increased the resilience of this material. A thick 4.25" diameter tube is drilled with a number of 4" deep, 1/4" diameter holes along its length, and then the end face is pierced through the hole system to produce severe interrupted cutting. The cutting condition is: 52100 steel , 650 sfpm (surface feet per minute), 0.016 ipr (inch per revolution), 0.04" depth of cut, and the use of coolant.
Excellent results
Tool life is achieved by observing and counting the number of strokes that are machined before the significant wear of the cutting edge occurs. Seco tested a range of competing P25 grades, including the TP200 and the first grade TP2500 featuring a Duratomic coating. The competitive P25 grade completed nearly 70 pieces before significant wear on the cutting edge occurred. The TP200 (remember this is an excellent material grade) completed 90 pieces before the cutting edge was significantly worn. Unforgettable, the TP2500 completed 130 pieces before the cutting edge was significantly worn.
The TP2500 offers unprecedented levels of wear resistance and toughness, exceeding the task in ISO P applications and being more durable than other material grades. The TP2500 also optimizes the use of stainless steel turning and cast iron for efficient processing of M20 and K30 applications. Don Graham said: "Overall, the TP2500 coating demonstrates increased toughness, excellent heat and wear resistance, and reduced built-up edge. Field trials have shown that the TP2500 increases productivity by 100%. Increased tool life by 400%."
The TP2500 is not only another brand new turning material, but also indicates that the next generation of carbide inserts made with Duratomic technology will make a significant contribution to the development of metal cutting performance, and it will surpass all existing products on the market. ability.
Duratomic technology - breakthrough in tool performance
Sometimes the appearance of a technology or process is accompanied by a significant increase in the performance potential of a material. The Duratomic technology from Seco Tools is a classic example. Songa's Don Graham and Roger Granström explain the scientific principles behind success.