Ultra-met. carbide metalworking technologies (800) (866)

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1 CEMENTED CARBIDE GRAIN STRUCTURES January 2006

2 720 North Main Street P.O. Box 313 Urbana, OH Fax: CEMENTED CARBIDE GRAIN STRUCTURES January 2006 Website Addresses Introduction Ultra-met Grade Table... 4 Ultra-met Carbide Grades Ultra-met Substrate Grades for Coating... 9 Ultra-met Mining Grades Ultra-met Ultra-Fine Grades Ultra-met Cermet Grades Ultra-met Nickel Grades ANSI / ISO Specifications Industry Codes Application Charts Hardness Comparison Chart Index 1

3 720 North Main Street. P.O. Box 313. Urbana, Ohio Phone: Fax: Modern high-speed machining of metals is possible only because of cemented carbides. Because of their singular combination of hardness, strength, and other physical and chemical properties, they are superior to all other tools in general. In addition to their applications to machining tools, cemented carbides are used for rock and coal drilling equipment, for dies, and for an increasing number of other applications where resistance to wear and corrosion is important. The hardmetals used in metal-cutting today are almost exclusively sintered carbides. Carbides of elements in group 4,5, and 6 of the periodic table and a binder metal of the iron group, predominately cobalt are produced by a powder metallurgy process. The powdered metal process is best described as mixing very fine grains or crystals of the various carbides with the binder cobalt to produce a powder that is pressed into unlimited geometries or shapes of inserts. The as pressed insert is then sintered into a hard dense tool. Sintering can be thought of as a type of heat treatment which takes place at a temperature lower than the melting point of carbides, but higher than the melting point of the binders. The major carbides are tungsten carbide (WC), titanium carbide (TIC), tantalum carbide (TaC), and niobium carbide (NbC). Binders are predominatley cobalt (Co) and to a lesser extent nickel (Ni). Carbide cutting tool material must meet the following minimum requirements to be used successfully for metal cutting applications. 1. High hardness and abrasion resistance at the tool - work material contact area. 2. Sufficient toughness to withstand friction and mechanical shock. 3. High - temperature strength and hardness to counter plastic deformation. 4. Low tendency towards sticking or welding to the work material. These requirements are satisfied by the various carbide and binders as follows: 1. / Nickel imparts toughness or strength. 2. Tungsten carbide is important in strength, hardness, and edge stability. 3. Titanium carbide reduces the diffusion of iron into the tool. Titanium carbide imparts good resistance to wear at elevated temperatures and exhibits a low tendency to sticking or welding. However, the toughness of the cutting tool is reduced by the addition of titanium carbide. 4. Tantalum / Niobium carbide additions, like titanium carbide imparts increased resistance to wear at elevated temperatures. Tanalum carbide bearing tools are tougher than tools containing only tungsten carbide / titanium carbide. Furthermore, tantalum / niobium carbide additions impart considerably more resistance to thermal shock. In recent years there have been two developments that have had a significant effect upon Cemented Carbide Cutting Tool composition and performance. The term micro grain has become a catchall phrase in the metal cutting industry to mean fine grain size composed tool material. Since micro grain is not specific and is interpreted differently, the term needs to be better explained. Very fine tungsten carbide grains having an average diameter less than 1.0 microns can be termed to be micro grain. The actual diameter ranges from 0.7 to 0.95 microns. 2

4 There is a more recent advance toward lower grain size tungsten carbide in the 0.4 to 0.6 micron range called ultra grain material; and even further to nano grain size (less than 0.2 microns). The impact that these very fine grain size materials have upon the metal cutting industry is that they allow the tool to possess a higher hardness for the same content of binder. In most applications, micro grain materials exhibit better wear characteristics. The following terms are commonly utilized to describe WC grain size. Description Range of Grain Sizes Extra Coarse over 5.0 microns Coarse 3.5 up to 5.0 microns Medium Coarse 2.0 up to 3.5 microns Medium 1.5 up to 2.0 microns Fine 1.1 up to 1.4 microns Extra Fine or Micrograin 0.6 up to 1.0 microns Ultra Fine or Nanograin below 0.6 microns The other significant development is a processing technique of sintering under pressure instead of vacuum or an ambient pressure atmosphere. This process is the Hot Isostatic Pressing or better defined Sinter HIP process. During sintering the cobalt or nickel binder melts around the various carbides to produce a densified tool. Often there are very small voids or pores left remaining in the product that can weaken the tool by producing localized stress risers. The Sinter HIP process eliminates nearly 100% of porosity, thus producing a tougher stronger tool. The strengthening effect is more pronounced with lower binder content tool material. As one can see from all this information, it is technically impossible to achieve the optimum combination of all the above characteristic properties into a single grade. The properties counteract each other in some areas and overlap in others. This is the predominate factor in the seemingly unlimited number of grades on the market today. It is therefore useful and sensible to define cemented carbides into groups according to properties and applications for which it is best suited. This grouping has resulted into the American C and the European ISO classifications. During metalcutting, the machine, the workpiece, and the cutting tool work together as a system, influencing each other. The degree of rigidity, the geometry, and the surface preparations of the cutting tool effect the useful life of the cutting tool. The cutting tool is therefore dependent upon all the above factors and not solely determined by its own properties. 3

5 Ultra-met Grade Table 4

6 Z15 Wear Z50 P30 C5 BALANCE % % % % % 8.8 % 8.25 % 8.7 % Ultra-met Carbide Grades Ra N/A N/A 91.3 Ra g/cc 310,000 psi FINE / COARSE MEDIUM Z52 P40 M30 C % 5.5 % 4.5 % 11.5 % 91.2 Ra g/cc 350,000 psi FINE / MEDIUM Z54 P50 M50 C % 9.0 % 4.0 % 12.5 % 90.3 Ra g/cc 380,000 psi MEDIUM Z55 P35 M25 C % 14.5 % 6.0 % 10.5 % 91.3 Ra g/cc 350,000 psi FINE / MEDIUM 5

7 Z56 P35 M35 C5 Z57 C15A % 12.7 % 7.05 % 10.1 % 66.0 % 20.0 % 14.0 % Ultra-met Carbide Grades 91.4 Ra g/cc 330,000 psi 87.8 Ra g/cc 380,000 psi MEDIUM / COARSE MEDIUM / COARSE Z60 P20 M15 C % 4.5 % 6.0 % 8.0 % 92.1 Ra g/cc 325,000 psi FINE Z70 P10 M10 C % 5.4 % 7.0 % 7.0 % 92.0 Ra g/cc 275,000 psi FINE Z72 P15 M10 C % 6.5 % % 10.0 % 91.8 Ra g/cc 300,000 psi FINE 6

8 Z76 P05 C8 Z % % 12.0 % 5.0 % Ultra-met Carbide Grades 91.7 Ra g/cc 240,000 psi EXTRA FINE K25 C % 8.0 % 91.7 Ra g/cc 450,000 psi EXTRA FINE Z9 K30 C % 10.0 % 91.3 Ra g/cc 480,000 psi EXTRA FINE Z14 K40 C % 2.5 % 0.5 % 12.0 % 90.2 Ra g/cc 540,000 psi FINE / MEDIUM Z20 K20 C % 4.25 % 6.25 % 92.0 Ra g/cc 340,000 psi FINE 7

9 Z22 Ultra-met Carbide Grades K20 C % 6.0 % 91.8 Ra g/cc 350,000 psi FINE Z23 K10 C % 6.0 % 92.8 Ra g/cc 360,000 psi EXTRA FINE Z4 K01 C3 / C % 3.75 % 92.8 Ra g/cc 275,000 psi EXTRA FINE 8

10 ZS-16 Substrate for Coatings P30 / K30 ZS-17 Substrate for Coatings P25 / K30 ZS-18 Substrate for Coatings P20 / K % 5.0 % 3.0 % 5.5 % 82.5 % 6.5 % 4.5 % 6.5 % % 6.0 % 3.0 % 5.5 % Ultra-met Substrate Grades for Coating 91.3 Ra g/cc 270,000 psi 91.8 Ra g/cc 250,000 psi 91.7 Ra g/cc 220,000 psi MEDIUM MEDIUM FINE ZS-19 Substrate for Coatings % 7.6 % 9.75 % 90.9 Ra g/cc 370,000 psi P25 / M25 FINE 9

11 ZM-6 Ultra-met Mining Grades C % 6.0 % 90.0 Ra g/cc 350,000 psi COARSE ZM-9 C % 9.5 % ZM-9 is a Non-Stocked Item. Check Availability Ra g/cc 400,000 psi MEDIUM / COARSE ZC9 C % 9.5 % 87.5 Ra g/cc 400,000 psi COARSE ZM-12 C % 12.0 % 88.3 Ra g/cc 390,000 psi MEDIUM / COARSE Z13 K40 C %.50 % 11.0 % 89.8 Ra g/cc 360,000 psi MEDIUM / COARSE 10

12 ZC-13 Ultra-met Mining Grades C % 10.5 % ZC-13 is a Non-Stocked Item. Check Availability Ra g/cc 400,000 psi COARSE ZM-15 C % 15.0 % 87.0 Ra g/cc 450,000 psi MEDIUM / COARSE ZM-18 C % 18.0 % 85.5 Ra g/cc 475,000 psi COARSE 11

13 UF306 Ultra - Fine Grades K10 C2 / C % 6.0 % 93.5 Ra g/cc 400,000 psi ULTRA - FINE UF108 K20 C1 / C % 8.0 % 92.6 Ra g/cc 475,000 psi ULTRA - FINE UF110 K25 C % 10.0 % 92.3 Ra g/cc 525,000 psi ULTRA - FINE UF112 K30 C % 12.0 % 91.8 Ra g/cc 550,000 psi ULTRA - FINE UF115 K35 C % 15.0 % 91.2 Ra g/cc 600,000 psi * Contains various % of grain inhibitors. 12 ULTRA - FINE

14 ZC3 Ultra-met Cermet Grades P01/P05 C7 / C8 See Chart on Page Ra 6.10 g/cc 225,000 psi ZC5 P05/P10 C7 See Chart on Page Ra 6.30 g/cc 300,000 psi ZC14 P05/P25 C6 / C7 See Chart on Page Ra 6.70 g/cc 325,000 psi Ultra-met Nickel Grades ZN8 K10 See Chart on Page Ra g/cc 325,000 psi 13

15 ANSI / ISO Specifications MAT L GRADE ANSI ISO High Temp Mat l Steels MAT L MAT L Aluminum Cast Iron Z54 C5 Z52 C5 Z55 C5 Z56 C5 Z50 C5 Z60 C6 Z70 C7 Z72 C7 Z76 C7-C8 GRADE ANSI Z14 C1 Z9 C1 Z1 C2 Z55 C5 C2 Z23 C3 Z50 C5 GRADE ANSI Z14 C1 Z9 C1 Z1 C1 Z22 C2 Z20 C2 Z28 C2 Z23 C3 C3 Z4 C4 P50 P40 P40 P40 P30 P25 P10 P20 P05 ISO M40 M40 M40 M30 M20 M20 M10 ISO K40 K30 K30 K20 K20 K20 K10 K05 K01 TOUGHER TOUGHER TOUGHER IMPACT RESISTANT IMPACT RESISTANT IMPACT RESISTANT HARDER HARDER HARDER BETTER WEAR BETTER WEAR BETTER WEAR / HEAT RESIST RESIST RESIST 14

16 ANSI / ISO Specifications MAT L GRADE Mining / Construction ZM6 Z13 ZC13 ZM12 ZC9 ZM15 TOUGHER SHOCK / IMPACT RESISTANT HARDER BETTER WEAR RESIST ZM18 15

17 U.S. Carbide Industry Codes INDUSTRY CODE C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11 C-12 C-13 C-14 C-15 C-15A C-16 C-17 C-18 C-19 APPLICATION Machining - Cast Iron, Non-Ferrous, and Non-Metallic Materials Roughing Cuts General Purpose Light Finishing Precision Finishing Machining - Steels Roughing Cuts General Purpose Light Finishing Precision Finishing Wear Surface No Shock Light Shock Heavy Shock Impact Light Medium Heavy Miscellaneous Light Cut Hot Flash Weld Removal Heavy Cut Hot Flash Weld Removal Rock Bits Cold Header Dies Wear at Elevated and/or Resistance to Chemical Reactions Radioactive Shielding, Counterbalances, and Kinetic Applications 16

18 Ultra-met Application Chart Hard Hardness - R a Heat Resistance Wear Resistance Non-ductile - Brittle CARBON STEEL ISO P - APPLICATION GROUP C-8 C-7 C-4 C-3 C-6 C-2 GENERAL PURPOSE NON -FERROUS / NON - METALS ISO K - APPLICATION GROUP C-5 C-1 Tough TRS (Transverse Rupture Strength) Shock Resistance Soft 17

19 Application Chart 18 Main groups of chip removal Groups of application Direction of increase in characteristic of hard cutting materials of cut Material to be machined Use and working conditions Designation Distinguishing colors Broad categories of material to be machined Symbol Finish turning and boring, high cutting speeds, small chip section, accuracy of dimensions and fine finish, vibration-free operation Steel, steel castings P01 Turning, copying, threading and milling, high cutting speeds, small or medium chip sections Steel, steel castings Toughness Increasing feed Turning, copying, milling, medium cutting speeds and chip sections, planing with small chip sections Steel, steel castings, malleable cast iron with long chips Turning, milling, planing, medium or low cutting speeds, medium or large chip sections, and machining in unfavorable conditions 1) Steel, steel castings, malleable cast iron with long chips P10 P20 P30 BLUE Ferrous metals with long chips P Turning, planing, slotting, low cutting speeds, large chip sections with the possibility of large cutting angles for machining in Steel, steel castings with sand inclusion and cavities unfavorable conditions 1) and work on automatic machines P40 For operations demanding very tough hard cutting materials: turning, planing, slotting, low cutting speeds, large chip sections, with the possibility of large cutting angles for machining in Steel, steel castings of medium or low tensile strength, with sand inclusion and cavities unfavorable conditions 1), and work on automatic machines P50 Turning, medium or high cutting speeds, small or medium chip sections Steel, steel castings, manganese steel, grey cast iron, alloy cast iron Turning, milling: medium cutting speeds and chip sections Steel, steel castings, austenitic or manganese steel, grey cast iron M10 M20 Turning, milling, planing: Medium cutting speeds, medium or large chip sections Steel, steel castings, austenitic steel, grey cast iron, high temperature resistant alloys M30 M40 K01 K10 K20 RED YELLOW Ferrous metals with long or short chips and non-ferrous metals M Turning, parting off, particularly on automatic machines Mild free-cutting steel, low-tensile steel, non-ferrous metals and light alloys Turning, finish turning, boring, milling, scraping Very hard grey cast iron, chilled castings of over 85 Shore, high-silicon aluminum alloys, hardened steel, highly abrasive plastics, hard cardboard, ceramics Wear resistance Increasing speed Turning, milling, drilling, boring, broaching, scraping Grey cast iron over 220HB, malleable cast iron with short chips, hardened steel, silicon aluminum alloys, copper alloys, plastics, glass, hard rubber, hard cardboard, porcelain stone Turning, milling, planing, boring, broaching, demanding very tough hard cutting materials Grey cast iron up to 220HB, non-ferrous metals: copper, brass, aluminum K Turning, milling, planing, slotting, for machining in unfavorable conditions 1) and with the possibility of large cutting angles Low-hardness grey cast iron, low-tensile steel, compressed wood K30 K40 Ferrous metals with short chips, non-ferrous metals and non-metallic materials Turning, milling, planing, slotting, for machining in unfavorable conditions 1) and with the possibility of large cutting angles Soft or hard wood, non-ferrous metals 1) Raw Material or components in shapes which are awkward to machine: casting or forging skins, variable hardness etc. Variable depth of cut, interrupted cut, work subject to vibrations

20 Hardness Comparison Chart Hardness Comparsion Chart Rockwell Standard Vickers C Scale A Scale DPH 10kg PSI x 10 Transverse Rupture Strength 3 Compressive Strength 3 PSIx10 R A Hardness % Strength vs Content 20 % Hardness vs Content % Effect of on Compressive Strength Fine Grain Coarse Grain 19

21 Notes

22 Index Z1... ZC3... Z4... ZC5 ZM-6... ZN8... Z9... ZC9... ZM-9... ZM Z ZC ZC-14 Z14... Z15... ZM ZS ZS ZM ZS ZS Z20... Z22... Z23... UF UF UF UF UF Z50... Z52... Z54... Z55... Z56... Z57... Z60... Z70... Z72... Z76... Grade Grade Pg. Pg. Ultra-met metalworking technologies Ultra-met metalworking technologies Ultra-met metalworking technologies Ultra-met carbide technologies carbide technologies

23 720 North Main Street. Urbana, Ohio (800) / (866) / (937)