The presently claimed invention relates to a method of making a PcBN
cutting tool insert. The method includes the following steps: mixing
raw material powders, (e.g., cBN, hBN, TiC,
TiN, Ti(C,N), WC, W, C, Co, Co2Al9, Al AlN, Al2O3) with a liquid (e.g.,
ethanol) and an agent (e.g.,
polyethylene glycol, PEG) to form a homogeneous
slurry with the desired composition; forming spherical
powder agglomerates, typically 100 mum in
diameter, preferably by
spray drying; pressing said agglomerates to form a body of desired dimensions and density using conventional tool pressing technology; removing the agent from the
powder at a suitable temperature and
atmosphere; raising the temperature to 1000-1350° C. in vacuum;
solid state
sintering the body at 1000-1350° C. in vacuum, for 1-90 minutes to form a body with 35-55 vol %
porosity; optionally, adding 0.5-1000 mbar of
nitrogen to the
sintering atmosphere at the
hold time or during cooling; and HP / HT treating the porous body to form a
dense body of desired shape and dimension.