TiAlSiON Sintered Material for Oxidation and Chipping Resistance
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Solution Overview
Problem
Sintered materials formed of Ti, Al, and N face challenges in achieving optimal oxidation resistance, abrasion resistance, and chipping resistance.
Innovation Solution
A sintered material composed of Ti, Al, Si, O, and N, with specific atomic ratios and incorporating additional compounds like cubic boron nitride and metal elements, is produced using a method involving grain preparation, heating, rapid cooling, and sintering to enhance oxidation, abrasion, and chipping resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sintered material is formed of Ti, Al, and N to provide abrasion resistance and chipping resistance, then the tool has good mechanical properties, but the oxidation resistance is insufficient
Solution Approach 1:
The patent creates a composite sintered material containing TiAlSiON compound particles dispersed in a TiAlN matrix. This composite structure combines the oxidation resistance of TiAlSiON (due to SiO2 formation) with the mechanical strength and abrasion resistance of TiAlN, thereby achieving both oxidation resistance and mechanical performance simultaneously
Solution Approach 2:
The patent modifies the chemical composition parameters by introducing Si and O elements into the traditional TiAlN system, creating TiAlSiON compounds with specific atomic ratios (0.01 ≤ a ≤ 0.70, 0.01 ≤ b ≤ 0.55, 0.06 ≤ a + b ≤ 0.88, 0.005 ≤ x ≤ 0.6, 0.4 ≤ y ≤ 0.995). This parameter change enables the formation of protective SiO2 oxide layers that significantly improve oxidation resistance
2Reliability
If additional elements like Si and O are added to improve oxidation resistance, then the oxidation resistance increases, but the manufacturing complexity increases
Solution Approach 1:
The patent incorporates Si and O elements into the powder mixture before sintering, so that during the sintering process, TiAlSiON compounds form in-situ within the TiAlN matrix. This preliminary preparation of powder composition eliminates the need for complex post-processing or coating steps, simplifying the overall manufacturing process while achieving the desired oxidation resistance
Solution Approach 2:
The patent merges the formation of TiAlN matrix and TiAlSiON compound particles into a single sintering process. By combining the powder materials (Ti, Al, Si, N, O) beforehand and sintering them together, the complex multi-step processes of creating separate layers or coatings are eliminated, reducing manufacturing complexity while achieving the composite structure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting sintered material exhibits superior oxidation, abrasion, and chipping resistance, leading to a longer tool service life and adaptability for various cutting conditions.
Implementation Method 1
the tool is required to have oxidation resistance, in addition to the characteristics such as abrasion resistance and chipping resistance
Implementation Method 2
the tool is required to have oxidation resistance, in addition to the characteristics such as abrasion resistance and chipping resistance
Implementation Method 3
the tool is required to have oxidation resistance, in addition to the characteristics such as abrasion resistance and chipping resistance
Data Source
Figure 1~3
AI summary
To provide a sintered material having excellent oxidation resistance, as well as excellent abrasion resistance and chipping resistance. A sintered material containing a first compound formed of Ti, Al, Si, O, and N is provided.