Synthesis and Fabrication of Nano Tungsten Carbide Cutting Inserts using Sinter HIP Technique

Abstract

The utilization of nano-sized tungsten carbide powder in the fabrication of cutting inserts through the Sinter HIP (Hot Isostatic Pressing) process signifies a notable advancement within the domain of material engineering. This method offers heightened mechanical attributes and heightened resistance to wear, rendering it exceptionally valuable for applications encompassing the machining of heat-resistant superalloys, especially in the aerospace sector. This study centers on the synthesis, processing, and characterization of these pioneering cutting inserts, accentuating their potential to bring about a transformative shift in metal cutting procedures and augment tool longevity.Within the scope of this research, functionally graded tungsten carbide powders were synthesized to achieve grain sizes below 100nm through the utilization of ball milling. This nano powder was subsequently compacted into the desired rectangular cutting insert form, followed by sintering at a temperature of 1480 degrees Celsius within a Sinter HIP furnace. A comprehensive examination and comparative analysis of mechanical properties, encompassing substrate hardness, fracture toughness, and thermal conductivity, were conducted between the newly crafted cutting inserts and pre-existing counterparts. The outcomes revealed that the augmentation in the hardness of the nano insert corresponded to an increase in brittleness. Consequently, a reduction in fracture toughness was observed, attributed to the presence of eta phases within the insert.This research contributes valuable insights into the development of cutting-edge cutting insert materials and their consequential mechanical behavior. The implications of these findings have the potential to significantly reshape and enhance various metal cutting processes, thus influencing both industrial practices and the overall efficiency of machining operations.