ED-machinable Ceramics with Oxide Matrix: Influence of Particle Size and Volume Fraction of the Electrical Conductive Phase on the Mechanical and Electrical Properties and the EDM Characteristics

Gommeringer, Andrea; Schmitt-Radloff, Ulrich; Ninz, Philipp; Kern, Frank; Klocke, Fritz; Schneider, Sebastian; Holsten, Maximilian; Klink, Andreas

doi:10.1016/j.procir.2017.12.016

Cited by 15 publications

(10 citation statements)

References 14 publications

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“…Therefore, slight changes in conductivity observed can only be traced back to a coarsening of the TZP matrix and an increase of relative density. Compared to the standard 3Y-TZP-WC materials with significantly larger TZP grains (370-430 nm), the matrix grain size effect on conductivity is striking, as the latter show electrical conductivities higher by a factor of 2-5 [28].…”

Section: Discussionmentioning

confidence: 87%

“…Hardness increased linearly from 1567 HV10 for 20 vol % WC to 1650 HV10 for 28 vol % WC. Electrical conductivity increased from 17 kS/m to 72 kS/m in the same range [28]. More demanding applications in complex structural components with a filigree structure, however, demand materials with higher damage tolerance.…”

Section: Introductionmentioning

confidence: 92%

“…The monoclinic content in the fracture faces rises between 1300-1350 • C and then stays at a constant level of~70% for the individual WC contents. The difference between fractured and polished samples which represents the stress-induced transformability of zirconia is very high compared to co-precipitated material [28]. In 1.75Y-1.25Nd-TZP-WC materials, the polished samples always contain much less monoclinic phase (0-3 vol %).…”

Section: Phase Analysismentioning

confidence: 99%

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Enhanced Mechanical Properties in ED-Machinable Zirconia-Tungsten Carbide Composites with Yttria-Neodymia Co-Stabilized Zirconia Matrix

2018

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The electrical discharge machining-process (EDM) is a smart solution to optimize the manufacturing chain of customized and complex shaped ceramic components. To comply with the high requirements for the machine and mold design, it is necessary to improve the mechanical properties of ED-machinable ceramics. In this study, ceramic composites with a tetragonal zirconia matrix and tungsten carbide as electrically conductive dispersion were investigated. To improve the toughness of this high strength material, co-stabilized zirconia coated with yttria and neodymia as dopants were used in the compositions with 1.5/1.5 and 1.75/1.25 mol %. These recipes were compared to commercial 3Y-TZP as a reference matrix material combined with the same WC raw powder. The electrically conductive phase content was varied from 20 to 28 vol %. For all compositions, the ceramic blanks were hot pressed at identical dwell and pressure, but with various sintering temperatures (1300 °C to 1450 °C) and then tested with respect to the mechanical and electrical properties. By variation of the stabilizer system, a significantly higher toughness of up to 11.3 MPa√m compared to 5.3 MPa√m for 3Y-TZP-20WC is achieved while the bending strength stays at a comparable high level of >1500 MPa.

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Section: Discussionmentioning

confidence: 87%

Section: Introductionmentioning

confidence: 92%

Section: Phase Analysismentioning

confidence: 99%

See 1 more Smart Citation

Enhanced Mechanical Properties in ED-Machinable Zirconia-Tungsten Carbide Composites with Yttria-Neodymia Co-Stabilized Zirconia Matrix

2018

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“…Instead of changing hardware, this study shows an approach to solving the DAE problem originating from studies of electrical discharge machinable (EDM) ceramics. By alloying oxide ceramics with a percolating electrically conductive dispersion (such as a transition metal carbides), it is possible to obtain an overall electrically conductive ceramic compound [3][4][5][6][7]. In this study, we tried to use this knowledge in a magnetron sputter process: high-power impulse magnetron sputtering (HiPIMS).…”

Section: Introductionmentioning

confidence: 99%

Deposition of 3YSZ-TiC PVD Coatings with High-Power Impulse Magnetron Sputtering (HiPIMS)

Gaedike¹,

Guth

Kern

et al. 2021

Applied Sciences

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Optimized coating adhesion and strength are the advantages of high-power impulse magnetron sputtering (HiPIMS) as an innovative physical vapor deposition (PVD) process. When depositing electrically non-conductive oxide ceramics as coatings with HiPIMS without dual magnetron sputtering (DMS) or mid-frequency (MF) sputtering, the growing coating leads to increasing electrical insulation of the anode. As a consequence, short circuits occur, and the process breaks down. This phenomenon is also known as the disappearing anode effect. In this study, a new approach involving adding electrically conductive carbide ceramics was tried to prevent the electrical insulation of the anode and thereby guarantee process stability. Yttria-stabilized zirconia (3YSZ) with 30 vol.% titanium carbide (TiC) targets are used in a non-reactive HiPIMS process. The main focus of this study is a parameter inquisition. Different HiPIMS parameters and their impact on the measured current at the substrate table are analyzed. This study shows the successful use of electrically conductive carbide ceramics in a non-conductive oxide as the target material. In addition, we discuss the observed high table currents with a low inert gas mix, where the process was not expected to be stable.

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“…To provide the necessary EC, the ECP can consist of various different materials; these can be transition-metal nitrides (TiN) [12,13,14,15,16,17], carbides (WC, TiC, ZrC, SiC) [15,18], carbonitrides (TiCN) [15], borides (TiB 2 ) [15,19], or carbon nanofillers, such as carbon nanotubes (CNTs) [20], graphene [21], or even cellulose nanofibers that transform in-situ during sintering into the 3D network of few layers of graphene [22]. The machinability of Y-TZP-based ceramics with EDM as opposed to that of metals, is strongly related to the various factors determining the ECP-containing bulk, such as the ECP properties and microstructural homogeneity, as was shown by Gommeringer et al [23]. Lauwers et al demonstrated that WC and TiC were shown to be the most promising ECP used for making Y-TZP-based ceramics EC and processed with EDM [24].…”

Section: Introductionmentioning

confidence: 99%

TiN-Nanoparticulate-Reinforced ZrO2 for Electrical Discharge Machining

et al. 2019

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This study presents a fabrication route for an electrically conductive ZrO2–TiN ceramic nanocomposite with a nanoscale TiN phase occupying ≤30 vol% to improve the mechanical reinforcement of the zirconia matrix, and at the same time provide electrical conductivity to facilitate electro-discharge machining (EDM). The TiN nanoparticles were incorporated into a 3 mol% yttria-stabilized tetragonal zirconia (Y-TZP) powder, either by admixing a TiN nanopowder (MCP) or by using in-situ synthesis (ISS) via the forced hydrolysis of a titanyl sulphate aqueous solution and the direct nitriding of as-synthesized titania nanoparticles, followed by consolidation and rapid sintering in a spark plasma sintering (SPS) system. The initial phase composition and crystal structure of the as-synthesized powders and the sintered samples were characterized by transmission electron microscopy (TEM) and X-ray difraction (XRD). The influence of the different fabrication routes on the microstructural evolution, electrical and mechanical properties, and affinity for EDM were assessed using TEM, focused ion beam scanning electron microscopy (FIB-SEM, Vickers indentation, electrical conductivity measurements, and profilometry. The MCP synthesis route resulted in finer microstructures that are less prone to microstructural inhomogeneities; however, using the ISS route, it was possible to fabricate electrically conductive Y-TZP nanocomposites containing only 15 vol% of the TiN nanoparticulate phase. Both synthesis routes resulted in an increase of the fracture toughness with an increase of the TiN phase due to the nanoparticulate TiN reinforcement of the Y-TZP ceramic matrix via crack-bridging toughening mechanisms. As both synthesis routes yielded Y-TZP nanocomposites capable of successful EDM machining at a TiN content of ≥30 vol% for the MCP and ≥ 15 vol% TiN for the ISS, a possible mechanism was developed based on the microstructure evolution and grain growth.

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ED-machinable Ceramics with Oxide Matrix: Influence of Particle Size and Volume Fraction of the Electrical Conductive Phase on the Mechanical and Electrical Properties and the EDM Characteristics

Cited by 15 publications

References 14 publications

Enhanced Mechanical Properties in ED-Machinable Zirconia-Tungsten Carbide Composites with Yttria-Neodymia Co-Stabilized Zirconia Matrix

Enhanced Mechanical Properties in ED-Machinable Zirconia-Tungsten Carbide Composites with Yttria-Neodymia Co-Stabilized Zirconia Matrix

Deposition of 3YSZ-TiC PVD Coatings with High-Power Impulse Magnetron Sputtering (HiPIMS)

TiN-Nanoparticulate-Reinforced ZrO2 for Electrical Discharge Machining

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