A variety of cutting tool materials are used for the contact mode mechanical machining of components under extreme conditions of stress, temperature and/or corrosion, including operations such as drilling, milling turning and so on. These demanding conditions impose a seriously high strain rate (an order of magnitude higher than forming), and this limits the useful life of cutting tools, especially single-point cutting tools. Tungsten carbide is the most popularly used cutting tool material, and unfortunately its main ingredients of W and Co are at high risk in terms of material supply and are listed among critical raw materials (CRMs) for EU, for which sustainable use should be addressed. This paper highlights the evolution and the trend of use of CRMs) in cutting tools for mechanical machining through a timely review. The focus of this review and its motivation was driven by the four following themes: (i) the discussion of newly emerging hybrid machining processes offering performance enhancements and longevity in terms of tool life (laser and cryogenic incorporation); (ii) the development and synthesis of new CRM substitutes to minimise the use of tungsten; (iii) the improvement of the recycling of worn tools; and (iv) the accelerated use of modelling and simulation to design long-lasting tools in the Industry-4.0 framework, circular economy and cyber secure manufacturing. It may be noted that the scope of this paper is not to represent a completely exhaustive document concerning cutting tools for mechanical processing, but to raise awareness and pave the way for innovative thinking on the use of critical materials in mechanical processing tools with the aim of developing smart, timely control strategies and mitigation measures to suppress the use of CRMs.

The Critical Raw Materials in Cutting Tools for Machining Applications: A Review

Mechanisms of WC plastic deformation in cemented carbide

Controlled crack growth in a WC-Co hardmetal has been observed in-situ in the SEM using an ultra-stiff test rig to allow controlled application and removal of loads. Cracks were observed to propagate in jumps of between 20 µm and 70 µm with each jump occurring in less than 200 ms. High resolution SEM images and EBSD mapping has been used to characterise the effects of microstructure and crystallography on the crack path and the degree of plastic deformation in both binder and carbide phases. The fracture in the hardmetal grade examined is dominated by transgranular fracture of the carbide phase with increased plastic deformation in grains fracturing on {10-10} planes observed by EBSD. At variance with earlier work, plastic deformation in the Co binder phase ahead of the crack tip has been observed over distances of several times the Co mean free path.

In situ observation of crack growth in a WC-Co hardmetal and characterisation of crack growth morphologies by EBSD.

In Europe, many technologies with high socio-economic benefits face materials requirements that are often affected by demand-supply disruption. This paper offers an overview of critical raw materials in high value alloys and metal-matrix composites used in critical applications, such as energy, transportation and machinery manufacturing associated with extreme working conditions in terms of temperature, loading, friction, wear and corrosion. The goal is to provide perspectives about the reduction and/or substitution of selected critical raw materials: Co, W, Cr, Nb and Mg.

Solutions for Critical Raw Materials under Extreme Conditions: A Review

Ceramic matrix materials have attracted great attention from researchers and industry due to their material properties. When used in engineering systems, and especially in aero-engine applications, they can result in reduced weight, higher temperature capability, and/or reduced cooling needs, each of which increases efficiency. This is where high-temperature ceramics have made considerable progress, and ceramic matrix composites (CMCs) are in the foreground. CMCs are classified into non-oxide and oxide-based ones. Both families have material types that have a high potential for use in high-temperature propulsion applications. The oxide materials discussed will focus on alumina and aluminosilicate/mullite base material families, whereas for non-oxides, carbon, silicon carbide, titanium carbide, and tungsten carbide CMC material families will be discussed and analyzed. Typical oxide-based ones are composed of an oxide fiber and oxide matrix (Ox-Ox). Some of the most common oxide subcategories are alumina, beryllia, ceria, and zirconia ceramics. On the other hand, the largest number of non-oxides are technical ceramics that are classified as inorganic, non-metallic materials. The most well-known non-oxide subcategories are carbides, borides, nitrides, and silicides. These matrix composites are used, for example, in combustion liners of gas turbine engines and exhaust nozzles. Until now, a thorough study on the available oxide and non-oxide-based CMCs for such applications has not been presented. This paper will focus on assessing a literature survey of the available oxide and non-oxide ceramic matrix composite materials in terms of mechanical and thermal properties, as well as the classification and fabrication methods of those CMCs. The available manufacturing and fabrication processes are reviewed and compared. Finally, the paper presents a research and development roadmap for increasing the maturity of these materials allowing for the wider adoption of aero-engine applications. 

/pdf/ceramic-matrix-composites-for-aero-engine-applications-a-esi2aboe.pdf

Ceramic Matrix Composites for Aero Engine Applications—A Review

Mechanics and mechanisms of fatigue in a WC-Ni hardmetal and a comparative study with respect to WC-Co hardmetals

In most of the applications where hardmetals are implemented, mechanical contact plays an important role from a design viewpoint, either as direct key parameter (e.g. wear resistance) or as indirect relevant factor (e.g. residual strength associated with contact-induced damage). In this work, the contact response of three cemented carbides WC–Co with different microstructural features is evaluated. The study is performed using spherical indenters (Hertzian contact) and it is focused on: 1) determining the critical loading parameters affiliated to the emergence and evolution of damage; and 2) investigating the relevance of microstructure on the levels of residual strength attained. It is found that strength retention is improved as contact damage mode goes from brittle to quasi-plastic, a transition directly dependent on microstructure. Hence, microstructural design searching for higher damage tolerance (i.e. deformation prevailing over fracture as damage mode) is concluded to be an optimal approach for the development of hardmetals with improved reliability. In practical terms, this is achieved by enhancing toughness through either higher binder content and/or microstructural coarsening, as far as the field application requirements are satisfied.

Contact damage and residual strength in hardmetals

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Mechanics and mechanisms of fatigue in a WC-Ni hardmetal and a comparative study with respect to WC-Co hardmetals

Contact damage and residual strength in hardmetals