The aim of this thesis work was to design and evaluate a wear test method for cemented carbides inserts used in rotary drilling. An appropriate in-house wear test method would provide a better understanding of the wear mechanisms limiting tool life in real drilling. The test method should be easy to use and be able to distinguish between wear of insert materials with different microstructure and properties. The literature study showed few published articles about wear tests and mechanisms concerning rotary drill bit inserts. These methods included two standard wear tests; ASTM G65 and ASTM B611. Furthermore, a modified ASTM G65 test was found as well as an impact-abrasion test. In this work the modified ASTM G65 test, using a rock counter surface, was evaluated in order to understand if the method would mimic the wear of cemented carbides used in rotary drilling. The test method was further developed and showed high repeatability. Measured weight losses showed that the test could distinguish between two common rotary grade materials with a small difference in hardness but with different microstructures. The wear of the tested materials was analyzed with scanning electron microscopy and compared with rotary drill bit inserts collected from the field. The modified test method proved able to produce wear by mechanisms very similar to those found on field worn inserts. Identified wear mechanisms included cracking, fragmentation and spalling of WC grains as well as embedded fragments of WC grains on the surface. In addition, the binder phase was removed and adhered material from the counter surface was detected.

The aim of this master thesis was to compare EELS in TEM with TEM-EDS and WDS-EPMA for quantitative analysis of γ-phase in cemented carbide. Especially, the quantification of the light elements nitrogen and carbon in compounds like TiCxN1-x is interesting, since this is problematic. The techniques were compared by acquiring spectra for quantification of two samples of cemented carbide containing γ-phase (Tix,W1-x)(CyN1-y) with different nitrogen and tungsten content. Also, a rigorous evaluation about how EELS spectra best is acquired and processed was performed in order to enable the comparison. Experimental results show that EELS gives satisfying results for TiC0.7N0.3 and that EELS is comparable with WDS-EPMA for quantification of nitrogen, carbon and titanium in (Tix,W1-x)(CyN1-y) when the atomic concentration of nitrogen is around 20%. However, EELS was not used for quantification of tungsten. Concluded is also that EELS and WDS should be considered as complementary rather than competing techniques.

This thesis work sought to find a tribological testing method suitable for cementedcarbide drill bit inserts used when drilling rock. A review of the literature publishedon the matter showed that there are quite a few test methods developed for wearstudies with cemented carbides, but most of them were not designed for the rockdrilling industry. Published studies performed with the found methods and articleswith analyzed field tests have been studied. It is generally agreed upon that the stepsof wear is that the binder disappears first, followed by removal of carbide grains. Themechanisms of binder phase and carbide grain removal is somewhat debated, butalmost every study observes fracture of the carbide grains. The wear test created inthis thesis was shown to give wear linear with time, but not with load. The newmethod was shown to be capable of distinguishing between different cementedcarbides worn in three body abrasion against different rocks. Analysis of the wornsamples shows that there are similarities with bit inserts worn in field testing. Many ofthe observations made during the analysis are also similar to observations inliterature.

This thesis work is performed at Sandvik Mining Rock Tools, a world leading supplier of rock drilling tools. The work is part of developing a new tribological wear test method for cemented carbide drill bit inserts. The test method has earlier been judged successful in mimicking the rotary-percussive rock drilling process because it gives the same wear mechanisms as have been observed for inserts used in rock drilling. During testing the cemented carbide drill bit insert is pressed against a moving rock surface while water and particles are added to the contact area. The particles are present to simulate the rock crushings formed during drilling. They are believed to cause abrasive wear of the inserts. In this work the effect of load, particle material and particle size are studied. When adding silica particles, which are softer than the cemented carbide material, no correlation is obtained between wear rate and load or particle size. Cracking of WC grains, added rock material and removal of pieces of carbide material are seen at the worn sample surfaces. These observations are similar to observations described in other works about wear of cemented carbide. Adding alumina particles, which are harder than the sample material, gives high wear rate and ground/striped sample surfaces. The wear rate increases with alumina particle size.

An experimental ball-milling study was performed to compare the deagglomeration behavior and the evolution of the particle size distribution with increasing milling time of two relatively coarse WC powders used for the production of cemented carbide cutting tools. The WC-powders were found to have distinctly different particle size distributions and particle morphologies prior to milling. Lab-scale WC samples were made using a range of different process parameters and milling times. These were then analysed by means of microscopy, laser light scattering, gas adsorption BET analysis and X-ray powder diffraction, XRD, to attain particle size distribution, specific surface area and a mean crystal size, respectively. The results suggested a linear relation between log(particle size) and log(milling time) between 10 and 80 hours milling. The viscosity was shown to have a minor effect on the milling efficiency. Both the number of collisions of milling balls per unit time as well as the kinetic energy of the milling ball affected the size reduction; more collisions or higher energy resulted in a higher milling efficiency. The evaluation of the effect of the process parameters on milling efficiency was facilitated by the use of simple scaling factors. For example, all milling curves for samples with different WC amounts coincided when rescaling the milling time using a scaling factor based on the weight of the WC and milling balls. The same scaling factor could be used with success for rescaling the results from different trials obtained with laser light scattering, gas adsorption and XRD. The results of this work are useful for future work on modeling of the milling process which should lead to more accurate predictions of the outcome of milling unit operations.

<p>Cemented carbides based on tungsten carbide and cobalt arecommonly produced by a powder metallurgy route including liquidphase sintering. The pressed compact densifies to almost halfits volume during sintering due to pore elimination. Thesintering behaviour changes with material composition, such ascarbide grain size, binder fraction, carbon content andaddition of cubic carbides.</p><p>This thesis is devoted to the study of constitutivebehaviour, in particular densification, and the microstructuralevolution during cemented carbide sintering. Dimensionalchanges are monitored using dilatometry with and withoutapplied external load. The microstructural evolution isinvestigated with light optical microscopy and scanningelectron microscopy. Thermodynamic calculations are used asreference.</p><p>Constitutive relations are derived for uniaxial viscosity,viscous equivalent of Poisson’s ratio and sintering stressbased on relative density and temperature. The relations areextended to a model describing sintering shrinkage withexplicit dependencies on carbide grain size and binder content.The model is divided in three stages of which two pertain tothe solid state and the third to liquid phase sintering. Solidstate shrinkage is suppressed in a material with coarsecarbides and in the stage of liquid phase sintering grain sizestrongly influences the uniaxial viscosity. The binder contentaffects primarily the later densification.</p><p>The effects of carbon content and grain size distribution onshrinkage have been studied. High carbon content enhancesshrinkage rate, but the effect of grain size distribution israther small. The mean carbide grain size is insufficient todescribe densification for very broad distributions only.</p><p>Shrinkage occurs through rearrangement andsolution-reprecipitation. Rearrangement is studied through theevolution of the pore size distribution and simulatedgenerically using a discrete element method.</p><p><b>Keywords:</b>Cemented carbides, Sintering, Constitutiverelations, Microstructure, Densification, Modelling</p>

In today’s inserts used for metal cutting the binder phase consists of cobalt (Co).However, EU’s REACH programme and the U.S’s National Toxicity Programme(NTP) classified Co as toxic/carcinogenic. Therefore, there is a strong need toinvestigate alternative binder phases. This thesis covers sintering and characterisationof cemented carbide with a binder phase consisting of nickel (Ni) and iron (Fe) withthe composition of 85Ni:15Fe. The aim was to study the gradient formation of turninginsert and find sintering processes to achieve a gradient structure with the targetedthickness of 26 microns. Simulations in ThermoCalc provided a suitable composition and a starting point forsintering parameters. The influences of sintering process parameters, such as holdingtime, temperature and counter pressure on the formation of the gradient zone wereinvestigated. Hot isostatic pressing (HIP) sintering was done in order to study thegradient formation as well as to reduce the porosity when needed. Sintered insertswere analysed by light optical microscopy. It was found that there are at least three possible ways to control the formation ofthe gradient: sintering in vacuum with a holding time of 20 min at 1450°C, sintering at1450°C with a counter pressure of 5 mbar nitrogen, and sintering with a counterpressure of 11.5 mbar followed by a double sinter-hip with 55 bar argon atmosphere.However, only the last process fulfilled the microstructure criteria in terms ofporosity and binder phase distribution. It is clear that the formation of gradient zonesin 85Ni:15Fe can be predicted, however calculations and simulations need to beoptimized in order to get more accurate results.

The present work was conducted in Sandvik Coromant to enhance the knowledge and understanding of general flank wear growth and specifically in this case flank wear growth on the cutting edge of the coated (Ti(C, N)/ Al2O3/ TiN) tool inserts.   Reliable modeling of tool life is always a concern for machining processes. Numbers of wear models studies predicting the tool life length have been created throughout the metal-cutting history to better predict and thereby control the tool life span, which is a major portion of the total cost of machining.   A geometrical contact model defining the geometry of the flank wear growth on the cutting tool inserts was proposed and then compared with four suggested models, which estimates flank wear. The focus of this work is on the initial growth of flank wear process and thereby short cutting-time intervals are measured.   Wear tests on cutting tool inserts were performed after orthogonal turning of Ovako 825 B steel and were analysed by optical instrument, 3D optical imaging in Alicona InfiniteFocus and EDS in SEM. Force measurements for cutting speeds, Vc, 150, 200, and 250 m/min and feed rate, fn, 0.15 mm/rev were recorded as well.   Results show that initial flank wear land, VB, growth is dominated by sliding distance per cutting length for different cutting speeds. A good correlation between the geometrical contact model and estimation models is indentified. The cutting force measurements compared with the flank wear land show proportionality between two parameters. For the machining data in the present study the flank wear rate per sliding distance, dW/dL, is estimated to 2x103 (μ3/m).

Rapid delivery of backfill to support underground openings attracted many mines to adopt paste backfilling methods. As a precaution to prevent liquefaction and to improve the mechanical performance of backfills, a small portion of a binder is added to the paste to form the cemented paste backfill (CPB). Recently, adding sand to mine tailings (MT) in CPB mixes has attracted attention since it enhances the flow and mechanical characteristics of the pastefill. This thesis investigates the effects of adding sand to CPB on the undrained mechanical behavior of the mixture (CPBS) under monotonic and cyclic loads. Liquefaction investigations took place at the earliest practically possible age. Beyond this age, the present research focused on characterizing the evolution of stiffness and obtaining the values of the stiffness parameters that could be useful for designing and modeling backfilling systems. The liquefaction investigation involved monotonic compression and extension triaxial tests. Neither flow nor temporary liquefaction was observed for all cemented and uncemented specimens under monotonic compression, while temporary liquefaction was observed for all specimens under monotonic extension. The addition of binder and sand to MT was found to slightly strengthen the pastefill in compression while weakening it in extension. Under cyclic loading, the addition of sand negatively impacted the cyclic resistance. However, binder was found to be more effective in the presence of sand. All specimens exhibited a cyclic mobility type of response. The evolution of effective stiffness parameters for two CPB-sand mixtures was monitored in a non-destructive triaxial test for five days. Self-desiccation was found to not be influential on the development of early age stiffness. Moreover, a framework is suggested to predict the undrained stiffness at degrees of saturation representative of the field. The credibility of the proposed test in providing stiffness parameters at representative strain levels of the field was verified.

Rapid delivery of backfill to support underground openings attracted many mines to adopt paste backfilling methods. As a precaution to prevent liquefaction and to improve the mechanical performance of backfills, a small portion of a binder is added to the paste to form the cemented paste backfill (CPB). Recently, adding sand to mine tailings (MT) in CPB mixes has attracted attention since it enhances the flow and mechanical characteristics of the pastefill. This thesis investigates the effects of adding sand to CPB on the undrained mechanical behavior of the mixture (CPBS) under monotonic and cyclic loads. Liquefaction investigations took place at the earliest practically possible age. Beyond this age, the present research focused on characterizing the evolution of stiffness and obtaining the values of the stiffness parameters that could be useful for designing and modeling backfilling systems. The liquefaction investigation involved monotonic compression and extension triaxial tests. Neither flow nor temporary liquefaction was observed for all cemented and uncemented specimens under monotonic compression, while temporary liquefaction was observed for all specimens under monotonic extension. The addition of binder and sand to MT was found to slightly strengthen the pastefill in compression while weakening it in extension. Under cyclic loading, the addition of sand negatively impacted the cyclic resistance. However, binder was found to be more effective in the presence of sand. All specimens exhibited a cyclic mobility type of response. The evolution of effective stiffness parameters for two CPB-sand mixtures was monitored in a non-destructive triaxial test for five days. Self-desiccation was found to not be influential on the development of early age stiffness. Moreover, a framework is suggested to predict the undrained stiffness at degrees of saturation representative of the field. The credibility of the proposed test in providing stiffness parameters at representative strain levels of the field was verified.