The purpose of this study was to evaluate four different measuring methods as potentialquality control tests for Tungsten Carbide (WC) raw material used in the hard metalmanufacturing at Seco Tools Fagersta. This was warranted as the current quality testcalled the HcK test, is very time consuming and the results provided that are used formilling time calculations cannot be relied on. The four measuring methods chosen wasLaser diffraction, X-Ray diffraction, Brunauer Emmett Teller analysis and Fisher Sub-Sieve Sizer measurement. These measuring techniques were chosen by Seco ToolsThe project followed the general structure of the project cycle modified to fit the projectand involving the steps project planning, present state analysis, goals and requirementdetermination, evaluation elimination of options and final of choice of option. Thealternative methods were evaluated using an evaluation matrix containing therequirements determined to be the most relevant for the quality control process. Therequirements were measurement precision, operator influence, ease of use, time requiredand operator time required. The ability of the measurement method to distinguishbetween all of the different WC powders used a Seco Tools was put as a must requirementas the new method is meant to serve as a verification test as well as a quality test.The analysis methods were evaluated practically through experiments and therefore atesting strategy was established. Initial test on two powder types was performed so thatan early evaluation could be done. During this stage both the Laser diffraction and the XRaydiffraction were eliminated due to poor results. The BET analysis and the Fisher Sub-Sieve Sizer performed better and was therefore tested further. Randomized testing wasthe method chosen when testing with all powders to minimize the environmental impacton the testing as this could affect the results of the study.The testing showed that only the Fisher SSS was able to distinguish between all thedifferent powders making it the only viable option as a new quality test. This was onlypossible when measuring on agglomerated material and the values extracted couldtherefore not be used further in the production. The Fisher SSS also performed the bestwhen ranked against the rest of the requirements, showing a high precision whenmeasuring on deagglomerated material and a combination of the two tests was thereforeconsidered.When compared to the HcK test the Fisher SSS showed a significant reduction in lead timebut also a reduction in information gathered and eventual defects controlled. The FisherSSS provides only an average particle size measurement and since no correlation has yetbeen established between the measured particle size and the required milling times it wasrecommended that the HcK test remains.It was recommended that a study is started aimed at establishing a correlation betweenthe measured particle size and the required milling time is started to investigate if this ispossible.

In dieser Studie wurde das Verhalten eines neuentwickelten Hartmetallfinierers der Firma Brasseler und herkömmlicher grober und feiner Diamantfinierer der Firmen Intensiv und Brasseler an vier verschiedenen Füllungsmaterialien untersucht. Bei dem Hartmetallfinierer handelt es sich um ein Kombinationsinstrument, das sich im Rechtslauf durch eine hohe Arbeitsleistung auszeichnet und zum Konturieren von Füllungen gedacht ist. Im Linkslauf soll das Instrument zur Feinausarbeitung eingesetzt werden, die Arbeitsleistung ist geringer. In 120 extrahierte menschliche Zähne wurden ovale Klasse-V-Kavitäten (Länge: 4 mm, Breite: 3 mm, Tiefe: 2 mm) präpariert, die jeweils zur Hälfte im Schmelz und Dentin lagen. Jeweils 30 Zähne wurden nach Herstellerangaben mit demselben Füllungsmaterial gefüllt (Prodigy, Silux Plus, Dyract AP, Fuji LC). Anschließend wurden die Restaurationen zunächst mit den gröberen Finierdiamanten und dem Kombifinierer im Rechtslauf konturiert. Jeweils 10 Proben eines jeden Füllungsmaterials wurden mit einem der Instrumente bearbeitet. Auf diese Weise ergaben sich 12 Material-Instrumenten-Kombinationen. Nach dreiwöchiger Wasserlagerung wurde die Rauhigkeit der Füllungsoberflächen mit einem Profilometer gemessen. Außerdem erfolgte eine Auswertung der Randqualität mittels quantitativer Randanalyse. Im Anschluß hieran wurden die Füllungen mit den feineren Diamantinstrumenten bzw. dem Kombifinierer im Linkslauf finiert. Die Füllungen wurden anschließend einer Temperaturwechselbelastung unterzogen (2000 Zyklen zwischen 5°C und 55°C). Erneut erfolgte eine quantitative Randanalyse und eine Oberflächenrauhigkeitsmessung. Die statistische Auswertung der Daten ergab, daß der Kombifinierer im Linkslauf im Gegensatz zu den feinen Diamantfinierern keine Verbesserung der Oberflächenqualität bewirkt. Die Auswirkungen der Instrumente auf die Randqualität ist gleich. Fuji LC weist die höchste Oberflächenrauhigkeit auf. Die übrigen Füllungsmaterialien unterscheiden sich diesbezüglich nicht statistisch signifikant voneinander. Die Silux Plus Restaurationen zeichnen sich durch einen im Vergleich zu den übrigen Materialien hohen Anteil an Randspalten sowohl im Dentin- als auch im Schmelzbereich aus. Die Prodigy Füllungen haben signifikant mehr Randspalten im Dentin als Fuji LC und Dyract AP Füllungen, jedoch auch signifikant weniger als Silux Plus im gleichen Bereich. / In this study a newly developed tungsten carbide finishing bur (Brasseler) and conventional coarse and fine grit finishing diamonds of the companies Intensiv and Brasseler were studied with four different filling-materials. The carbide bur is a combination-instrument, that distinguishes itself in the right-hand rotation by a high performance and is intended for the contouring of fillings. When used in a left-hand rotation the instrument should be applied for polishing. In this case the cutting performance is inferior. Oval class-V-cavities (length: 4 mm, width: 3 mm, depth: 2 mm) were prepared into 120 extracted human teeth with one half of the margin length in dentin and one half in enamel. In each case, 30 teeth were filled according to manufacturer-recommendation with the same filling-material (Prodigy, Silux Plus, Dyract AP, Fuji LC). Subsequently the restorations were trimmed with the coarser finishing diamonds and the combination bur with a right-hand rotation. Ten samples of each filling-material were ground with one of the instruments. Thus 12 material-instrument-combinations were established. After three weeks of water-storage, the surface roughness of the fillings was measured with a profilometer. Furthermore, an evaluation of the margin-quality was carried out by means of quantitative margin analysis. After this, the fillings were either polished with the finer diamond-instruments or with the combination-instrument in a left-hand rotation. Afterwards the samples were subjected to a thermocycling procedure (2000 cycles between 5°C and 55°C). Again a quantitative margin analysis and a surface-roughness-measurement were performed. In contrast to the fine diamond instruments, the statistical evaluation of the data revealed that the combination finishing bur does not improve the surface quality in a left-hand rotation. The effect of the instruments on the margin quality is the same. Fuji LC shows the highest surface-roughness, the other filling-materials do not differ statistically significantly from one another. The Silux Plus restorations are characterized by a high percentage of marginal openings in both enamel and dentin. The Prodigy fillings show significantly more marginal gaps in dentin than Fuji LC and Dyract AP fillings, but significantly less than Silux Plus in the same area.

Thesis (M.S.)--University of Alabama at Birmingham, 2008. / Description based on contents viewed June 2, 2008; title from title screen. Includes bibliographical references (p. 36).

Les carbures et oxydes des métaux de transition sont d'une importance capitale dans le domaine industriel voir catalytique. Le carbure de tungstène WC a été identifié comme un bon substituant des métaux nobles tel que le platine dans le domaine catalytique. Le but de ce travail de thèse est d'appliquer des méthodes de chimie quantique les plus poussées pour déterminer la structure électronique, la stabilité et la nature de liaison chimique des diatomiques WC et WC2+. Notre recherche préliminaire est motivée par les données spectroscopiques disponibles sur W, W+, W2+, WC et WC2+. La méthodologie adoptée, CASSCF/MRCI/MRCI+Q/aug-cc-pV5Z(-PP) implémentée dans le code MOLPRO, consiste à réaliser des calculs quantique tenant en compte des effets de corrélation et relativistes avec un traitement spécifique du couplage spin−orbite pour la recherche des courbes d'énergie potentielle de l'état fondamental et des états excités de plus basses énergies de WCn+ (n=0-2) tout en utilisant une base suffisamment étendue. Les résultats de ce travail sont en bon accord avec ceux disponibles dans la littérature. En outre, dans ce travail nous avons confirmé pour la première fois que le carbure diatomique dicationique WC2+ est thermodynamiquement stable / Metal carbides and oxides are more interesting in catalytic and industrial domains. Tungsten carbide WC has been detected as serious substituent of platinum Pt catalytic. The ultimate goal of this thesis is theoretical studies of electronic structure, stability and the bound nature on WC, WO and its cations. Our preliminary research were motiving by the available spectroscopic data on W, W+, W2+, WC et WC2+. We used the methodology (CASSCF/MRCI/MRCI+Q/aug-cc-pV5Z(-PP)) implemented on MOLPRO package to perform quantum calculations with high accuracy taking into account the correlation and relativistic effects with a specific treatment of spin orbit coupling for some low lying excited electronic states of WCn+, (n=0, 1 et 2). Our results are shown in good agreement with those available in the literature. Furthermore, in this work for the first time we demonstrated that a carbide dication (WC2+) is thermodynamically stable

Thesis (MScEng)--Stellenbosch University, 2011. / ENGLISH ABSTRACT: The aerospace industry actively pursues innovation, especially in materials and their use in new applications, to improve their aircraft as well as their competitive position. Ti-6Al-4V has been available now for more than 50 years. Yet, in the new generation of aircraft using structural composites, a dramatic increase in the proportion of Ti-6Al-4V will be seen along with emerging application in automotive and chemical industries. This material possesses superior material properties compared to conventional materials such as steel and aluminium, although it is at the expense of machinability. Researchers are therefore actively searching for improved cutting technologies to improve production rates for Ti-6Al-4V. At higher cutting speeds than the industry norm of 60 - 90 m/min, machining becomes a challenge, resulting in low productivity on titanium parts. The limiting factor in the machining of Ti-6Al-4V is high tool temperatures of the order of 1000oC, caused by its resistance to absorb heat and good mechanical strength at elevated temperatures. The result is extreme temperatures that are concentrated on the cutting edge of the tool. The challenge to improve the tool life is therefore focused on removing heat from the insert. Liquid nitrogen was identified as a good candidate as coolant with the additional advantage of being environmentally friendly. The research presented investigates the use of a gravity feed enclosed liquid nitrogen cooling system to improve the tool life of the cutting inserts. The liquid nitrogen is contained on the insert rake face by means of a tool cap. To improve the effectiveness of the cooling method, a polycrystalline diamond (PCD) insert was used. This insert has a considerably higher thermal conductivity that aids in cooling the cutting edge. Tungsten carbide inserts are used for benchmark testing. The round tungsten carbide inserts with conventional cooling performed exceptionally well for machining titanium compared to square inserts, yielding exceptional tool life improvements while significantly increasing the material removal rate. Positive results were recorded with the liquid nitrogen cooling system when used with the polycrystalline diamond cutting insert. A number of far reaching performance issues are identified relating to the design of the tool cap that hindered clear scientific outputs. From a research perspective, the project makes a contribution to the knowledge base in this field. Additionally a new approach in cooling was investigated, resulting in clear indications of design changes required. / AFRIKAANSE OPSOMMING: Die lugvaart industrie streef aktief innovasie na, veral op die gebied van materiale en hul gebruike, om hul vliegtuie en kompeterende posisie in die mark te verbeter. Ti-6Al-4V is al vir meer as 50 jaar beskikbaar. ‘n Drastiese verhoging in die aanvraag na Ti-6Al-4V deur die lugvaart, motor en chemiese industrieë word verwag wanneer die volgende geslag vliegtuie wat koolstofvesel as strukturele materiaal begin gebruik, in produksie gaan. Die materiaal het beter materiaaleienskappe as konvensionele materiale soos staal en aluminium, maar dit kom egter teen die prys van masjieneerbaarheid. Ti-6Al-4V se masjienering bo die industrie norm van 60 – 90m/min is ‘n groot uitdaging. Navorsers soek daarom deurentyd na verbeterde sny tegnologieë om die produksie tempo van Ti-6Al-4V te verbeter. Die beperkende faktor vir Ti-6Al-4V masjienering is die temperatuur wat genereer word. Die weerstand van die materiaal om hitte te absorbeer en sy goeie meganiese eienskappe veroorsaak dat temperature in die beitel 1000oC bereik. Hierdie temperature word egter op die snykant van die beitel gekonsentreer. Die uitdaging is dus om hierdie temperature in die beitel te beheer. Vloeibare stikstof is geïdentifiseer as ‘n goeie kandidaat vir verkoeling met die bykomende voordeel dat dit omgewingsvriendelik is. Die navorsing wat hier uiteengesit word, ondersoek die gebruik van ‘n geslote kamer beitelverkoelingstelsel wat deur gravitasie met vloeibare stikstof voorsien word om die beitel leeftyd te verbeter. Die oppervlak van die beitel word in hierdie konsep direk aan die vloeibare stikstof blootgestel. Om die effektiwiteit van die stelsel te verbeter word van PCD beitels gebruik gemaak. Die beitel se verbeterde hittegeleidingsvermoë help om die beitel se snykant koel te hou. Tungstenkarbied beitels word gebruik om ‘n standaard te stel vir eksperimentele analise. Die ronde tungstenkarbied beitels en konvensionele verkoeling het verstommend goed presteer vir Ti-6A-4V masjienering in vergelyking met vierkantige beitels. Die materiaalverwyderingstempo is aansienlik verhoog sonder om die beitel se leeftyd in te boet. Positiewe resultate is waargeneem met die vloeibare stikstof sisteem saam met die PCD beitels. ‘n Aantal verreikende uitdagings is geïdentifiseer wat suiwer wetenskaplike afleidings bemoeilik. Hierdie probleme kan almal aan die ontwerp van die toerusting toegeskryf word. Die werk lewer egter steeds ‘n bydrae tot die kennis in die veld. ‘n Bykomende benadering vir verkoeling is ondersoek wat duidelik ontwerp-veranderings aandui.

Les carbures et oxydes des métaux de transition sont d'une importance capitale dans le domaine industriel voir catalytique. Le carbure de tungstène WC a été identifié comme un bon substituant des métaux nobles tel que le platine dans le domaine catalytique. Le but de ce travail de thèse est d'appliquer des méthodes de chimie quantique les plus poussées pour déterminer la structure électronique, la stabilité et la nature de liaison chimique des diatomiques WC et WC2+. Notre recherche préliminaire est motivée par les données spectroscopiques disponibles sur W, W+, W2+, WC et WC2+. La méthodologie adoptée, CASSCF/MRCI/MRCI+Q/aug-cc-pV5Z(-PP) implémentée dans le code MOLPRO, consiste à réaliser des calculs quantique tenant en compte des effets de corrélation et relativistes avec un traitement spécifique du couplage spin−orbite pour la recherche des courbes d'énergie potentielle de l'état fondamental et des états excités de plus basses énergies de WCn+ (n=0-2) tout en utilisant une base suffisamment étendue. Les résultats de ce travail sont en bon accord avec ceux disponibles dans la littérature. En outre, dans ce travail nous avons confirmé pour la première fois que le carbure diatomique dicationique WC2+ est thermodynamiquement stable / Metal carbides and oxides are more interesting in catalytic and industrial domains. Tungsten carbide WC has been detected as serious substituent of platinum Pt catalytic. The ultimate goal of this thesis is theoretical studies of electronic structure, stability and the bound nature on WC, WO and its cations. Our preliminary research were motiving by the available spectroscopic data on W, W+, W2+, WC et WC2+. We used the methodology (CASSCF/MRCI/MRCI+Q/aug-cc-pV5Z(-PP)) implemented on MOLPRO package to perform quantum calculations with high accuracy taking into account the correlation and relativistic effects with a specific treatment of spin orbit coupling for some low lying excited electronic states of WCn+, (n=0, 1 et 2). Our results are shown in good agreement with those available in the literature. Furthermore, in this work for the first time we demonstrated that a carbide dication (WC2+) is thermodynamically stable

L’objectif de ces travaux de thèse est l’optimisation par une approche expérimentale d’un modèle de micro-fraise hémisphérique en carbure de tungstène revêtu, de diamètre 0,5 mm, destiné à l’usinage des aciers durs. Les données expérimentales obtenues résultent donc de l’usinage d’un acier 40NiCrMo16 à l’état trempé (54 HRC). Les résultats permettent de mettre en évidence certains phénomènes de coupe, d’usure et de comportement dynamique de l’outil liés au procédé, et leur évolution en fonction du type de fraise considéré et des conditions de coupe choisies. La géométrie de l’outil et son comportement dynamique sont ici principalement commentés. Dans un premier temps, l’étude de différentes nuances de carbure, préparation de surface ainsi que l’optimisation des géométries globale et locale des micro-fraises a permis de proposer un modèle optimisé pour notre partenaire outilleur Magafor. Dans un second temps, une approche numérique du micro-fraisage a été utilisée. Un premier modèle de calcul analytique des efforts de coupe a été testé et il a été mis en évidence les limites d’identification des coefficients spécifiques de coupe dans notre cas. Ensuite, une modélisation numérique par éléments finis du micro-fraisage a été réalisée afin d’appréhender l’étude du comportement dynamique des micro-fraises en fonction de la géométrie globale de l’outil développé. / The aim of this PhD work is optimized by experimental approach with 0.5 mm diameter micro-ball-end mills made from micro-grain tungsten carbide and PVD coated for hardened tool steels machining. The experimental data are obtained on machining of hardened steel (54/55HRC), typically used for the production of plastic injection molds. Results permit to highlight some cutting phenomena of wear and dynamic behavior of the process related tool, and changes depending on the type of milling considered and selected cutting conditions. The geometry of the tool and dynamic behavior are primarily discussed here. As a first step, the study of different carbide grades, surface preparation and optimization of global and local geometries of micro-cutters helped provide an efficient model for our partner Magafor toolmaker. In a second step, the modelling of micro-milling is discussed and an analytical model for cutting forces calculation is introduced. It was demonstrated the identifying limits of the specific cutting coefficients in our case. Then, a test of finite element modelling of micro-milling is made in order to estimate the potential of such a method for the study of the dynamic behaviour of micro-mills.

The target of the study is theoretical explaining the condition of creation of the soldered point with regard to basic and additional mat. Below, the detailed analysis of the existing technical problem and consecutive design of the solution method.Content of the study is also technological process of production of the barking knife and choice of the efficient producer.

Heat generated in a machining process is a common and critical obstacle faced in today's machining industries. The heat generated in the cutting zone has a direct negative influence on the tool life which, in turn contributes to increase the manufacturing costs. Especially, in machining of Heat Resistant Super Alloys, HRSA this is a very limiting factor. HRSA are capable of retaining their mechanical strength and hardness at elevated temperatures. This property is advantageous in the application in e.g. aero-engines but also a disadvantage, since it also lowers the machinability significantly. This work is an attempt to improve the heat transfer from the cutting zone, which would lead to an increase in the tool life. To achieve this goal, the cutting tool has been modified to create an improved interface between the coolant and tool in the high-temperature areas. Two generations of inserts have been designed and investigated. Firstly, an insert with surface texture features has been created with the purpose of increasing the available surface area for heat dissipation: First generation, Gen I. Secondly, a GenII was designed as a further improvement of Gen I. Here, several channel features on the rake face were added, reaching out from the contact zone to the near proximity of the cutting edge. This with the purpose of improving access of the coolant closer to the cutting edge. The experiments were conducted in facing operations of Alloy 718 with uncoated round carbide inserts. All experiments were carried out with high-pressure coolant assistance, with a pressure of 16 MPa on the rake face and 8 MPa on the flankface, respectively.The two generations of inserts, Gen I and Gen II, were experimentally evaluated by tool wear analysis in comparison with a regular insert. The results shows that the tool life increased significantly for the Gen I insert, compared to a catastrophic failure of the regular insert at the same conditions. Regarding the Gen II insert,an increase in tool life by approximately 30 to 40 percent compared to Gen I insert was observed.

The aim of this work was to systematically study how the microstructure evolution is affected by the carbon activity in WC-Ni cemented carbides. Seven WC-9.59at%Ni alloys with different carbon activity were sintered at 1500 °C. From investigating these alloys, the carbon window has been experimentally evaluated using light optical microscopy and compared to theoretical carbon window calculated using Thermo-Calc. The overall microstructure of cross sections and raw surfaces have been investigated using scanning electron microscopy. Finally, the WC grain size and distribution have been evaluated using electron backscatter diffraction. It was found that the experimental carbon window was slightly wider than the theoretical carbon window. The WC grain size increased and the grain size distribution got wider with increasing carbon activity. In addition, the largest WC grains showed the largest grain growth by increasing carbon activity. By comparing the present results of grain size and distribution of WC-Ni to previous results of WC-Co, it was found that the WC grain growth was more pronounced and more influenced by the carbon activity.