Press Release Summary:
KC9110 and KC9125 have coating bonding technology that can apply 3 main layers and several sub-layers of coating with total thickness of 18 microns. Grade KC9110 is ISO class P10 grade for finishing operations while Grade KC9125 is P25 class grade for universal machining on all types of steel. Both have coatings 25 to 75% thicker than company's conventional coated carbides and increase metalcutting productivity without sacrificing tool life.
Original Press Release:
Two New Kennametal Grades Provide Dramatic Improvements in Steel Turning
(Latrobe, PA) -- Kennametal has introduced two new steel turning grades, KC9110 and KC9125, that provide dramatic improvements in performance, beating almost 80% of existing grades with substantial tool life improvement. Grade KC9110 is an ISO class P10 grade that is designed for finishing operations while Grade KC9125 is a P25 class grade designed for universal machining on all types of steel. The key to the performance gains offered by these new grades is advancements in coating bonding technology that make it possible to apply three main layers and several additional sub-layers of coating with a total thickness of 18-microns. These coatings are 25% to 75% thicker than conventional coated carbides. "The new materials offer dramatic improvements in performance that make it possible to substantially increase metalcutting productivity without sacrificing tool life," said Rich Denton, Senior Product Manager, Turning Inserts for Kennametal.
"These new inserts incorporate graded interface layers that increase the adhesion between the coating layers," said Mark Greenfield, Manager of Carbide Product Development. "We have also increased the interfacial surface area of each layer by changing the formulation of the precursors in the chemical vapor deposition (CVD) process to increase surface roughness. These improvements make it possible to provide a unique combination of three coating layers on both KC9110 and KC9125, which is the main reason for the outstanding performance of these new grades." Starting from the substrate and moving outward, the main coating layers include: medium temperature titanium carbonitride (TiCN), fine-grain alpha structure aluminum oxide (A1203), and a thin layer of titanium carbonitride (TiCN) and titanium nitride (TiN) . The substrates of the new inserts have been improved by changing the composition of the insert locally so that cobalt content is higher near the surface of the substrate where toughness is most important and much lower in the core where deformation resistance is the most important property.
In addition to advancements in coating and substrate technology Kennametal has developed and incorporated state of the art edge preparation technology on these products. Micro-finishing of the cutting edge reduces surface roughness and removes the TiN outer coating layer exposing the inner A1203 layers. Advantages of a micro - finished cutting edge are reduced build-up of the workpiece material on the cutting tool, smoother chip flow and better performance in interrupted wet machining applications. This technology yields longer tool life and better part finishes.
"In a recent series of over 100 field tests conducted with the new grades, they exhibited amazing performance," Denton said. "They outperformed the best previous technology in 80% of the applications." The materials in the tests ranged from relative easy to machine materials such as 8620 and 1548 steels, and ductile irons as well as more difficult to machine materials such as 4340, 4340 heat treated forgings, M2 tool steel, powdered metal automotive bearing caps, and 52100 bearing steel.