In order to ensure the highest quality of our services, we use small files called cookies. When using our website, the cookie files are downloaded onto your device. You can change the settings of your browser at any time. In addition, your use of our website is tantamount to your consent to the processing of your personal data provided by electronic means.
Public Information Bulletin Logo

The National Centre for Research and Development

Back

Next generation titanium-based tool material produced using the fast spark plasma sintering process

1460x616 (2)

square with tentacles  Project title

Next generation titanium-based tool material produced using the fast spark plasma sintering process

outline of the upper man silhouette  Name of Beneficiary/Beneficiaries

Łukasiewicz Research Network – Poznań Technological Institute

briefcase icon  Name of programme

Domestic programmes

newspaper icon  Competition

LIDER XI

two heaps of coins icon  Project value

PLN 1,372,707.98

hand icon with two circles above it  Funding value

PLN 1,372,707.98

clock icon  Project delivery period

from 1 January 2021 to 1 January 2024

Meet our team

1

dr hab. inż. Dariusz Garbiec

See the results of our work

2

A set of graphite tools for sintering cutting inserts using the FAST/SPS method, designed within the project based on FEM modelling

 

3

Prototype of a cutting insert made from the developed material

 

4

Prototype of an RNGN 1204 cutting insert made from the developed material

What problem does our project solve

The aim of the project was to develop the technology for manufacturing a new tool material for use in machining processes. To date, the most commonly used tool material in machining is cemented carbide of the WC-Co type, which contains cobalt as the metallic matrix. Due to the limited supply of this element, as well as its toxicity and carcinogenicity, finding a suitable substitute for this metal in tool materials is one of the challenges posed to materials engineering. This was our main motivation for undertaking research on this topic. The solution to the problem was, therefore, the development of a new, cobalt-free tool material that would offer at least comparable properties to conventional WC-Co cemented carbides. The use of tungsten carbide (WC) and titanium (Ti) powders, followed by a combination of high-energy ball milling (HEBM) and spark plasma sintering (FAST/SPS) technologies, enabled the production of a very hard carbide material with uniform properties that outperform conventional reference materials. The developed material was also subjected to preliminary operational tests, which confirmed its competitiveness.

Who will benefit from the project's results?

The main entities that can benefit from the results of the project are companies engaged in manufacturing tools for machining, mainly cutting inserts for turning, as well as companies involved in this machining process. However, the potential application of the developed material is much broader due to its properties—high uniformity, hardness, and good wear resistance over a wide temperature range. With this in mind, this material could potentially be used in the production of measuring tool tips, consumable parts in machinery, equipment, and instruments for space technology, the defence industry, communications, aviation, electronics, energy industries, and even for sports equipment.

What was the biggest challenge for us in implementing the project?

The biggest challenge during the project was finding a balance between the high hardness of the material and its resistance to brittle fracture. These are two mechanical properties that are usually mutually exclusive—hardest materials tend to be brittle and easily crack, while materials that can withstand impact loads often have unsatisfactory hardness (and thus, low wear resistance). Maintaining high hardness while also achieving resistance to brittle fracture at the desired level was a demanding task. The research carried out as part of the project resulted in the development of a carbide material with a satisfactory hardness-to-brittle-fracture resistance ratio.

Our advice to other Applicants

Based on our experiences gained from the implementation of this and many other national and international projects, we highly recommend thoroughly planning the scope of applied research and development work during the conceptual phase of the project. Thoughtfully dividing the work into measurable tasks will enable the smooth execution of the project without the risk of getting lost in the flood of ongoing tasks. In case of failure to secure funding for your idea, we also encourage you not to give up, to continuously improve your application, and to apply for funding in future rounds.