In WP1, the major effort for this reporting period was concentrated on continued in-depth experimental analysis of wear mechanisms. This was accompanied by thermodynamic modelling for selected tool-workpiece systems, performed in close cooperation with ISM. Similarly, two test rigs for rock cutting were built and performance tests for both reference cemented carbide and PCD, but also for all newly developed PCD grades were performed and analysed. Wear mechanisms in machining titanium and nickel alloys were also in-depth investigated. Lund, in cooperation with Seco, achieved significant progress in modelling and measurement of thermal phenomena in machining. Extended performance testing program was performed amounting to over 1000 for RP3 and nearly 1900 tests overall.
In WP2, CNRS investigated chemical interaction and phase relations in the binary B-X systems (X = N, P, Si, S, Se) and comprehensively characterized a number of new superhard B-X phases. TUBAF established preparation routines for new binder components based on polymer ceramic precursors, chemical vapour, solid state synthesis and subsequent thermal and/or plasma treatment. A large variety of potential binder systems with different binder phases, hard phases and additives (sintering aids, functional materials) were screened. An upscaled preparation route was established to provide material to be sintered by Element Six for one system so far. Upscalable methods to prepare particularly submicron- or even nanopowders, which can be easily and homogeneously mixed with diamond or cBN powders, even without the use of organic solvents were developed. This will reduce process steps and therefore help to reduce production costs and will be more environmentally friendly as compared to conventional mixing procedures.
In WP3 ISM worked on improvement of binder phase content and composition for HPHT sintering of diamond and cBN based materials. In RP3 eight different ratios of binder components for the superhard materials were investigated: two of them included combining two dissimilar types of binder at the same time. Over forty compositions of cBN-based materials were produced by HPHT sintering. The characterization of obtained materials in terms of phase composition, microstructure and mechanical properties was conducted in close cooperation with Lund. The description of sintering technology of prospective binder candidates was transferred to E6 for further implementation to their production line in WP4. 5 binder systems were upscaled independently of E6 and transferred to Seco for tool making.
In WP4 E6 has developed the upscaled process for the developed materials and delivered samples for WP5. In WP5 tool manufacturing was followed by testing. Tool life modelling approaches were investigated to obtain high accuracy data for Cost to Performance Ratio (CPR) analysis. CPR models have been built and investigated for judgement of different technologies and development scenarios. Detailed CPR analysis was completed for reference cemented carbide, pcBN and three novel non-CRM materials.
In WP6, bifa has created an initial dataset for LCA and eco-efficiency analysis which has been updated according to the progress made. bifa has determined, collected and analysed main and by-products with respect to substitution, viable recovery routes and re-use opportunities, and potential customers of different industries were identified for recycling, recovery, re-use of main and by-products as feasible.
WP7 disseminated the results and concluded with a booklet that presents a project overview.
