Alumina-titanium carbide-silicon carbide composition

Claim 2

A fired ceramic composition comprising: about 1.0 to less than 30 volume percent silicon carbide whiskers having an average diameter between about 0.3 and about 0.7 microns; about 5 to about 40 volume percent titanium carbide phase selected from the group consisting of substantially equiaxed titanium carbide particles having an average diameter between 1 and 10 microns, titanium carbide whiskers having an average diameter of between about 1 to about 10 microns, and mixtures thereof; wherein the sum of said silicon carbide whiskers and said titanium carbide phase is less than about 60 volume percent; an alumina based matrix forming essentially the remainder; and wherein said silicon carbide whiskers and said titanium carbide phase are dispersed in said alumina based matrix.

Claim 3

The fired ceramic composition according to claim 2 wherein said titanium carbide phase consists of said titanium carbide whiskers.

Claim 4

The fired ceramic composition according to claim 1 further comprising up to about 3 volume percent of a sintering aid residue.

Claim 5

The fired ceramic composition according to claim 1 wherein said titanium carbide phase forms about 10 to about 35 volume percent of said fired ceramic composition.

Claim 6

The fired ceramic composition according to claim 1 wherein said silicon carbide whiskers form about 2.5 to about 25 volume percent of said fired ceramic composition.

Claim 7

The fired ceramic composition according to claim 1 containing 15 to 35 volume percent of said titanium carbide whiskers.

Claim 8

The fired ceramic composition according to claim 1 containing 2.5 to 20 volume percent silicon carbide whiskers.

Claim 9

The fired ceramic composition according to claim 1 containing 2.5 to 20 volume percent silicon carbide whiskers.

Claim 10

A cutting tool comprising: a ceramic body having a flank face, a rake face and a cutting edge formed at a juncture of said rake face and said flank face; said ceramic body composed of about 1.0 to less than 30 volume percent silicon carbide whiskers having an average diameter between about 0.3 and about 0.7 microns; about 5 to about 40 volume percent titanium carbide phase; wherein the sum of titanium carbide phase plus silicon carbide whiskers is less than 60 volume percent; an alumina based matrix forming essentially the remainder; and wherein said silicon carbide whisker and said titanium carbide phase are dispersed in said alumina based matrix and said titanium carbide phase has a larger average diameter than the average diameter of the silicon carbide whiskers.

Claim 11

A cutting tool comprising: a ceramic body having a flank face, a rake face and a cutting edge formed at a juncture of said rake face and said flank face; said ceramic body composed of about 1.0 to less than 30 volume percent silicon carbide whiskers having an average diameter between about 0.3 and about 0.7 microns; about 5 to about 40 volume percent titanium carbide phase; wherein the sum of titanium carbide phase plus silicon carbide whiskers is less than 60 volume percent; an alumina based matrix forming essentially the remainder; and wherein said silicon carbide whisker and said titanium carbide phase are dispersed in said alumina based matrix and said titanium carbide phase has a larger average diameter than the average diameter of the silicon carbide whiskers.

Claim 12

The cutting tool according to claim 9 wherein said titanium carbide phase is titanium carbide whiskers having an average diameter of about 1 to 10 microns.

Claim 13

The cutting tool according to claim 9 characterized by a K IC (E&C) fracture toughness of greater than 5.5 MPam 1/2 and a flank wear resistance of greater than 400 minutes/inch when turning AISI 1045 steel having a hardness of 180-195 BHN at a speed of 1000 surface feet/minute, a feed rate of 0.024 inch/revolution and a depth of cut of 0.100 inch.

Claim 14

The cutting tool according to claim 11 wherein said flank wear resistance is greater than 500 minutes/inch.

Claim 15

The cutting tool according to claim 11 wherein said wear resistance is greater than 650 minutes/inch.

Claim 16

The cutting tool according to claim 9 containing about 2.5 to 25 volume percent silicon carbide whiskers.

Claim 17

The cutting tool according to claim 9 containing about 2.5 to 20 volume percent silicon carbide whiskers.

Claim 18

The cutting tool according to claim 14 containing 10 to 35 volume percent titanium carbide whiskers having an average diameter between 1 and 10 microns.

Claim 19

The cutting tool according to claim 15 containing 15 to 35 volume percent titanium carbide whiskers having an average diameter between 1 and 10 microns.

Claim 20

The cutting tool according to claim 9 wherein the volume percent of titanium carbide phase is at least equal to the volume percent silicon carbide whiskers.

Claim 21

The cutting tool according to claim 9 wherein the volume percent of titanium carbide phase is greater than the volume percent of silicon carbide whiskers.

Claim 22

A fired ceramic composition comprising: about 1.0 to less than 30 volume percent silicon carbide whiskers; about 5 to about 40 volume percent of substantially equiaxed titanium carbide particles having an average diameter between 1 and 10 microns; wherein the sum of said silicon carbide whiskers and said substantially equiaxed titanium carbide particles is less than about 60 volume percent; an alumina based matrix forming essentially the remainder; wherein the average diameter of said substantially equiaxed titanium carbide particles is greater than the average diameter of the silicon carbide whiskers; and wherein said silicon carbide whiskers and said substantially equiaxed titanium carbide particles are dispersed in said alumina based matrix.

Claim 23

A fired ceramic composition comprising: about 1.0 to less than 30 volume percent silicon carbide whiskers; about 5 to about 40 volume percent of substantially equiaxed titanium carbide particles having an average diameter between 1 and 10 microns; wherein the sum of said silicon carbide whiskers and said substantially equiaxed titanium carbide particles is less than about 60 volume percent; an alumina based matrix forming essentially the remainder; wherein the average diameter of said substantially equiaxed titanium carbide particles is greater than the average diameter of the silicon carbide whiskers; and wherein said silicon carbide whiskers and said substantially equiaxed titanium carbide particles are dispersed in said alumina based matrix.

Claim 24

The fired ceramic composition according to claim 20 wherein said substantially equiaxed titanium carbide particles have an average diameter between 3 and 7 microns.

Claim 25

A fired ceramic composition comprising: about 1.0 to less than 30 volume percent silicon carbide whiskers having an average diameter between about 0.3 and about 0.7 microns; about 5 to about 40 volume percent of substantially equiaxed titanium carbide particles having an average diameter between 1 and 10 microns; wherein the sum of said silicon carbide whiskers and said substantially equiaxed titanium carbide particles is less than about 60 volume percent; an alumina based matrix forming essentially the remainder; and wherein said silicon carbide whiskers and said substantially equiaxed titanium carbide particles are dispersed in said alumina based matrix.

Claim 26

A fired ceramic composition comprising: about 1.0 to less than 30 volume percent silicon carbide whiskers having an average diameter between about 0.3 and about 0.7 microns; about 5 to about 40 volume percent of substantially equiaxed titanium carbide particles having an average diameter between 1 and 10 microns; wherein the sum of said silicon carbide whiskers and said substantially equiaxed titanium carbide particles is less than about 60 volume percent; an alumina based matrix forming essentially the remainder; and wherein said silicon carbide whiskers and said substantially equiaxed titanium carbide particles are dispersed in said alumina based matrix.

Claim 27

A cutting tool comprising: a ceramic body having a flank face, a rake face and a cutting edge formed at a juncture of said rake face and said flank face; said ceramic body composed of about 1.0 to less than 30 volume percent silicon carbide whiskers; about 5 to about 40 volume percent of substantially equiaxed titanium carbide particles having an average diameter of about 1 to 10 microns; wherein the sum of titanium carbide particles plus said silicon carbide whiskers is less than 60 volume percent; an alumina based matrix forming essentially the remainder; and wherein said silicon carbide whisker and said titanium carbide phase are dispersed in said alumina based matrix and said titanium carbide phase has a larger diameter than the average diameter of the silicon carbide whiskers.

Claim 28

A cutting tool comprising: a ceramic body having a flank face, a rake face and a cutting edge formed at a juncture of said rake face and said flank face; said ceramic body composed of about 1.0 to less than 30 volume percent silicon carbide whiskers; about 5 to about 40 volume percent of substantially equiaxed titanium carbide particles having an average diameter of about 1 to 10 microns; wherein the sum of titanium carbide particles plus said silicon carbide whiskers is less than 60 volume percent; an alumina based matrix forming essentially the remainder; and wherein said silicon carbide whisker and said titanium carbide phase are dispersed in said alumina based matrix and said titanium carbide phase has a larger diameter than the average diameter of the silicon carbide whiskers.

Claim 29

The fired ceramic composition according to claim 20 wherein said substantially equiaxed titanium carbide particles form about 10 to about 35 volume percent of said fired ceramic composition.

Claim 30

The fired ceramic composition according to claim 20 wherein said silicon carbide whiskers form about 2.5 to about 25 volume percent of said fired ceramic composition.

Claim 31

The fired ceramic composition according to claim 20 containing 2.5 to 20 volume percent silicon carbide whiskers.

Claim 32

The fired ceramic composition according to claim 24 containing 2.5 to 20 volume percent silicon carbide whiskers.

Claim 33

The cutting tool according to claim 23 characterized by a K IC (E&C) fracture toughness of greater than 5.5 MPam 1/2 and a flank wear resistance of greater than 400 minutes/inch when turning AISI 1045 steel having a hardness of 180-195 BHN at a speed of 1000 surface feet/minute, a feed rate of 0.024 inch/revolution and a depth of cut of 0.100 inch.

Claim 34

The cutting tool according to claim 25 wherein said flank wear resistance is greater than 500 minutes/inch.

Claim 35

The cutting tool according to claim 28 wherein said wear resistance is greater than 650 minutes/inch.

Claim 36

The cutting tool according to claim 22 containing about 2.5 to 25 volume percent silicon carbide whiskers.

Claim 37

The cutting tool according to claim 23 containing about 2.5 to 20 volume percent silicon carbide whiskers.

Claim 38

The cutting tool according to claim 23 wherein the volume percent of said substantially equiaxed titanium carbide particles is at least equal to the volume percent silicon carbide whiskers.

Claim 39

The cutting tool according to claim 23 wherein the volume percent of said substantially equiaxed titanium carbide particles is greater than the volume percent of silicon carbide whiskers.