US6204213B1 — Whisker reinforced ceramic cutting tool and compo…

Claim 1

Independent Claim 132 words

A composition produced by the consolidation of a blend of starting components, the composition comprising: a matrix comprising one or more of the carbides, nitrides and carbonitrides of hafnium, molybdenum, tungsten, zirconium, tantalum, niobium, vanadium, titanium, and solid solutions thereof in an amount that is greater than 50 volume percent of the matrix, the matrix further includes sintering aid residue present from the use of one or more sintering aids as a starting component in an amount less than 0.5 weight percent of the starting components wherein the sintering aid comprises one or more of yttria, magnesia and zirconia, the matrix comprising between 60 and 99.8 volume percent of the composition; and ceramic whiskers uniformly dispersed throughout the matrix, the ceramic whiskers comprising between 0.2 and 40 volume percent of the composition.

Claim 2

Dependent Claim 132 words

A composition produced by the consolidation of a blend of starting components, the composition comprising: a matrix comprising one or more of the carbides, nitrides and carbonitrides of hafnium, molybdenum, tungsten, zirconium, tantalum, niobium, vanadium, titanium, and solid solutions thereof in an amount that is greater than 50 volume percent of the matrix, the matrix further includes sintering aid residue present from the use of one or more sintering aids as a starting component in an amount less than 0.5 weight percent of the starting components wherein the sintering aid comprises one or more of yttria, magnesia and zirconia, the matrix comprising between 60 and 99.8 volume percent of the composition; and ceramic whiskers uniformly dispersed throughout the matrix, the ceramic whiskers comprising between 0.2 and 40 volume percent of the composition.

Claim 3

Dependent Claim 56 words

The composition of claim 1 wherein the ceramic whiskers comprise silicon carbide whiskers, and the silicon carbide whiskers having an average length between about 20 micrometers and about 50 micrometers, an average diameter of between about 0.3 micrometers and about 1 micrometer, and the crystalline structure of the silicon carbide whiskers is predominantly beta silicon carbide.

Claim 4

Dependent Claim 38 words

The composition of claim 2 wherein the fracture toughness of the ceramic cutting tool is equal to or greater than about 6.3 MPam ½ K IC and a hardness of greater than or equal to 94.7 Rockwell A.

Claim 5

Dependent Claim 51 words

The composition of claim 1 wherein the ceramic whiskers comprise silicon carbide whiskers, and the silicon carbide whiskers having an average length between about 10 micrometers and about 80 micrometers, an average diameter of about 0.6 micrometers, and the crystalline structure of the silicon carbide whiskers is predominantly alpha silicon carbide.

Claim 6

Dependent Claim 38 words

The composition of claim 4 wherein the fracture toughness of the ceramic cutting tool is equal to or greater than about 7.5 MPam ½ K IC and a hardness of greater than or equal to 94.7 Rockwell A.

Claim 7

Dependent Claim 144 words

A ceramic cutting tool comprising: a rake face; and a flank face, a cutting edge at the juncture of the rake face and the flank face; a ceramic composition having a matrix comprising at least 50 volume percent of one or more of the carbides, nitrides and carbonitrides of hafnium, molybdenum, zirconium, tantalum, niobium, vanadium, tungsten, titanium, and solid solutions thereof, the matrix further includes sintering aid residue present from the use of one or more sintering aids as a starting component in an amount less than 0.5 weight percent of the starting components wherein the sintering aid comprises one or more of yttria, magnesia and zirconia, wherein the matrix comprises between 60 and 99.8 volume percent of the ceramic composition; and ceramic whiskers uniformly dispersed throughout the matrix wherein the ceramic whiskers comprise between 0.2 and 40 volume percent of the ceramic composition.

Claim 8

Dependent Claim 144 words

A ceramic cutting tool comprising: a rake face; and a flank face, a cutting edge at the juncture of the rake face and the flank face; a ceramic composition having a matrix comprising at least 50 volume percent of one or more of the carbides, nitrides and carbonitrides of hafnium, molybdenum, zirconium, tantalum, niobium, vanadium, tungsten, titanium, and solid solutions thereof, the matrix further includes sintering aid residue present from the use of one or more sintering aids as a starting component in an amount less than 0.5 weight percent of the starting components wherein the sintering aid comprises one or more of yttria, magnesia and zirconia, wherein the matrix comprises between 60 and 99.8 volume percent of the ceramic composition; and ceramic whiskers uniformly dispersed throughout the matrix wherein the ceramic whiskers comprise between 0.2 and 40 volume percent of the ceramic composition.

Claim 9

Dependent Claim 39 words

The ceramic cutting tool of claim 6 wherein the ceramic cutting tool further includes a coating, and the coating comprises a layer selected from the group consisting of alumina, titanium carbide, titanium nitride, titanium carbonitride, and titanium aluminum nitride.

Claim 10

Dependent Claim 16 words

The ceramic cutting tool of claim 7 wherein the layer is applied by chemical vapor deposition.

Claim 11

Dependent Claim 16 words

The ceramic cutting tool of claim 7 wherein the layer is applied by physical vapor deposition.

Claim 12

Dependent Claim 15 words

The ceramic cutting tool of claim 7 wherein the ceramic whiskers are silicon carbide whiskers.

Claim 13

Dependent Claim 50 words

The ceramic cutting tool of claim 10 wherein the silicon carbide whiskers having an average length between about 20 micrometers and about 50 micrometers, an average diameter of between about 0.3 micrometers and about 1 micrometer, and the crystalline structure of the silicon carbide whiskers is predominantly beta silicon carbide.

Claim 14

Dependent Claim 40 words

The ceramic cutting tool of claim 11 wherein the fracture toughness of the coated ceramic cutting tool is equal to or greater than 6.6 MPam ½ K IC and a hardness of greater than or equal to 94.7 Rockwell A.

Claim 15

Dependent Claim 45 words

The ceramic cutting tool of claim 10 wherein the silicon carbide whiskers having an average length between about 10 micrometers and about 80 micrometers, an average diameter of about 0.6 micrometers, and the crystalline structure of the silicon carbide whiskers is predominantly alpha silicon carbide.

Claim 16

Dependent Claim 40 words

The ceramic cutting tool of claim 13 wherein the fracture toughness of the coated ceramic cutting tool is equal to or greater than 7.5 MPam ½ K IC and a hardness of greater than or equal to 94.7 Rockwell A.

Claim 17

Independent Claim 261 words

A method of cutting metal wherein a ceramic cutting tool is brought into contact with a metal workpiece and the ceramic cutting tool and metal workpiece move relative to each other whereby metal is removed by the ceramic cutting tool from the metal workpiece using a ceramic cutting tool comprising: a rake face and a flank face wherein the rake face and the flank face intersect to form a cutting edge; the composition of the ceramic cutting tool comprising a matrix including: titanium carbonitride in an amount of about 50 volume percent or more of the matrix; alumina in an amount that is greater than about 40 volume percent of the matrix; and sintering aid residue present from the use of one or more sintering aids as a starting component in an amount less than 0.5 weight percent of the starting components wherein the sintering aid comprises one or more of yttria, magnesia and zirconia; the matrix comprising between 60 and 99.8 volume percent of the composition of the ceramic cutting tool; the composition of the ceramic cutting tool further comprising ceramic whiskers uniformly dispersed throughout the matrix, the ceramic whiskers comprising between 0.2 and 40 volume percent of the composition; the titanium carbonitride having the formula Ti(C x N y ) wherein y is less than 0.9 and greater than or equal to 0.5, and x+y=1; and the ceramic cutting tool having a fracture toughness of greater than or equal to about 6.3 MPam ½ K IC and a hardness of greater than or equal to about 94.7 Rockwell A.

Claim 18

Independent Claim 261 words

A method of cutting metal wherein a ceramic cutting tool is brought into contact with a metal workpiece and the ceramic cutting tool and metal workpiece move relative to each other whereby metal is removed by the ceramic cutting tool from the metal workpiece using a ceramic cutting tool comprising: a rake face and a flank face wherein the rake face and the flank face intersect to form a cutting edge; the composition of the ceramic cutting tool comprising a matrix including: titanium carbonitride in an amount of about 50 volume percent or more of the matrix; alumina in an amount that is greater than about 40 volume percent of the matrix; and sintering aid residue present from the use of one or more sintering aids as a starting component in an amount less than 0.5 weight percent of the starting components wherein the sintering aid comprises one or more of yttria, magnesia and zirconia; the matrix comprising between 60 and 99.8 volume percent of the composition of the ceramic cutting tool; the composition of the ceramic cutting tool further comprising ceramic whiskers uniformly dispersed throughout the matrix, the ceramic whiskers comprising between 0.2 and 40 volume percent of the composition; the titanium carbonitride having the formula Ti(C x N y ) wherein y is less than 0.9 and greater than or equal to 0.5, and x+y=1; and the ceramic cutting tool having a fracture toughness of greater than or equal to about 6.3 MPam ½ K IC and a hardness of greater than or equal to about 94.7 Rockwell A.

Claim 19

Dependent Claim 56 words

The method of claim 15 wherein the ceramic whiskers comprise silicon carbide whiskers, and the silicon carbide whiskers having an average length between about 20 micrometers and about 50 micrometers, an average diameter of between about 0.3 micrometers and about 1 micrometer, and the crystalline structure of the silicon carbide whiskers is predominantly beta silicon carbide.

Claim 20

Dependent Claim 51 words

The method of claim 15 wherein the ceramic whiskers comprise silicon carbide whiskers, and the silicon carbide whiskers having an average length between about 10 micrometers and about 80 micrometers, an average diameter of about 0.6 micrometers, and the crystalline structure of the silicon carbide whiskers is predominantly alpha silicon carbide.

Claim 21

Dependent Claim 22 words

The method of claim 17 wherein the fracture toughness of the composition is equal to or greater than 7.5 MPam ½ .

Claim 22

Dependent Claim 36 words

The method of claim 15 wherein the ceramic cutting tool includes a coating, and the coating comprises a layer selected from the group consisting of alumina, titanium carbide, titanium nitride, titanium carbonitride, and titanium aluminum nitride.

Claim 23

Dependent Claim 15 words

The method of claim 19 wherein the coating layer is applied by chemical vapor deposition.

Claim 24

Dependent Claim 15 words

The method of claim 19 wherein the coating layer is applied by physical vapor deposition.

Claim 25

Dependent Claim 28 words

The ceramic cutting tool of claim 6 wherein the ceramic cutting tool further comprising a coating scheme comprising one layer of titanium carbonitride and another layer of alumina.

Claim 26

Dependent Claim 25 words

The ceramic cutting tool of claim 22 wherein the layer of titanium carbonitride and the layer of alumina is each applied by chemical vapor deposition.

Claim 27

Dependent Claim 48 words

The ceramic cutting tool of claim 6 further comprising a coating scheme comprising a first layer of titanium carbonitride applied to at least a portion of one or both of the rake face and the flank face, and the coating scheme further including a second layer of alumina.

Claim 28

Dependent Claim 25 words

The ceramic cutting tool of claim 24 wherein the second layer of alumina being applied to the surface of the first layer of titanium carbonitride.

Claim 29

Dependent Claim 29 words

The method of claim 15 wherein the ceramic cutting tool includes a coating, and the coating comprising a first layer of titanium carbonitride and a second layer of alumina.

Claim 30

Dependent Claim 31 words

The method of claim 26 wherein the first layer of titanium carbonitride being applied to at least a portion of one or both of the rake face and the flank face.

Claim 31

Dependent Claim 20 words

The method of claim 27 wherein the second layer of alumina being applied to the first layer of titanium carbonitride.

Claim 32

Dependent Claim 25 words

The method of claim 26 wherein the first layer of titanium carbonitride and the second layer of alumina is each applied by chemical vapor deposition.

Claim 33

Dependent Claim 160 words

A coated ceramic cutting tool comprising: a substrate presenting a rake face and a flank face, a cutting edge at the juncture of the rake face and the flank face; the substrate having a composition comprising a matrix comprising at least 50 volume percent of one or more of the carbides, nitrides and carbonitrides of hafnium, molybdenum, zirconium, tantalum, niobium, vanadium, tungsten, titanium and solid solutions thereof, the matrix further comprising the sinter aid residue present from the use of one more sintering aids as a starting component in an amount less than 1 weight percent of the starting components wherein the sintering aid comprises one or more of yttria, magnesia, and zirconia, wherein the matrix comprises between 60 and 99.8 volume percent of the substrate composition; ceramic whiskers uniformly dispersed throughout the matrix wherein the ceramic whiskers comprises between 0.2 and 40 volume percent of the substrate composition; and a coating on at least a portion of the substrate.

Claim 34

Dependent Claim 160 words

A coated ceramic cutting tool comprising: a substrate presenting a rake face and a flank face, a cutting edge at the juncture of the rake face and the flank face; the substrate having a composition comprising a matrix comprising at least 50 volume percent of one or more of the carbides, nitrides and carbonitrides of hafnium, molybdenum, zirconium, tantalum, niobium, vanadium, tungsten, titanium and solid solutions thereof, the matrix further comprising the sinter aid residue present from the use of one more sintering aids as a starting component in an amount less than 1 weight percent of the starting components wherein the sintering aid comprises one or more of yttria, magnesia, and zirconia, wherein the matrix comprises between 60 and 99.8 volume percent of the substrate composition; ceramic whiskers uniformly dispersed throughout the matrix wherein the ceramic whiskers comprises between 0.2 and 40 volume percent of the substrate composition; and a coating on at least a portion of the substrate.

Claim 35

Dependent Claim 29 words

The coated ceramic cutting tool of claim 30 the coating comprising layer selected from the group consisting of alumina, titanium carbide, titanium nitride, titanium carbonitride, and titanium aluminum nitride.

Claim 36

Dependent Claim 50 words

The coated ceramic cutting tool of claim 30 wherein the matrix comprising titanium carbonitride in an amount of about 50 volume percent or more of the matrix, alumina in an amount that is greater than about 40 volume percent of the matrix; and the ceramic wiskers comprising silicon carbide whiskers.

Claim 37

Dependent Claim 46 words

The coated ceramic cutting tool of claim 32 wherein the matrix comprising between about 70 volume percent and about 90 volume percent of the substrate composition, and the silicon carbide whiskers comprising between about 10 volume percent and about 30 volume percent of the substrate composition.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2004-03-19	2004-09-18	2005-03-20	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2008-03-19	2008-09-18	2009-03-20	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2012-03-19	2012-09-18	2013-03-20	$7700.00	Window Closed / Lapsed

Whisker reinforced ceramic cutting tool and composition thereof

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