WA1Roughing (no scale) to semi-finishing heat resistant alloys | Whisker ceramic

High-speed machining not achievable with carbide tools

High speed and efficienct machining of heat resistant alloys

SiC fibers in the material provide strength, flank wear resistance and thermal shock resistance

Features

  • Alumina ceramic material with enhanced toughness due to the addition of SiC whiskers.
  • High-speed machining is possible due to flank and notch wear resistance and toughness

Tooling application

Roughing (no scale) to semi-finishing heat resistant alloys
Turning/Grooving/Milling

Grade characteristics

Cutting conditions

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Grade Material Operation type Machining Cutting speed (SFM) Feed (IPR / IPT) DOC(inch) Coolant
WA1 Heat resistant alloys Turning Roughing 600 - 1000 .005 - .010 .040 - .100 WET
Profiling / Semi-finishing 600 - 1100 .004 - .010 .040 - .080
Grooving .002 - .004 -
Milling Indexable 1600 - 3300 .003 - .008 〜 .150 DRY

Why are Sialon ceramics so effective at high-speed machining of heat resistant alloys?

Silicon nitride (Si3N4) is combined with Aluminum (Al) and oxygen (O) to make SiAlON.
Sialon has needle-shaped particles similar to that of Silicon nitride.
The arrangement of these particles makes the material withstand the impact force during cutting.
The addition of the alumina improves its heat resistance characteristics.
The property advantages makes it perfect for machining heat resistant alloys.

Whisker ceramic structure

The addition of the silicon carbide (SiC) to alumina greatly improves the strength of material.
Prevents the progression of cracks caused by impact forces during machining.

Inconel 718 Profiling

[ Cutting conditions ]
Material : Inconel718 (Semi-finishing)  Cycle time : 5.0 min 800 SFM .006 IPR  .039 DOC Wet
[ Tools used ]
Insert used : RPGX120700

Case study

Jet engine part
Material :
Inconel718
Cutting speed :
670 SFM
Feed :
.0039 IPR
DOC :
.0118 inch
Coolant :
WET
WA1

3.15 inch / corner (Consistent performance)

Competitor's whisker ceramic

3.15 inch / corner (Streaks visible on part surface)

WA1 had stable machining performance compared to competitor's whisker grade.
Gas turbine case
Material :
Inconel718
Cutting speed :
2700 SFM
Feed :
.0039 IPR
DOC :
.079 inch
Coolant :
DRY
WA1

1 pass = 2min

Competitor's carbide end mill
1 pass = 60min
WA1 significantly reduced cycle time compared to the competitor's carbide end mill.

Tool lineup

Please check product catalog for tooling lineup


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