CARBIDOSTAL
A composite wear-resistant carbide-steel material consisting of a steel binder (matrix) and solid particles of refractory titanium carbide (TiC) is offered for production. As the ligament powder is used high-speed or die steel.
The developed composite inherits such properties of steels as the possibility of machining, as well as the possibility of plastic deformation of the material by hot extrusion and rolling to produce round or square bars, or a strip up to 1 mm thick. In the annealed condition (hardness HRC 38-40) from carbide steel it is possible to manufacture tools of any complex shape, the material is welded to steel by friction and electric welding.
After quenching and tempering, carbide steel acquires hardness at the level of hard alloys HRA 86-89. At the same time, carbide steel surpasses hard alloys in bending strength by 1.5 times (220-240 kgf / mm2), in toughness by 2-4 times (100-140 kJ / m2). When tested under production conditions, the tool life of carbide steel is superior to high speed steels by 2-5 times, die steels are 3-10 times. In some applications, for example, cutters of coal combines, drill bits for soil, broach, deforming firmware, mills when machining titanium or high-temperature alloys, the resistance of carbide steel reaches the level of hard alloys.
Carbidestal has a low coefficient of friction, has the effect of self-lubricity, resists sticking, enveloping, which is crucial in the processing of non-ferrous metals, stainless steels; minor changes in the dimensions of the products during heat treatment.
The material is lighter than hard alloys by 2 times (7.1 g/cm3), respectively, at equal costs it is possible to buy twice as many tools.
Material assignment
- In tool making: end, disk, gear-cutting cutters, taps, countersinks, drills, broaches, etc., tools of the second order and other complex shapes; heading, exhaust and separation dies of cold and hot stamping; rolling tools, gauges, support plates, center, etc.
- In metallurgical production: dies and mandrels for cold and hot profile deformation and pipes, drawing and calibration dies, piercing needles in pipe production, rolls of small section and cold rolling mills, isothermal stamping and pressing dies of metal and ceramic powders, casting molds, circular knives.
- In other areas: inserts for drilling tools, cutting coal, shallow soil, chalk, stone, etc .; tools for processing wood, boards, cutting paper, cardboard, fabrics, plastics; wear-resistant parts of plows; rotating face seals, other wear-resistant parts of machines operating in abrasive conditions, dusty or corrosive environments, sea water.
Work on development of compositions and technologies for production of carbide steel was carried out in the Ukrainian Research Institute of Special Steels, Alloys and Ferroalloys (UkrNII Ispecstal) of 1980s and 1990s. Production of material was carried out on the experimental site of the Institute in the amount of up to 1 ton per year.
Carbidestal was used for carrying out stochastic tests of various tools at the engineering plants of the Union, including at the plants of the Ministry of Medium Machine Building, in the metallurgical, aviation, automobile, mining industries, at sectoral institutes including. in VNII instrument, Moscow.
In Ukraine, the tests were carried out at SE “PA Yuzhny Machine-Building Plant named after A. Makarov”;SE Ivchenko-Progress; NIKOPOL TUBE SOUTH PLANT, PUBJSC;STATE PLANT OF POWDER METALLURGY, DP;DONBASANTRATSYT, DP;Dneprotyazhmash, PJSC (formerly Dnepropetrovsk Metallurgical Equipment Works);V. Bakul Institute for Superhard Materials.
About 30 types of various tools were tested in 25 organizations. According to the test results, 20 test reports were issued. The feasibility of the production of the material is confirmed by applications for the supply of carbide steel received from 40 enterprises of the Union, incl. from 7 enterprises in Ukraine.
17 author’s certificates were obtained for carbide steel and its manufacturing technology. The technical conditions for the supply of material TU 3-483-87 Minsredmash have been developed and approved.
Currently, similar materials are produced in Germany by the company DEUTCHE EDELSTAHLWERKE GMBH under the trademark Ferro-Titanit. Company produces 8 compositions, incl. with a working temperature of 400-600 °C carbide steel. In America, the concern PSM Industries Inc, a division of Ferro-Tic SBC, produces material under the trademark Ferro-Tic. At present, 10 compositions are being produced, including those with a tool working temperature of 980 o C.
The developed carbide steel surpasses foreign analogues in its properties. First of all, carbide steel, unlike foreign ones, can work as a sharp-cutting cutting tool. None of the well-known brands is designed for cutting tools. In addition, with equal hardness with foreign analogues (HRA 86-89), deformed carbide steel in strength and toughness exceeds foreign analogues by 2-4 times.
In 1994, LLC IZPM, together with the Dneprovsky Branch of the UANNP, Dnepropetrovsk, began the construction of industrial production of carbide steel in a volume of 100 tons per year. Space was leased at the ‘Spetszhelezobeton plant’ in Zaporozhzhia, a technological assignment (TLZ), a feasibility study (TEO) were developed, and the project “Pre-design study” was completed. A loan in the amount of 60 million rubles was issued at the employment center to create 65 jobs. The inflation in 1995 did not allow the project to be implemented.
The production of carbide steel is carried out by powder metallurgy methods including the operations of grinding, mixing, recovery, pressing, sintering. Tool making from carbide steel of any shape is carried out with conventional cutting tools at lower cutting speeds. Heat treatment tools are made in salt baths, vacuum furnaces.
Organization of production is proposed to carry out in two stages. At the first stage, the task is to develop production technology in new conditions, the development of new material in industry; portfolio formation. Part of the pressing operations is planned for the cooperation. At this stage, it is advisable to supply carbide steel in the form of a finished tool in the hardened state.
Initial costs are estimated at about 500-750 thousand dollars, the required area of 750 m2, the production volume of 3 tons per year. The estimated cost of carbide steel is 1200 UAH. for 1 kg.
At the second stage, the expansion of the assortment of blanks is envisaged for the production of lengthy, as well as large-sized tools with an increase in production to 25-50 tons per year.
The cost of equipment for large-scale production is estimated at about $ 5 million.
The cost of equipment for large-scale production is estimated at about $ 5 million.
Chief of Work on Carbide Steel from 1973 to 1994, Leading Researcher of the State enterprise Ukrainian Research Institute Special Steels, Alloys and Ferroalloys ( "USSI" GP), metallurgical engineer; Director of LLC "IZPM" Bokiy Yuriy. tel. +38 (067) 611-04-60, Viber, WhatsApp Skype: izpm-zp1