SBIR Phase I: High Toughness Cermet Tool and Die Materials

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This Small Business Innovation Research Phae I project will create tough, very high strength cermets from alumina, silicon carbide, and titanium carbide ceramics in cobalt and/or nicket matrices, using a new nanoengineered particle manufacturing technique. Ceramic materials such as diamond, titanium carbide, silicon carbide, alumina, and others have superior hardness and wear resistance compared to tool steel and cemented carbide tool and die materials. However, due to poor toughness and relatively poor thermal shock resistance and strenght, the use of these materials on metal cutting and forming applications is limited. Through controlled chemistry and thickness, Phase I will apply interfacial coatings to the ceramic particles to provide superior bonding and load transfer to the particles in the resultant tool material. This is expected to make cermet tools with mechanical properties approaching those of cemented carbides and tool steels, but with wear resistance approaching that of ceramics.Cermet/ceramic tools with higher strength, toughness, and impact resistance will enable the application of high wear resistance ceramics to operations such as milling, roughing, forming, and other fabrication functions requiring impact toughness and strength.