Technology assessment for CVD-diamond-coated cutting tool inserts

Journal Article · Sat Dec 31 23:00:00 EST 1988 · Materials and Society; (United States)

OSTI ID:5332201

Walton, K R; Dismukes, J P ^[1]; Krueger, R A; Field, III, F R; Clark, J P ^[2]

---

1. Exxon Research and Engineering Co., Annandale, NJ (United States)
2. Massachusetts Inst. of Tech., Cambridge (United States)

This study assesses the potential for manufacturing diamond-coated, cutting tool inserts by plasma-enhanced chemical vapor deposition (PA-CVD), an emerging technology expected to compete with the static, high-pressure sintering method presently used for the commercial production of polycrystalline diamond composite (PDC) coatings on tool inserts. Using a 4-step manufacturing model based upon microwave PA-CVD for diamond growth, insert manufacturing costs were estimated for three technology scenarios, representing the present (1988, 1st generation) near-term (1990-1999, 2nd generation), and possible long-term (2,000+, 3rd generation) development of diamond PA-CVD technology. Model calculations were then analyzed to provide research guidance on insert manufacturing characteristics, insert performance, and insert life required for the development of markets for thin (1-25 micron) and thick (500-1,000 micron) CVD-diamond-coated inserts. Analysis shows that present technology requires a prohibitively large investment in multiple reactors to grow thin-diamond-coated inserts in commercial quantities. However, technology now under development shows promise for the economical manufacture of thin-diamond-coated inserts, provided tough, adherent coatings can be achieved at high yield. The US market for thin-diamond-coated WC-Co inserts could approach 2M inserts ($25M) by the year 2000. Thick, CVD-diamond-coated inserts (500-1,000 microns), necessary for the most demanding cutting applications, will require development of new technology to be competitive with sintered PDC inserts.

• OSTI ID: 5332201
• Journal Information: Materials and Society; (United States), Journal Name: Materials and Society; (United States) Vol. 13:3; ISSN 0146-6399; ISSN MSOCD
• Country of Publication: United States
• Language: English

Related Subjects

36 MATERIALS SCIENCE
360601* -- Other Materials-- Preparation & Manufacture
42 ENGINEERING
422000 -- Engineering-- Mining & Underground Engineering-- (1980-)
ALKANES
CARBIDES
CARBON
CARBON COMPOUNDS
CHEMICAL COATING
CHEMICAL VAPOR DEPOSITION
COATINGS
COBALT
COST
CUTTING TOOLS
DATA
DEPOSITION
DIAMONDS
DIMENSIONS
ECONOMIC ANALYSIS
ECONOMICS
ELEMENTAL MINERALS
ELEMENTS
FABRICATION
HYDROCARBONS
INFORMATION
MANUFACTURING
MARKET
MATHEMATICAL MODELS
METALS
METHANE
MINERALS
NONMETALS
ORGANIC COMPOUNDS
PERFORMANCE
PLASMA ARC SPRAYING
REFRACTORY METAL COMPOUNDS
SENSITIVITY ANALYSIS
SERVICE LIFE
SINTERING
SPRAY COATING
SURFACE COATING
TECHNOLOGY ASSESSMENT
THICKNESS
TOOLS
TRANSITION ELEMENT COMPOUNDS
TRANSITION ELEMENTS
TUNGSTEN CARBIDES
TUNGSTEN COMPOUNDS
VAPOR DEPOSITED COATINGS