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Advanced Ceramics Excel in High-Speed Metalforming Tools

By Cris DiRuggiero, Senior Product Manager, Norton Advanced Ceramics (a division of
Saint-Gobain Industrial Ceramics), Colorado Springs, CO.

Although traditional ceramics are known for being brittle in nature and for their uses in our everyday lives, newly developed advanced ceramics with engineered microstructures are proving to be very useful in the precision metalforming industry.

and design for each application. Finally, the benefits of advanced ceramic tooling will be demonstrated through specific case studies where significant increases in tooling life have been obtained.

What are Advanced Ceramic Materials?

Ceramics is a general term used to describe broad classes of materialssimilar to the word metals. Ceramics differ from metals primarily in their atomic bonding. Unlike metallic bonding in metals, the bonding mechanisms in ceramic materials are ionic and covalent. Examples of different types of ceramics include oxides (e.g., aluminum oxide), nitrides (e.g., silicon nitride) and carbides (e.g., silicon carbide). These classes are analogous to families of metals such as titanium, aluminum or steel. Ceramics may consist of single or multiple phases. Their chemistries and microstructures can vary greatly. Alloy manipulation in ceramic materials results in principle subfamily classifications. Material processing methods also can impact end-product properties. Ceramics are diverse materials and a variety of properties can be obtained based upon the materials selected. Unlike traditional ceramics, which are porous and brittle, advanced ceramics are characterized
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dvanced ceramic tooling components (punches and dies), are replacing traditional tungsten carbide (WC) materials in precision, high-speed metal stamping and forming of lead frames and connectors. Extremely low wear rates (up to 1700 percent increases in tooling life), and reduced metal pickup and scrap are benefits that are driving significant cost reduction. This article will examine advanced ceramic materials and compare their properties to traditional materials in use today. Knowledge of the available materials, key properties and grinding techniques are essential to take full advantage of ceramic tooling. Such knowledge will allow the tooling manager or engineer to specify the proper material

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by high strength, high fracture toughness, fine grain size and little or no porosity. They often are used in high-wear or corrosive environments. Following is a brief overview of advanced ceramics used in precision, high-speed metal stamping and forming applications. ry TTZ alloys existmagnesia partially stabilized zirconia (Mg-PSZ) and yttria tetragonal zirconia polycrystalline (Y-TZP). Transformation toughening is a mechanism that resists crack propagation and enhances toughness. Consider a flaw in a Mg-PSZ or YTZP ceramic component. The stress field at the crack tip causes the transformation of tetragonal grains to monoclinic in the vicinity of the tip. The transformation is accompanied by a local increase in volume of transformed grains placing them in compression. This compressive stress acts to shield the crack from an applied stress and thereby resist propagation. The higher the fracture toughness value, denoted as KIC, the greater the materials resistance to crack propagation1. Although both Mg-PSZ and YTZP possess similar toughening mechanisms, differences in their microstructures exist. In contrast to Mg-PSZ, Y-TZP ceramic materials can be produced with virtually no porosity through post-sintering pressure densification techniques. As a result, high flexural strengths approaching tungsten carbide are achieved. Although Mg-PSZ has a slightly higher fracture toughness than Y-TZP, the latter materials have much higher flexural strengthsa key property when producing 0.006 -in. to 0.012-in. thick punches, for example. As the case studies will demonstrate, a zirconia alloy, ZMAT 250, has been found to greatly extend tooling life in precision, high-speed stamping and forming.

Table ITypical Properties for Advanced Ceramics Compared with Traditional Materials
Property Zirconia Z-Mat 250 ZrO2 Zirconia MG-PSZ ZrO2 Alumina/ Zirconia ZTA (Al2O3/ZrO2) 4.82 Silicon Nitride EDMable Si3N4/TiN 3.98 High Speed Steel M4 Tungsten Carbide WC-15% CO 8 14.0

Aluminum Oxide (Alumina, Al2O3)

Alumina ceramics are the most common materials used for industrial applications. They are characterized by extreme hardness and abrasion resistance. Most alumina compositions have a coarse, porous microstructure. Although high purity alumina grades are available and can be produced with engineered microstructures suitable for metal forming, they still are relatively brittle. Two successful methods have been developed to strengthen their microstructurezirconia toughening and whisker reinforcement. Although various reinforced alumina ceramics are successful in metalforming applications (such as drawing and forming), they are not effective materials for punches and dies because of their poor mechanical properties. Therefore, we will focus predominately on the most successful advanced ceramic used for punches and dies: Z-MAT 250 (zirconium oxide).

Density (g/cm3) Flexural Strength (MPa) RT Compressive Strength (MPa) RT Youngs Modulus (GPa) Hardness, HV 10Kg (GPa) Fracture Toughness (Mpam0.5) Thermal Exp. Coeff. (x10-6/C Thermal Conductivity (W/m-K) at 25C Corrosion Resistance

6.07

5.83

2000

650

1200

950

5100

3450

3500

3500

>2000

2500

N/A

4485

220

200

295

280

214

560

13

10.7

16

15

13

Fig. 1This scanning electron microscope (SEM) photograph shows the grain structure of Z-MAT 250 ceramic material.

10

5.1

N/A

16

10

10

5.7

11.5

12

28

N/A

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Zirconium Oxide (Zirconia, ZrO2)

Although it was discovered in the mid-to-late 1970s, transformation toughened zirconia (TTZ), first gained commercial acceptance in the mid-1980s. In the 1990s, improved processing and cost reduction techniques continued the commercialization success of TTZ. These materials represent perhaps the most significant innovations in modern ceramic technology. Their properties (high strength and toughness) are reviewed in Table I. Two prima50

Excellent

Excellent

Excellent

Excellent

Poor

Moderate

The values quoted should be used only for guidance as typical results obtained from test pieces and published literature.

Electrically Conductive Ceramics (EDMable)

Virtually any electrically insulative ceramic material can be made electrically conductive if enough conductive phase is added to its composition. Oxides and nitrides containing electrically conductive phases are available and permit elecFebruary 2000/MetalForming

Fig. 2SEM photograph of 15 percent Co WC(2). Dark areas represent the cobalt binder phase, which is not homogenous throughout the matrix.
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trical discharge machining (EDM). One commercial EDMable ceramic is composed of silicon nitride (Si3N4) doped with 50 percent titanium nitride (TiN). This material is predominately used in applications such as drawing, ironing, powder compaction, and hot and cold extrusion. Although electrically conductive
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oxide-based ceramics have been used for punches and dies, grain pullout during electrical discharge machining creates unsuitable surface finishes for some applications. Determining the correct EDM parameters to meet stringent surface finish requirements is challenging and has been found to be a stumbling
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block for the tool and die maker. When doping a single-phase ceramic material with a conductive secondary phase, its microstructure and mechanical properties are compromised. A two-phase material has the potential to be nonhomogeneous and typically contains porosity. Strength and fracture toughness usually is lower when compared to a single-phase ceramic materials. To promote high strength and excellent wear resistance, a fine grain, single-phase microstructure is required. Fig. 1 depicts a SEM (scanning electron microscope) photograph of Z-MAT 250 ceramic. Note the absence of porosity. The average grain size is less than one micron. This is a good example of a microstructure suitable for precision, highspeed metal stamping and forming. EDMable ceramics certainly are convenient from a processing standpoint. However, one must consider the trade-offs in tooling performance. In place of EDM (tungsten carbide for example), die sections made from an electrically insulative ceramic (Z-MAT 250 for example) must be split and ground. Ceramic die sections are held in place via drilled and tapped soft plugs epoxied into preformed holes. By substituting split and ground ceramic die sections in place of EDMed carbide dies, tool life is greatly extended (reference Case Study 1). different. Even if the chemistries of two ceramic materials are similar, their properties and performance in the field often will vary due to different powder processing, forming, densification and grinding techniques. It often is difficult to compare the properties of two similar ceramic materials with their brochures. Ultimately, the best way to evaluate a ceramic material is through a field trial. Table I lists typical properties for advanced ceramics compared to traditional materials. terial purity, grain size, porosity and precision finishing techniques control surface finish. However, a twophase material, tungsten carbide for example, is susceptible to metal pick-up, even with a high surface finish, for two reasons: 1) the metallic binder phase (typically cobalt) has an affinity for other metals and 2) cobalt depletion occurs during EDMing.

Cobalt Depletion
Most ceramics are inert and electrically insulative. In contrast to tungsten carbide, the absence of a metallic binder system in singlephase oxide ceramics eliminates the possibility of wear due to cobalt depletion. Fig. 2 represents a recent SEM photograph of a typical carbide grade used for punches and dies. Dark areas represent the cobalt binder phase, which is not homogenous throughout the matrix. Cobalt regions act as sites for metal pickup. Low cobalt regions are susceptible to cobalt depletion during EDMing, which leads to increased wear. Cobalt depletion frequently is encountered during electrical discharge machining in which a rough surface finish is createddevoid of cobalt. Exposed carbide grains act as a site for increased wear and metal pickup during precision, high-speed metal stamping and forming. In addition, cobalt-depleted carbide tools can create buring of the strip being stamped, leading to poor part quality. Z-MAT 250 ceramic reduces metal pickup and wear during precision, high-speed metal stamping and forming due to the absence of a metallic binder phase (Fig. 1). In addition, ZMAT 250 ceramic is inert, corrosion resistant and nonwetting when contacting metalsa key to its success.

Grinding Procedures
Grinding techniques can affect the strength and wear resistance of a ceramic material. The amount of damage created during grinding relates to the ceramics microstructure, Punch Assembly

Key Properties for Success

Advanced ceramics within the same class of materials can be quite

Die Plan Die Assembly Fig. 3 bDie and punch assembly schematics of a typical tool in which advanced ceramics have replaced tungsten carbide.

Punch Plan Fig. 3a Die and punch plan schematics of a typical tool in which advanced ceramics have replaced tungsten carbide.
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strength and fracture toughness. Grinding techniques similar to those used with tungsten carbide are being employed to successfully produce precision punches and dies. Tolerances of 0.000025 in. are being achieved. Although wet grinding is preferred, Z-MAT 250 can be ground dry under certain conditions. GrindFebruary 2000/MetalForming

ing procedures, wheel recommendations and small cross-section punch design will not be reviewed in detail but represent key factors to achieve extended tool life.

A New Era Begins: Advanced Ceramics Surface Finish Surface finish is important be- Achieve Breakthrough
cause it affects metal pickup and the materials coefficient of friction. Mawww.metalforming.com

As steels once gave way to tungsten carbide for certain metalform53

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Case Study 1: Precision Stamping, Copper Lead
Item Existing Stamping Parameters Z-Mat Ceramic Tooling Replacement
External punch Internal punch Pierce punch 0.008 in.-0.012 in. cross-sections Z-Mat Ceramic sub-micron

Frame2

Case Study 2: Precision Stamping, Copper Heat Sink3

Item Existing Stamping Parameters Z-Mat Ceramic Tooling Replacement
Internal punch 0.225 in. square up to 0.3 in. x 0.5 in. Z-Mat Ceramic sub-micron

Comments

Comments

Punch Type

External punch Internal punch Pierce punch 0.008 in.-0.012 in. cross-sections WC: 10% - 15% Co sub-micron

Direct replacement Direct replacement Direct replacement Direct replacement

Punch Dimensions Punch Material

No breakage of small cross-section punches due to tight stripper clearances Stripper clearances must be almost metal-metal Direct replacement

Stripper Clearances Die Type

0.0001 in. per side max. Die sections produced via EDM 3-5% of material thickness 0.008 in.-0.012 in. thick copper alloy 194 450 spm 2.5 million strokes between resharpenings

0.0001 in. per side max. Die Sections, split and ground 3-5% of material thickness 0.008 in.-0.012 in. thick copper alloy 194 450 spm 11+ million strokes between resharpenings

Die Clearances Material Stamped Press Speed RESULTS

Direct replacement

Head-to-head evaluation

tain the component in compression. Punches used in precision, highspeed, metal stamping and forming should be designed with tight stripper and die clearancesspecific details will be provided in the case studies. Figs. 3a and 3b (die plan, die assembly, punch plan and punch assembly), represent schematics of a typical tool in which advanced ceramics have replaced tungsten carbide. In addition, Fig. 4 is an example of a tool in which Z-MAT 250 punches and dies have replaced tungsten carbide. Replacing carbide components with an advanced ceramic material in precision stamping dies is not trivial. However, the effort and patience that is exercised brings significant results in extending tool life. The case studies document these breakthrough results.

ramic punches and dies deliver a 400+ percent increase in tooling life between resharpenings. When coining a silver alloy, a 1700 percent increase in tooling life was obtained. Significant cost savings are being realized. It is clear that some advanced ceramic materials are proving to be viable alternatives to tungsten carbide. Z-MAT 250 is becoming widely accepted for the applications described above. Advanced ceramic materials have made a significant breakthrough and will continue to provide significant value and benefits to the precision metalforming industry. MF References: 1. Dr. Ted Lilley, Review of Low Temperature Degradation In YTZPs, Technical Paper 2. SEM Photograph courtesy Dr. Oh-Hun Kwon, Northboro R&D Center, Saint-Gobain Industrial Ceramics. 3, 4, 5. Results made available with permission from end-user.

Punch Type Punch Dimensions Punch Material

Internal punch 0.225 in. square up to 0.3 in. x 0.5 in. WC: 15% Co sub-micron

Direct replacement Direct replacement

No breakage of small cross-section punches due to tight stripper clearances Punches originally broke due to excessive stripper clearances. Half-hard copper

Stripper Clearances

0.0002 in. per side

0.0002 in. per side

Material Stamped Press Speed RESULTS

0.060 in. thick copper alloy 194 and 110 400-450 spm 750,000 strokes between resharpenings

0.060 in. thick copper alloy 194 and 110 400-450 spm 2.25 million strokes between resharpenings

Case Study 3: Forming Silver Alloy Coining4

Ceramic punches and dies are significantly extending tool life. Estimated cost savings from reducing WC tooling rebuilds alone exceed $2 million.

Only ceramic punches have been replaced. WC punches require 0.070 in. stock to be removed during resharpening. Ceramic punches only require 0.035 in. stock to be removed.

The results obtained in Case Study 1 have been duplicated with another company stamping similar products. Ceramic punches as small as 0.006 in. on cross-section are operating successfully at 400 spm. Manufacturing punches below 0.010 in. on cross-section requires special design and grinding procedures. ing applications, today tungsten carbide cannot compete with advanced ceramics for precision, high-speed stamping and forming of lead frames and connectors. In all cases where precision tooling is being used, Z-MAT 250 ceramic is directly replacing tungsten car54

bide punches and dies. Costly guiding systems are not necessary. Ceramics are much stronger in compression versus tension (bending). (See Table I) Therefore, when considering the use of ceramic tooling, every design effort should be made to reduce bending forces and mainwww.metalforming.com

A 0.090-in. thick silver alloy lead is coined onto a copper strip using 15 percent Co WC upper and lower coining stakes. Press speed is 150 spm. Severe metal pickup and wear forced frequent resharpenings and costly downtime. Replacement ceramic lower coining stakes increased punch life between resharpenings from 30,000 strokes to 500,000 strokesalmost a 1700 percent improvement over WC. At 500,000 strokes, the ceramic punches were removed and analyzed. No wear or metal pickup was evident, and the coining surface looked brand new.

About the Author

Cris DiRuggiero graduated from Ohio State University with a B.S. in Ceramic Engineering in 1989. He is a Sr. Product Manager with Norton Advanced Ceramics (a division of Saint-Gobain Industrial Ceramics) in Colorado Springs, CO, and has 10 years experience developing new applications and markets for oxidebased ceramic materials. For further questions, Cris can be reached at: Tel: 719/380-7001; Fax: 719/3805591; e-mail: crisd@nortonmg.com.
February 2000/MetalForming

Ceramic punches originally failed in Case Study 2 due to loose stripper clearances (0.0005 in. per side). Due to the large cross-section of the punches (0.225 in. square), 0.0002 in. stripper clearances per side prevented breakage. The results in Case Study 2 represent ceramic punches against tungsten carbide dies. Based upon Case Study 1 results, an additional 200 percent to 300 percent increase in tool life could be realized in Case Study 2 if ceramic dies were used. The total increase in tooling life between resharpenings then would increase to between 400 and 600 percent. Fig. 4This tool is typical of those using direct replacement advanced ceramic punches and dies. Photograph courtesy of Co-Planer Inc., Rockaway, NJ. (www.co-planar.com)
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Summary
A paradigm shift in the selection of precision stamping tool materials now is taking place. When stamping copper-based alloys, Z-MAT 250 ceMetalForming/February 2000