What is a Ceramic Insert?
Ceramic Inserts are indexable inserts made from Aluminium Oxide Al2O3 or Silicon Nitride Si3N4. They have a hardness of 2,100-2,500 HV (About 40% above carbide), which enables them to machine Hard Steel up to 55 HRC. It can also machine cast iron and nickel-based alloys six times faster compared to coated carbide inserts.
What are Ceramic inserts used for?
- Machine Steel heat treated up to 55 HRC. (Coated carbide inserts cannot machine materials above 45 HRC).
- Machine Cast Iron 6 times faster compared with coated carbide inserts. (~ 2,000 mm/min, 6,50 SFM)
- Machine Nickel-based superalloys seven times faster compared with coated carbide (400 mm/min, 1,300 SFM)
CERAMIC inserts working materials and cutting speeds
|Price per Cutting Edge [USD]||4$||10$||40$||160$|
|Machining Hard Steel||
|Machining Cast Iron||
|Machining Super Alloys||
Main Types of Ceramic Inserts
|Silicon Nitride||Grey||Silicon Nitride (Si3N4)||Used for roughing and finishing applications in grey cast iron.|
|White Ceramics||White||Aluminium Oxide (Al2O3)||Used for roughing and finishing applications in alloyed cast iron.|
|Black Ceramics / Mixed Ceramics / Composite Ceramics||Black||Aluminium Oxide (Al2O3) with Titanium||Finishing applications on Hard Steel and Cast Iron|
|Sialon||Grey||α and β SiAlON||Used for turning Nickel-Based alloys at very high cutting Speeds. Provide slightly lower performance when compared to Whiskers but at a much lower price|
|Whiskers||Green||silicon carbide whiskers (SiCw)||Exterme toghness. Used for turning Nickel-Based alloys at very high cutting Speeds|
Machining Nickel-based superalloys with Ceramic Inserts
Machining Nickel-Based Superalloys is the most popular application for Ceramic inserts because it enables machining these difficult-to-cut materials 5-7 times faster than with the best suitable carbide grades. For example, Inconel 718 is cut at 40 mm/min (130 SFM) with suitable carbide grades. Can be machine at 400 mm/min (1,300 SFM) with Ceramic inserts. Manu typical parts from this material are vast in size, and it can take many hours to machine a single part. In such cases, the higher price of the inserts is negligible compared to the money saved on machining time.
Best machined with Sialon Grades.
- Lower price when compared with CBN.
- High hardness level.
- High wear resistance.
- Low thermal conductivity
- Very good stability in high temperatures
- Very high cutting speeds
- Higher price compared with carbide.
- Low toughness.
- Problematic for interrupted cuts.
Machining Cast Iron with Ceramic inserts
Machining Hard Steel with Ceramic Inserts
The more common and also technically superior solution to machine hard steel is with CBN inserts. They can work on harder materials at higher cutting speeds and produce a superior surface finish. The major drawback is their very high price. Ceramic inserts fall in the middle between coated carbide and CBN in both price and performance and are the preferred option to machine hard steel in the range of 45-55 HRC.
Best machined with Black (composite) Grades.