A new β-SiAlON ceramic tool prepared by microwave sintering and its cutting performance in high-speed dry machining Inconel718

A new β-SiAlON ceramic tool with satisfactory cutting performance was prepared by microwave sintering. Effects of sintering additives and sintering process on mechanical properties and microstructure of the β-SiAlON ceramic tool were studied. Cutting performance of the tool was evaluated by high-speed milling Inconel718. The β-SiAlON ceramic tool with 5 wt% Y2O3 + 0.5 wt% Yb2O3 sintering additives possessed the homogeneous microstructure and best mechanical properties, but the transformation of plate-like grain to columnar grain was restrained as the content of Yb2O3 exceeded 1 wt%. The β-SiAlON ceramic tool was prepared at 1600 °C with the holding time of 5 min. Compared with conventional sintering technologies, the holding time was reduced by more than 90%. The highest material removal volume was obtained at vc = 800 m/min, ap = 1 mm, and fz = 0.05 mm/z, which was 5 times more than that of commercial coated tool. The main failure mechanisms of the tool were adhesive wear and cutting edge fracture.