Kennametal introduces KCS10B for superalloy applications

27th Aug 2020, 09:03 • In Products

Kennametal has introduced its newest and most advanced turning grade, KCS10B, for nickel, cobalt and iron-based superalloys used in aerospace and other high temperature applications.

KCS10B, which features an innovative coating applied to an ultra-fine grain carbide substrate for superior layer adhesion, delivers up to 50% greater tool life, more predictable processes, and improved productivity when working with difficult to machine superalloys.

KCS10B overcomes the most common challenges encountered in turning superalloys—cratering and depth-of-cut notching—two wear modes that often lead to unexpected and even catastrophic tool failure.

Inconel 718 (NiCr19FeNbMo DIN), 36-39 HRC, continuous cut, flood coolant. Cutting conditions: 61m/minute; 0.25mm/rpm; 1.5mm DOC. Depth-of-cut notching and crater wear are far more manageable thanks to the super smooth coating and special edge-prep of inserts coated with KCS10B

Special Sputtering

Robert Keilmann, senior global product manager for turning, explains that the secret behind the success of KCS10B is Kennametal’s proprietary High-Power Impulse Magnetron Sputtering (High-PIMS) technology: “Rather than the light rain of droplets that fall on cutting tools during traditional PVD coating processes, High-PIMS generates a fine mist of AlTiN, building a series of extremely thin, smooth, and wear-resistant layers,” he explains.

Beating wear

Metals such as Inconel 718 and Stellite 31 are notorious for causing rapid wear and unpredictable tool life, KCS10B is proven to reduce DOC (depth of cut) notching and extend tool life from three minutes to upwards of five minutes in roughing operations. Tool life in finishing operations fares even better, with visible cratering and subsequent tool failure often delayed by a factor of two or three compared to competitive brands.

Inconel 718 (NiCr 19 FeNbMo DIN), 36-39 HRC, continuous cut, flood coolant. Cutting conditions: 91m/minute; 0.15mm/rpm; 0.25mm DOC

Positive and negative rake inserts are available, as well as various chip formers, edge preparations, and geometries, making KCS10B the ideal solution when turning iron-based (S1), cobalt-based (S2), or nickel-based (S3) alloys.

“Aside from a smoother surface, the new coating process also allows us to create a much sharper edge,” Mr Keilmann says. “Our advanced honing and edge-preparation process reduces the friction that leads to heat, which further improves tool life. It also means less built-up edge, another common failure mode in super alloy materials.

“When coupled with the excellent dimensional accuracy that Kennametal turning inserts are known for, shops can now expect the increased performance, stability, and predictability needed to be successful with these challenging alloys.”

Kennametal www.kennametal.com

Author

Michael Tyrrell

Company

Kennametal