(2) Ultra-fine grains and nanoscale cermets. In recent years, long-term production experience and the latest research have found that in the composition of cermets, when the bonding phase remains unchanged, the key factor that determines its mechanical properties is mainly the grain size of the hard phase in the material. Because ultra-fine grained and nano-sized cermets have higher comprehensive properties such as strength, toughness, hardness, and wear resistance than conventional cermets, they have been favored by major industrial countries in the world (the United States, Switzerland, Japan, Germany, Britain, Russia, etc.) ), many scientific workers are researching and developing this new type of cermet with great enthusiasm.

Cermet refers to a composite material composed of one or several ceramic phases and a metal phase or alloy. The broad sense of cermets also includes refractory compound alloys, cemented carbide, and metal-bonded diamond tool materials. The ceramic phase in cermets is an oxide or refractory compound with high melting point and high hardness. The metal phase is mainly transition elements (iron, cobalt, nickel, chromium, tungsten, molybdenum, etc.) and their alloys.

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The basic concept of tolerance stacks is simple addition and subtraction. With each stack you ask: will the variability I naturally get from part to part in my assembly lead to malfunctions of my design?

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At this point you might be wondering what the numbers inside the chart mean. These are ‘influencers’ and if you were doing a CETOL or vis-vsa analysis, those 3D tolerance stack softwares will tell you by % which dimensions are driving your result. If you use these tools and see something in the box that is equal or greater than 30% in our example, that’s an immediate critical dimension! Once again, your goal is to try to eliminate this issue with engineering drawing controls or a design change.

As we go through the examples, I recommend downloading this free tolerance stack calculation workbook, which will enable you to calculate your own tolerance stacks.

Oh hey — I caught your attention! Guessing it was the 5-oh-one in the title, up from the 101 you might already be familiar with (self high five for engineer David trying to be a marketer).

The graphite-metal composite material used to make electrical contacts can be used for: metal contacts of electric motors and engines, whose metal phase is copper or bronze; sliding contacts under low friction speed and low contact pressure. Head, the metal phase is silver. In addition, these materials are widely used in the manufacture of brake linings and clutch linings. Cermets consisting of diamonds ranging from coarse fragments to fine powders are added to a metal matrix to create grinding, polishing, sawing, cutting, dressing and shaping tools.

Researchers from Japan’s Toyo Kohon Company found that FeB-Mo-based alloys can not only improve their wear resistance and corrosion resistance, this cermet uses a method called “boration reaction sintering” prepared by the method. Ternary boride as a hard phase is formed during the sintering process, which is significantly different from ordinary cermet production processes.

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Ok, now that I’ve explained what Cpk is and how it helps predict the stability of your design, the next level thought process is… why? You are doing the tolerance stack—great—but why are you doing it in the first place?

Step one here is to do a tolerance stack as a root cause; the phenomena has been seen that the canister jams/gets stuck or is hard to translate.

Zhang Xinghong and others prepared TiC-16.8Ni-4.2Mo-based cermets through self-propagating high-temperature synthesis combined with quasi-hot isostatic pressing (SHS/PHIP), studied their mechanical properties, and Its microstructure was analyzed. The study found that the microstructure of the cermet is composed of TiC particles and Ni solid solution. The TiC particles are connected together to form a skeleton-like structure, and the Ni phase is discontinuously distributed in the skeleton. The interface between TiC phase and Ni phase has good wettability, and there are a large number of dislocations near the interface and inside the bonding phase. The mechanical properties of materials prepared under two pressures (90MPa and 160MPa) were also studied, and it was found that under 160MPa pressure, the strength of the material was very close to K138A with similar composition produced by traditional methods.

In the example, we’re going to talk about RSS (Root Sum Squared) tolerance stacks, because pretty much every engineer has access to a spreadsheet.

Careful study of the properties of borides began after the late 1980s. Studies have shown that metal borides have high thermal conductivity and high temperature stability. The mechanical properties of TiB_2 exceed all other ceramic materials (diamond, cubic boron nitride, carbides, carbonitrides) when the temperature exceeds 1100°C. Boride-based cermets are used under conditions that require very high heat and corrosion resistance, such as in contact with active hot gases and molten metals. The main metals that can be used to bond boride are Fe, Ni, Co, Cr, Mo, B or their alloys.

Based on the types of main non-metallic phases in cermets, cermets can be divided into five types: oxide-based, carbide-based, carbonitride-based, boride-based and containing graphite or diamond-like carbon of cermets.

WC-based cermets are the most studied and widely used type of cermets among carbide-based cermets. So far, the best structural combination and classical example of interatomic interaction that can ensure high mechanical properties of materials is still WC-Co-based cermets. Because the structural parameters of their phase components at 20°C are close, and the high-temperature transformation of Co is from a face-centered cubic lattice to a hexagonal lattice through the twinning method. This transition is initiated by the low energy of the Co alignment defects, resulting in strong dislocation splitting within Co, thus ensuring a high yield limit.

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Here’s some example CAD to help us start to break down the tolerance stack process: a linear rail from  GrabCad. So let’s pretend we need to do tolerance stacks for this assembly — where do we start (and remember this is more about a process to yield repeatable results for you as a design engineer)?

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Among carbide-based cermets, in addition to WC, TiC-based cermets are also well researched and widely used. The metals or alloys that can be used as the metallic phase include: Ni, Ni-Mo, Ni-Mo-Al, Ni-Cr, Ni-Co-Cr, etc. TiC-Co, TiC-Ni, TiC-Cr and other cermets can be made into high-temperature bearings, cutting tools, measuring tools, gauge blocks, etc. Since the melting point of TiC ceramics (3250℃) is higher than that of WC (2630℃), it has good wear resistance, its density is only 1/3 of WC, its oxidation resistance is much better than that of WC, and it can be wetted by Co, it can be used to replace the current WC-Co-based cermets are widely used in the cutting tool industry to greatly reduce costs, thus arousing great interest. Research on TiC-based cermets has achieved great success, such as the WZ series produced by the Austrian Metallwerk Plansee company, the HR series produced by the British Hard Metal Tools company, the K series produced by the American Kennametal company, and the FS series produced by the American Firth Sterling company. is a successful example.

Welcome to my article (TED talk?). Here I’m going to walk you through the flow of how to set up tolerance stacks, why you do tolerance stacks in the first place, and most importantly, how you determine you are done with the tolerance stack.

This is beyond just: 1) will my parts fit/go together 2) will it perform 3) Can steps (1) and (2) be done repeatedly. When most people talk about tolerance stacks they are likely addressing only one of these steps, but all three is where you need to get to!

Ti(C, N)-based cermets are developed on the basis of TiC-based cermets and have high hardness, high strength, excellent high temperature and wear resistance, good toughness and low density. , new cermets with high thermal conductivity. Its main component is TiC-TiN, with Co-Ni as binder and other carbides as additives, such as WC, Mo C, (Ta, Nb)C, Cr3C2, VC, etc. The physical and mechanical properties of Ti(C,N)-based cermets can be adjusted within a certain range. Due to the addition of various carbide additives and the use of Co-Ni as a binder, the comprehensive properties of cermets are greatly improved. Adding a certain amount of high melting point TaC and NbC can improve the plastic deformation resistance of the alloy, and VC can increase the shear strength of the alloy and improve the mechanical properties of the alloy. Mo C can improve the strength of Co-Ni binder and play a connecting role between carbides, nitrides and binders. Under the same cutting conditions, the wear resistance of Ti(C,N)-based cermet tools is much higher than that of WC-based and coated cermets. At high speed, the wear resistance of Ti (C, N)-based cermets is 5 to 8 times higher than that of YT14 and YT15 alloys, 0.3 to 1.3 times higher than that of YC10 alloy, and 0.5 times higher than that of coated cermets. ~3 times.

The product has been having difficulty sliding a fluid canister into the device. See GIF and zoomed in image of cap below.

From the results we can see that the lower spec limit is being calculated at 1.58. This isn’t quite what I need to retire the risk.

Cpk tells you the relationship between the size of the car, the size of the garage and how far away from the middle of the garage you parked the car. The value itself can be thought of as the amount the process (car) can widen before hitting the nearest spec limit (garage door edge).

ZrO2Base cermet is another type of ceramic that can be bonded with metal, making it a useful refractory material. ZrO2Based cermets can be made into crucible materials suitable for manufacturing rare and active metals. Use stabilizationZr with a particle size of 2 to 3μ m O2 powder is mixed with -300 mesh metal w powder, formed by any suitable method, pre-sintered in a vacuum at 1000°C, and finally heated at 1780°C under hydrogen protection fired. This material has good wear resistance, high temperature resistance, oxidation resistance and impact resistance, and is a good rocket nozzle material.

(5) Development of basic research The main problem limiting the further development of cermets is that related basic research is relatively lagging behind, and many issues involving the nature of materials have not been resolved. In recent years, relevant research has received attention, and relevant theories have also made great progress. The main research hotspots include: material preparation process mechanism; obtaining materials with specific structures through controlled processes; material structure formation mechanisms; the relationship between preparation process and performance; wettability issues of metals and ceramics; interface structure research, etc. question.

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BeO-based cermets use W as the bonding metal, which has good thermal shock resistance and only softens at higher temperatures. This material can be used to make crucibles. ThO2< made of W or Mo as bonding metal based cermets can be made into many products used in the electronics industry. Composed of Al, stainless steel or w-bonded fissile UO2 Cermets can be used as fuel elements in nuclear reactor cores. This kind of cermet can better suppress fission products and has good thermal conductivity, thus preventing melting when working at high temperatures.

With Cr3C2 is the main component and uses Ni, Ni-Cr or Ni-W as the bonding metal. Cermets have low density, good wear resistance, good corrosion resistance, low thermal expansion coefficient, and high temperature resistance. It has a series of excellent properties such as good oxidation resistance, so it has been applied in tools and chemical industry. It can be used as guide rings for salt water fishing rods, bearings and sealing materials resistant to hot salt water corrosion and wear, block gauges, micrometer joints and other measuring tools, brass extrusion dies, high temperature bearings, valve balls for manufacturing oil well valves, etc. The HRA of this material is 88.3 and the density is 7.0g/cm3, the flexural strength is 779MPa, and the surface only darkens slightly after 5 hours of heat exposure at 982°C.

From this quick breakdown I see at least a few obvious interactions between the top rail and other parts.  You can also use the “exploded view” inside Solidworks. And once again, remember you are just trying to get an understanding of what’s going on with the assembly as a starting point.

You now know what your nominal clearance needs to be to drive your design to be in the “As Low As Possible” zone. You could repeat this for Cpk of 2 (nominal = 0.3162mm) and if it doesn’t introduce another risk, do it. Eliminate it and avoid the ‘why’d you do that?’ shame bell look from your manufacturing team four months from now.

So theoretically if the part was gone, the gap would be infinity but it wouldn’t drag so this is a theoretical solution to the problem. But for this I could have said my USL (upper spec limit) is 5, 1—it doesn’t truly matter as long as it’s greater than 0. So my lower spec limit (LSL) is, well, 0.

In addition to the carbides mentioned above, there are currently found B4C and SiC can be used as the hard phase in carbide-based cermets. For example, B4C-stainless steel, B4C—Al cermet can be made into atomic reactor control rods; SiC—Si—UO_2 cermet can be made into nuclear fuel components etc.

Note: In reality, the top rails and chassis in this example are all off-the-shelf components, so the need to do this would be moot for a CpK analysis. Just treat this as an example!

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You likely did tolerance stack ups in your first Intro to Engineering course homework on a made up assembly that maybe felt kind of pointless because it wasn’t actually an assembly you made and so success = course credit. Now you’re in the real world and a solid tolerance stack can be the difference between success and failure.

As an example, if cars or guns were held to the same standard as medical devices, they would be recalled noting improper usage or inability for a user to control the intended usage of the product to get the desired result of the design.

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Now that I’ve finagled and messed with my tolerances, I can see I’m not quite getting the desired result. So how do I figure out what I need to do? I back calculate my equation to determine what I need:

Using CrB crystal and CrB-based cermet bonded with Cr-Mo alloy with a mass fraction of 0.10, it has good fracture strength and high enough resistance to mechanical vibration, so it can make steam and gas Turbine blades, internal combustion engine valve seats and valve seat rings, and jet engine exhaust nozzles and exhaust pipes. Ni bondedMoB2cermet It has excellent corrosion resistance, such as resistance to corrosion by dilute sulfuric acid. Former Soviet scientist I. P. Borovinskaya and V. I. Ratnikov et al. successfully prepared TiB-Ti-based cermets using the self-propagating combustion synthesis (SHS) pressurization method. The cermet has the characteristics of low density, small grain size, thermal fatigue resistance, corrosion resistance and good process performance.

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In simpler terms, this is the head, shoulders, knees and toes of tolerance stacks. Ask yourself: what’s connected to what?

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Mo2F The eB2-based cermet has high fracture toughness and a thermal expansion coefficient similar to that of steel, while the thermal expansion coefficient of ordinary cermets is half that of steel. . Mo2FeThe wear resistance of B2-based cermets is equivalent to or even better than powder metallurgy high-speed steel and ordinary cermets. With the help of SEM and XRD research, it was found that:Mo2FeB< When2-based cermets are rubbed at high speed, formations such as Mo< are formed on the wear surface.O2, a small amountB2O3‘s low melting point oxides, these oxides can prevent adhesive wear. Ordinary cermets do not form these oxides. In addition, Mo2Fe B2-based cermets have good corrosion resistance in various media such as organic acids, inorganic acids, and alkaline solutions; in molten resin It also shows good corrosion resistance in molten non-ferrous alloys like Zn and Al. Masao Komai and others studied Mo2Ni B2-based cermets were reported in detail and found to have the characteristics of Mo2FeB2Based cermet-based ceramics have similar properties.

Let’s start by looking at the chassis (purple image) and the top rail. If you are doing a tolerance stack, you are attempting to mitigate a risk so take credit for it! Risks are mitigated via a hand calculation, a simulation, or a test (sometimes all three of these, depending on risk).

And news flash: on the first step of this you are just making an educated guess as the engineer. In bigger organizations there is an entire team dedicated to investigate risk levels. But your job as the engineer is to always reduce risk (protect the user, protect the business, protect the product). These things can also be non-safety related too. They can include basic functioning, customer satisfaction, intuitiveness and more.

SinceTiB2Ceramics have some unique physical and chemical properties, such as: extremely high hardness at high temperatures, low density and resistivity, high elastic modulus, good thermal conductivity, low adhesion and friction coefficient with metal, high oxidation resistance, chemical Due to its good stability, it is considered to be a promising hard phase for manufacturing a new generation of cermets. However, due to the low self-diffusion coefficient, TiB2 is greatly affected; in addition, almost all metals used as cermet bonding phases are related toTiB2 both undergo strong chemical reactions that cause cermets to become brittle, so T< The research oniB2-based cermets is progressing slowly. Currently in TiB2 based cermets , the one with more research is TiB2 -Fe、TiB2-FeMo, TiB2-Fe—Cr—N and other cermets. TiB2-FeMo-based cermet and Compared with other cermets, it has good wear resistance, so it can be used as cutting tools, rock drilling tools and wear-resistant parts. However, due to the low strength and high brittleness of this type of material, it is not suitable for use under impact loads.

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The first thing I like to do with a big problem is to break it down into a series of smaller problems, or subsystems. How do you do this? Sometimes there is a super logical method and some days you just pick something and start. Today, we be doin’ it live folks (Lee-Roy Jenkins!) so let’s just jump in.

The 21st century is a century of high technology. The development of high technology has promoted the development of metal-ceramic composite materials. At present, the development of cermets mainly focuses on the following aspects:

My friend Zach from Sonny has allowed me to share some images from his product that’s moving along in development (check out his indiegogo here).

(3) Application and development of gradient cermets. Since some cermet products often have different performance requirements for different working parts when used, it is difficult to meet such working conditions if single materials such as existing heat-resistant metals, ceramics or cermets are used, and the use of ceramic-metal layered structures It will also cause thermal stress concentration at the interface, which requires the development of thermal stress-relieving cermets, that is, gradient cermets. It is a functional composite material whose properties are gradually changed due to continuous changes in the structure. This material can be used as thermal protection material for space shuttles, inner wall materials for nuclear reactors, combustion chamber materials for automobile engines, and gradient blade materials.

All of these levels and definitions can vary company to company and by industry. The next step is to determine how likely this risk is to happen.

Once you’ve set up a simple interaction image you want to lay out which interactions need a tolerance stack by looking at each interaction line. There’s a good chance that there is a tolerance stack in the interaction line. Another good reason to use this method is that it will also help you and your quality engineer from doing duplicate work on your DFMEA (Design Failure Modes Effects Analysis).

Cpk is a statistical measurement that tells you how capable a given process is. You can get into the nitty gritty formulas here on ISIXSIGMA. Whereas a Cpk gives you information about what the process is capable of doing in the future (assuming it remains in a state of statistical control), a Ppk tells you how the process has performed in the past. The reason you can’t use Ppk as a predictive measure is because the process is not in a state of control; Cpk and Ppk values will converge to be almost the same when the process is in statistical control because sigma and the sample standard deviation will be identical (F-test).

TiB2 bonded with Nb-based cermets have also been studied. As the Nb content increases, TiB< The number of2 phases gradually decreases due to the formation of complex diborides (Nb, Zr)B2New phase components. When the Nb content is greater than 20 mol%, it is similar to TiB2At the same time, the phase (Nb, Zr)B with a hardness of 2890HV appears, which is a solid solution of Zr in NbB. At this time, the cermet will be prone to brittle failure.

Another method to break things down is to create interaction maps between your subsystems or parts. If you are new to a technology or team this can be a very good place to start, to help ground you in what’s what and guide you to: “noticed this” or “can you explain why this is like this” — all the observations that get you up to speed on the engineering OCD of “why”?

Other carbides, such as ZrC, HfC, TaC, NbC, etc. Cermets can be made using ductile metals as binders, but these carbides have poor high-temperature oxidation resistance and are very brittle, so they have not been really used.

In this example, I was taking measures from drawings already created (or CAD if not present) and using the tolerance stacks to review if the drawings had all the applicable information. “Orange“ cells in the table were for me to remember that they weren’t on the drawing—meaning the risk is not being managed. The way to manage the risk would be to add to the drawing. Then the risk is being attempted to be controlled.

If the car is a lot smaller than the garage (Six Sigma process), it doesn’t matter if you park it exactly in the middle; it will fit and you have plenty of room on either side.

So I have an engineering issue that has an occurrence rate of “probable” (as it’s been seen in the first 10 devices) and if this failure were to occur in a sold product or on the production line it makes the device useless. So from a product perspective this is “serious.”

Image

The ceramic phase in cermets is usually composed of high melting point oxides (such as Al2O3, Zr O2, BeO, MgO, etc.), carbides (such as TiC, SiC, WC, etc.), borides (such as TiB2, ZrB2, Cr B2, etc.), nitrides (such as TiN, BN, Si3N4, TaN, etc.). Although silicide has a high melting point, it easily reacts with metals, so it is rarely used in cermet formulations. The raw materials used as the metal bonding phase can be composed of various elements, such as Ti, Cr, Ni, Co, Fe, Mo, W, etc., which can be used alone or in combination, or can be other metal materials, such as stainless steel, bronze or high temperature alloy.

In this design you also need to set limits for your Cpk analysis. What’s important to understand when setting the limits is that it is very specific to the direct problem you are trying to solve or the condition you have identified with your arrows. You are looking for a gap and the gap needs to be greater than 0, such that if it were negative the cap would not drag the canister body.

Use B with a mass fraction of 0.02 to 0.05 to bond TiB2’sTiB2Based cermets can be used at extremely high temperatures, including in combustion chambers, rocket engines and jet engine reaction systems. Use SiC and TiB2< with a mass fraction of 0.15 reaction, this consolidated cermet can further strengthenTiB 2 has excellent oxidation resistance and can withstand the oxidizing environment in the range of 1900 to 2500°C. This cermet can be used in systems that handle molten metal, such as the impellers and bearings of pumps used to cast liquid alloys on die-casting machines; nozzles used to atomize metal powders; and furnace parts that come into contact with molten reactive metals or vapors.

(1) Research and development of new materials. The rapid development of industrial technology has put forward higher requirements for cermets. According to different use environments, scientists from various countries are actively engaged in the research and development of new cermet materials, which mainly include three aspects: The hard phase is developing in a diversified direction. , committed to the development of new hard phases and composite hard phases; the types of metals or alloys used as bonding phases are constantly increasing, and resource-rich metals are used to replace resource-scarce metals (such as Fe and Ni instead of Co); phase composition range Gradually broadening, the contents of hard phase and bonding phase continue to break through the range of previous research.

If you have a process that is in control and with little variation, you should be able to park the car easily within the garage and thus meet requirements.

Next we’re going to move into a real world example from a Fictiv customer that needed a tolerance stack to determine root cause for a fit issue.

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In this example, the garage defines the specification limits and the car defines the output of the process. If the car is only a little bit smaller than the garage, you had better park it right in the middle of the garage (center of the specification) if you want to get all of the car in the garage.

(4) The problem of cermet recycling and reuse. In recent years, influenced by the awareness of environmental protection and resource utilization, research on the recycling and reuse of cermets has continued to expand and deepen. However, there are also some problems. For example, the quality of cermet products made from recycled materials in some countries is poor. Therefore, the use of modern technology and large-scale production models to fully utilize resources and unify economic benefits has become an issue that cannot be ignored in the development of cermets.

It’s because you’re likely concerned about something, that is a risk, in engineering terms. One of the first steps is to describe your risk and/or failure mode.  What can go wrong with your design? For example:

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Al2O 3based cermets can be used as cutting tools and are suitable for high-speed cutting. Al2O using Cr as the metal component 3based cermet ratioAl2O3 Ceramics have high mechanical strength, and as the Cr content in the composition increases, the flexural and tensile strengths increase. The effect of using Cr-Mo alloy is better and can be applied under many high temperature conditions. For example, it can be used as jet flame controller, missile nozzle bushing, molten metal flow control needle, “T” gate, furnace tube, flame protection rod, thermocouple protection sleeve and mechanical sealing ring, etc. Al2O3-Fe-based cermets have high hardness, wear resistance, corrosion resistance, and high thermal stability. They are widely used as mechanical seal rings and agricultural submersible pump mechanical seals. In addition, they can also be used as high temperature resistance, thermal conductivity, and electrical conductivity applications. For high temperature parts. The ring has a long service life and does not break due to the large amount of heat generated by temporary activation.

When you do the loops you create your image and you need to remember that you have to pick a direction (in my case for this one, to the left is positive); things that are interference are negative.

Next, create a table as the basis of each tolerance stack “score card.” This will ultimately be a big list of tolerance stacks that could result in some type of risk relative to the design—either function or simple assembly.

So moving to the Cpk chart (table 2), I go over to the “serious” column. Looking at the different colors, I want to be in the green zone “Acceptable” or yellow zone “As Low as Possible”. If you can’t get into these zones it likely means either a design change or some type of inprocess step handed to the manufacturing team to mitigate/control the risk is needed. That’s why anything in the orange or red zones requires an internal team/managerial review or a cross functional team review to keep everyone informed and find a solution.

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Due to the excellent properties of polyboride-based cermets, this material has been used in Japan to make can stamping molds, copper hot extrusion dies, steel wire hot and cold drawing dies, and boilers. Protective parts for heat exchangers, hot forging dies for automobile valves, etc.

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At present, the application of Ti(C,N)-based cermets in the processing field has become a reality. It can be made into various micro indexable inserts, which are used in fine boring and fine hole processing as well as “turning instead of grinding” and other finishing fields, and because Ti (C, N)-based cermets have low density and low friction coefficient , high wear resistance, good acid and alkali corrosion resistance and stable high temperature performance. It can also be used for: high temperature parts of various engines, such as small bearings, impeller root flanges, valves, valve seats, push rods, rocker arms, Eccentric shafts, hot nozzles, piston rings, etc.; it can also be used for various sealing rings and valves in the petrochemical industry. It is also suitable for various measuring tools, such as slip gauges, plug gauges, and ring gauges.

Below I take a cross section for an area of focus and start thinking about what could potentially go wrong or where there are deeper interactions.