Processing Brittle Metals
Brittle metals are among the hardest metals to process due to their physical properties and tendency to fracture easily when subjected to stress. Most of the brittle metals used in manufacturing are classified as refractory materials. Refractory materials are heat-resistant and have extremely high melting points, meaning they require high temperatures to achieve the desired properties.
The primary challenge in working with brittle metals is controlling cracks and preventing fractures from occurring during the working process. To minimize this risk, several strategies are employed in manufacturing processes. The use of a lower temperature for the machining process helps to reduce the risk. The use of special additives can provide further protection from fractures by promoting adhesion between the metal and the tooling material. In some cases, a mechanical lubricant between the machining tool and the brittle metal can provide a cushion and reduce the likelihood of fractures.
In order to ensure that a product is free of fractures, other testing methods may be necessary. Visual inspection can reveal surface or subsurface fractures, while x-ray radiography or ultrasound can detect hidden cracks.
Given the risk of fracture and the inherent difficulty of processing brittle metals, extreme caution must be taken in handling these materials. Protective equipment and safety glasses should be worn to prevent eye injuries, while proper ventilation and air filtration should be provided in the work area.
Lastly, machinists should adhere to proper machining techniques and tool maintenance. Careful monitoring and frequent adjustments of the cutting speed are necessary to ensure the safe and effective operation of the machinery. In addition, frequent tool changes can help to prevent burrs and chips that can cause fractures during machining.
By understanding the challenges of working with brittle metals, taking the necessary precautions, and utilizing the right techniques and tools, manufacturers can ensure that their operations run as safely and efficiently as possible.
