Design, optimization, and verification of self‐lubricating ceramic tool microstructure by MC method

Abstract The computer‐aided analysis of microstructure evolution during the sintering process of self‐lubricating ceramic tools can unveil the underlying sintering mechanism and optimize experimental parameters. In this study, a novel self‐lubricating ceramic tool material, Al 2 O 3 /SiC/h‐BN@Al 2 O 3 , was fabricated with Al 2 O 3 as the matrix, SiC as the reinforcement phase, and h‐BN@Al 2 O 3 as the solid lubricant. The Monte Carlo (MC) method was employed to construct a model of self‐lubricating ceramic tool material, consisting of Al 2 O 3 /SiC/h‐BN@Al 2 O 3 . Subsequently, the sintering process was analyzed to investigate the influence of particle size and content of reinforced SiC, as well as the content of coated solid lubricant h‐BN@Al 2 O 3 , sintering pressure, and temperature on the microstructure of the tool. Optimal composition and sintering parameters were determined: 3 vol% for SiC additive amount with a particle size of 0.05 μm; 5 vol% for h‐BN@Al 2 O 3 additive amount; and an optimal sintering temperature at 1650°C. The development of self‐lubricating ceramic tool materials, Al 2 O 3 /SiC/h‐BN@Al 2 O 3 , was realized through the employment of the aforementioned parameters. Their mechanical properties and microstructure were comprehensively characterized. The bending strength, fracture toughness, and Vickers hardness of the experimentally‐prepared Al 2 O 3 /3 vol%SiC/5 vol%h‐BN@Al 2 O 3 self‐lubricating ceramic tool material were determined to be 722.42 MPa, 6.5 MPa·m 1/2 , and 20.65 GPa, respectively.