EMT100: The Carbide Substrate

Enhanced rigidity, purity & consistency make EMT100 the ideal substrate for PCD carrying AND diamond coating!

Weight reduction is an integral key to increasing aircraft operational efficiencies. Where aluminum alloys were still widely used as a base material 20 years ago, a whole new range of materials, from titanium alloys to complicated composite stacks, are finding their way into the new era of flight. Aircraft developers set the highest goals for themselves in all facets of manufacturing. It is now possible to build aircraft which operate over 15% more efficiently compared to other modern passenger jets from the 1990s. Extensive use of advanced materials such as fiber-reinforced plastics and composite stacks make it possible to achieve this goal. Accordingly, with every advance in structural materials so too requires an advance in machine tools and consumables.

The Challenge

An optimum hole can be achieved easily in individual materials with a suitable carbide grade. Boring into composite materials is much more difficult, because the properties of the various materials differ greatly. Burr formation must be prevented when drilling a titanium layer, because burr removal is not possible for structural reasons; as it would adversely affect the accuracy and integrity of the construct. A controlled, rounded edge is ideal for titanium machining. However, in order to avoid delamination, sharp edges are required to drill the carbon-fiber-reinforced layer. These contrasting properties require a tool geometry specifically designed for the overall work-piece. The carbide substrate is the foundation for any such tool whether coated, uncoated or acting as a PCD carrier.

EMT 100 Form Blank

The Solution

Step 1: Carbide Grade Selection

Traditionally, RAMET (the original C2 10% micro-grain carbide) was the top choice substrate due to its wide range of machining applications. Today, knowledgeable engineers and machinists demand EXTRA attention be paid to application specific tooling. EXTRAMET recognizes and embraces the fact that every application, every work-piece, and every scenario dictates optimal grade selection. And that selection process always requires a little something more than a general purpose “solid, C2 10% micro-grain”.

The Bottom Line!

The aircraft industry exemplifies the advantages of transparent coordination between Extramet, the tool manufacturer, the coater, and the end user to achieve significant improvements in the machining of any work-piece.