Horn USA Unveils IG3 and IG6 Carbide Grades: Revolutionizing Machining with TOUGHNESS and Performance

written by​ Bernard Martin

In a significant development that is set to redefine machining standards, Horn USA has announced the launch of its new carbide grades, IG3 and IG6. These introductions signal a major breakthrough in extending tool life in the machining of materials such as stainless steels, titanium alloys, and superalloys, offering unmatched performance and longevity thanks to their unique coating thicknesses and substrate materials.

The IG3 grade is distinguished by its 3-micron coating thickness, a feature denoted by the "3" in its name. Meanwhile, the IG35 insert, which falls under the IG3 grade, designates carbide substrate 5, a MG12 10% cobalt micrograin that Horn designed to be an optimal balance of hardness and toughness for enhanced durability. For more demanding applications, the IG6 grade steps up with a thicker, 6-micron coating, ensuring even greater efficiency and performance longevity.

A pivotal aspect of these new grades is the application of High Power Impulse Magnetron Sputtering (HIPIMS) coating technology. This advanced coating method ensures that the AlTiSiN coating adheres exceptionally well to the tool surface without necessitating hones or edge preparation. The coating adhesion remains consistent even on upsharp inserts.

This breakthrough not only extends tool life significantly but also contributes to a tougher tool capable of withstanding temperatures up to 1100 degrees Celsius and maintaining a Vickers hardness of 1820 (HV10). The AlTiSiN coating, applied using HIPIMS technology, facilitates a lower coefficient of friction and ensures that the heat generated during machining is directed to the chip instead of being absorbed by the insert substrate. This innovative approach allows for higher machining temperatures without compromising the tool's performance.

The enhancements brought by the IG35 variant are particularly noteworthy. Turning tools coated with IG35 have shown a remarkable increase in tool life compared to those using the previous TH3 grade, as evidenced by extensive testing. Although the IG3 grade matches the performance of the TH3 in milling applications in terms of tool life, the introduction of the IG6 grade with its thicker coating has significantly improved tool life in milling operations, without sacrificing the quality of the finish.

These improvements have been achieved while running the surface feet per minute (SFM) of the older TH3 grade, highlighting the substantial advancements in tool life and efficiency.  In some milling applications it was found to increase tool life beyond twice that of TH3, making it a good choice as a drop-in replacement in established processes.  Most engineers seems to feel that higher SFM rates should be able to be attained with the IG6 while still getting great tool life and finish.

The applications for the IG3 and IG6 grades are extensive, covering a wide array of machining tasks from grooving, both internal and external, to more specialized operations such as chamfering, face grooving, and thread machining. This versatility ensures that Horn USA's new carbide grades can meet the diverse needs of the machining industry, setting new benchmarks in performance, efficiency, and tool longevity.

Horn USA's commitment to pushing the boundaries of innovation is evident in the launch of the IG3 and IG6 grades. These new offerings not only cater to the evolving demands of the machining sector but also underscore Horn USA's dedication to enhancing manufacturing efficiency and tool performance.

Operating from Nashville, Tennessee, Horn USA, a subsidiary of the globally renowned Horn Group, continues to lead the way in delivering high-performance cutting tools and solutions. With a steadfast focus on innovation, quality, and customer service, Horn USA is poised to drive the machining industry forward, helping customers achieve unparalleled manufacturing success.

For more details on the IG3 and IG6 grades and other products from Horn USA, interested parties are encouraged contact F&L Technical Sales Inc. today.

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