Greenleaf ® GSN-100

Greenleaf ® GSN-100 GSN to GSN-100 Review of Silicon Nitrides GSN-100 Description Current data and successes Turning Gray Iron Ductile Iron Milling Other applications GSN-100 vs. HSN-100 & 200

Silicon Nitrides Greenleaf ® GSN-100 Developed for Cast Iron Applications Higher thermal shock resistance when compared to Whisker Ceramics Lower high temperature stability compared to Whisker Ceramics Best in interrupted cutting due to high thermal shock resistance Scale Milling

Greenleaf ® GSN-100 An engineered blend of silicon nitride and proprietary toughening agents that redefine productivity in the machining of cast iron. GSN100 delivers outstanding tool life at high cutting speeds in turning, grooving and milling applications.

GSN-100 Test Data

GSN-100 Class 30 Gray Iron Turning

Gray Cast Iron, class 30, 20 R/C Competitor: GC-4187 K40C 2000 SFM (610 M/Min) .004 IPR plunge (0,10 mm/rev) .008 IPR turn (0,20 mm/rev) Greenleaf ® WG-6218-2A SG-0173 4000 SFM (1220 M/Min) .008 IPR plunge (0,20 mm/rev) .012 IPR turn (0,30 mm/rev) 7

Gray Cast Iron, class 30, 20 R/C This customer presently running competitor GC-4187 K40C grade and completing 15 parts per insert with a cycle time of 13.44 minutes. Ran test with WG-6218-2A GSN-100 insert and completed 74 parts per insert Cycle time 11.38 minutes 5X greater tool life SFM is 2X present tool Feed rate is 4X present tool. Inserts ran parts for 3+ days before needing changed.

GSN-100 Class 435 Gray Iron Turning

Round 1 testing The areas of focus for testing were: Tool #1 Back Face and Rough Pilot Area of focus Customer target: 150 parts per edge

Tool #1 - Back Face and Rough Pilot Round 1 testing Tool #1 - Back Face and Rough Pilot Customer target: 150 parts per edge

$240,554 total yearly savings

Round 2 testing The areas of focus for testing were: Tool #3 – Inboard Bottom Face. Tool #6 – Finish Pilot Tool #6 Tool #3 Customer target: 300 parts per edge

Tool #3 – Inboard Bottom Face. Round 2 testing Tool #3 – Inboard Bottom Face. Customer target: 300 parts per edge

$112,970 total yearly savings

Round 2 testing Tool #6 – Finish Pilot. Customer target: 300 parts per edge

$112,970 total yearly savings

GSN-100 Ductile Iron Turning

65-45-12 Ductile Iron, 30 R/C 5X tool life over HSN-100 Prior: Greenleaf WG-6218-2A HSN-100 1350 SFM (412 M/Min) .0065 IPT (0,17 mm/tooth) Machining 15 grooves/insert ® Greenleaf WG-6218-2A GSN-100 1350 SFM (412 M/Min) .0065 IPT (0,17 mm/tooth) Machining 75 grooves/insert ® 5X tool life over HSN-100

GSN-100 Cast Iron Milling

Gray Cast Iron, as cast We are running: Milling Cutter- C404 Insert- CNGN-454 (CNGN120716) Two Nests are used so both the 80⁰ and 100⁰ corners of the Insert can be utilized Material – Gray Cast Iron Grade- GSN-100 (GSN-100) DOC- .13- .19 (3.3- 4.8 mm) Speed- 4,000- 5,000 SFM (1,220- 1,525 M/Min) Feed- .0065-.0085 (.16- .22 mm) Fd/Insert Cut time- approx. 80 minutes per Insert index. A 3⁰ reverse lead cartridge is used to circle interpolate Bores

GSN-100 Class 500 Gray Iron Milling

Class 500 Gray Iron as cast 73% reduction in cut time Ball Screw Housing Prior: Seco carbide APKT 16 MM Insert 625 SFM (190 M/Min) .005 IPT (0,13 mm/tooth) 11 Minutes cut time Greenleaf SNGN-434 (SNGN-120416) T2 GSN-100 3” Diameter C4 cutter 4000 SFM (1220 M/Min) .005 IPT (0,13 mm/tooth) 3 Minutes cut time ® 73% reduction in cut time

GSN-100 Ductile Iron Milling

Insert – SPGN-434 T2A (SPGN120416) Objective: To prove out GSN-100 as a replacement for HSN-200 in Ductile Iron Milling We are running: Milling Cutter – CP-403R Nest – XFNPS-8043 Insert – SPGN-434 T2A (SPGN120416) Material – Ductile Cast Iron: Grade – HSN-200 DOC – .06” (1.52 mm) x 3 passes Speed – 3000 SFM (915 M/Min) Feed – .0045” (.11 mm) Actual Chip thickness Cutting time – 13.5 minutes Parts – 90 Material – Ductile Cast Iron: Grade – GSN-100 DOC – .06” (1.52 mm) x 3 passes Speed – 3000 SFM (915 M/Min) Feed – .0045” (.11 mm) Actual Chip thickness Cutting time – 13.5 minutes Parts – 90

GSN-100 Ductile GGG-50 Milling

GGG-50 Milling 290-350 BHN

Other GSN-100 Applications

GSN-100 Jethete M152 Milling

Jethete M152 A 82% iron, 12% chromium material classified as a Martensitic Stainless Steel which has high tensile strength and sufficient ductility at elevated temperatures as well as high corrosion resistance. The material is very sensitive to heat during the machining process which makes the material rapidly work harden. The application of Jethete M152 is mainly in high stress gas turbine parts.

Jethete M152 32-36 R/C 2 minutes cut time, inserts burned, Cutter: WSRP-60002 RH Insert: RPGN-43 T1A HSN-200 Speed: 1500 SFM (458 M/Min) Feed: .0033 IPT (.08 MM/tooth) DOC: .050” (1.27 MM) WOC: 2” (51 MM) 2 minutes cut time, inserts burned, show flank wear, have deformation, and built up edge. 32

Jethete M152 32-36 R/C Cutter: WSRP-6001.2 RH Insert: RPGN-43 T1A HSN-200 Speed: 1600 SFM (488 M/Min) Feed: .0015 IPT (.04 MM/tooth) DOC: .050” (1.27 MM) WOC: 1.25” (31.8 MM) 3 ½-4 minutes cut time, inserts showing flank wear, and experiencing heat in part 33

4 minutes tool life, 37 % increase in feed over HSN-200’s best run! Jethete M152 32-36 R/C Cutter: WSRP-6001.5 RH Insert: RPGN-43 T1A GSN-100 Speed: 1600 SFM (488 M/Min) Feed: .0028 IPT (.07 MM/tooth) DOC: .050” (1.27 MM) WOC: 1.5” (38.1 MM) 4 minutes tool life, 37 % increase in feed over HSN-200’s best run! 34

GSN-100 HRSA Milling

GSN-100 42 R/C Age Hardened Waspaloy

42 R/C age hardened Waspaloy Cutters Inserts FMRN-050R FMRN-063R RNGN-45 FMRN-080R T2A FMRN-100R FMRP-5040R RPGN-43 FMRP-6340R T2A From running all the tests it is apparent that we have a safe secure process with all sizes of cutters (both negative and positive) running at a feed rate of 0.0027”-0.0029”, (0.07mm-0.075mm) tooth. The surface speed is dependent on width of cut. (3000-3600 SFM/915-1100 SMM range)

GSN-100 Stocking Program

GSN-100 Stocking Program CNGN-432 T2 CNGN-433 T2 CNGN-433 T9 CNGN-434 T2A CNGN-453 T1A CNGN-453 T2 CNGN-454 T1A CNGN-454 T2 CNGN-454 T2A CPGN-433 T2A DNGA-432 T2 DNGA-433 T2 RPGN-2.52 T1 RPGN-2V T2 RPGN-32 T1 RPGN-3V T1A RPGN-3V T2 RPGN-43 T1 RPGN-43 T1A RPGN-43 T2A RPGN-4V T2 SNGA-433 T2 SNGA-434 T2 SNGA-454 T2 SNGN-433 T1A SNGN-433 T2 SNGN-433 T2A SNGN-434 T1A SNGN-434 T2 SNGN-453 T2 SNGN-454 T2 SPGN-322 T1A SPGN-434 T2A TPGN-322 T2A WG-6250-2A WNGA-433 T2 RCGN-3V T1 RCGN-4V T1 RNGN-43 T2 RNGN-45 T1 RNGN-45 T1A RNGN-45 T2 RNGN-45 T2A RNGN-45A ACHN-3222 T1A ACHN-3422 T1A CNGA-432 T2 CNGA-432 T2A CNGA-433 T2 CNGA-434 T2 CNGA-434 T3A CNGA-453 T2 CNGA-454 T2

Review Silicon Nitrides have their place in the high speed ceramic machining market. Grades such as Greenleaf GSN-100 work well in interrupted cutting and Milling operations due to Silicon Nitrides high thermal shock resistance. Greenleaf GSN-100 works well in the machining of Gray, Ductile, and Nodular cast irons. Although developed for Cast Iron machining, Greenleaf GSN-100 works on other materials such as selected high temp alloys. You will want to start gearing your HSN customers to the new Greenleaf GSN-100. ® ® ® ®

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