PVD-Grade Carbide Milling Inserts Address Mold Machining Challenges

Walter USA introduces its Tiger·tec Gold physical vapor deposition (PVD) grade WSP45G, a new generation of indexable carbide inserts for milling that dramatically expands capabilities for slotting, shoulder and copy milling. The new grade can efficiently process demanding machining applications such as interrupted cuts and difficult materials, desirable for mold building, when mold component interchangeability, ever-tightening tolerances and hardened tool steels are common. 

This new grade is now reportedly capable of longer tool life, greater reliability and approximately 30% greater performance in stainless steels (ISO M) and heat-resistant super alloys (ISO S), and up to 75% greater performance in steels (ISO P) than comparable grades. With the launch phase now complete, the PVD-grade WSP45G Tiger·tec Gold can be used universally in all standard Walter milling cutters.

According to Walter, the key to the grade’s performance is its next generation coating technology and its special layer structure. The gold-colored ZrN top layer is said to facilitate exceptional low-friction characteristics as well as optimized wear detection, thus making it possible to use the full potential of the indexable insert to extend tool life. Next, multiple layers of aluminum oxide (Al₂O₃) increase the inserts’ temperature resistance.

All are applied on top of a TiAlN base layer and a premium carbide substrate as a foundation, greatly increasing the overall wear resistance. These properties make the new inserts ideal for challenging conditions, such as interrupted cuts, long overhangs with a tendency to vibrate or wet machining.