A coated cutting tool includes a substrate with a rake side, a clearance side and a cutting edge, and a coating including a first layer and a second layer. The second layer includes an inner layer and an outer layer, wherein the first layer is exposed through an opening in the inner layer and the opening extends over at least a portion of the width of the cutting edge. Thereby, a double layer is provided in critical areas, whereas a single layer is provided in other areas. Preferably, the double oxide layer includes aluminum oxide layers. A method for manufacturing the coated cutting tool is also provided.

Provided is a hard coating having, in particular, excellent oxidation resistance, high hardness, and excellent abrasion resistance as compared with conventional hard coatings such as TiSiN, TiAlSiN, TiCrAlSiN, and AlCrSiN coatings. The hard coating according to the present invention has a compositional formula of (Ti.sub.αCr.sub.1-α).sub.1-aGe.sub.a(C.sub.1-xN.sub.x), where the atomic ratios of the elements satisfy the expressions: 0≦α≦1, 0.010≦a≦0.20, and 0.5≦x≦1.

An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.

Disclosed is a hard coating including a chemical composition specified by formula: (Ti.sub.aAl.sub.bSi.sub.cR.sub.d)O.sub.x, where R represents at least one rare-earth element; and a, b, c, d, and x are atomic ratios respectively of Ti, Al, Si, R, and O. The atomic ratios meet conditions as specified by formulae: 0.30≦a≦0.7, 0.30≦b≦0.70, 0≦c≦0.2, 0.005≦d≦0.05, a+b+c+d=1, and 0.5≦a/b<1. The atomic ratios meet a condition as specified by Formula (1) when R does not include Ce. The atomic ratios meet a condition as specified by Formula (2) when R includes Ce. The hard coating has better wear resistance as compared with conventional nitride films and oxide films.
0.8≦[x/(2a+1.5b+2c+1.5d)]≦1.2  (1)
0.8≦[x/(2a+1.5b+2c+2d)]≦1.2  (2)

Disclosed herein is a method of forming a multilayer thin film by depositing target particles, detached from a target by plasma discharge of inert gas, on a metal object using a multilayer thin film deposition apparatus and a multilayer thin film formed by the method. More specifically, a sputtering deposition apparatus is used as the multilayer thin film deposition apparatus. The method includes coating a metal object with a coating layer, depositing at least one hardness-enhancing layer on the coating layer, and depositing a color layer on the at least one hardness-enhancing layer.

A plated steel material comprising a steel base material and an Al—Zn—Mg-based plating layer formed on a surface of the steel base material, wherein the plating layer has a predetermined chemical composition, and in a surface structure of the plating layer, there is, by area ratio, 2.0% or more of an acicular Al—Zn—Si—Ca phase.

In an Al coating layer-equipped stainless steel sheet, a base steel sheet has a predetermined chemical composition, and a total content of Fe and Cr at a first depth of an Al coating layer is 20 mass % to 70 mass %.

A system and method are detailed for aluminizing surfaces of metallic substrates, parts, and components with a protective alumina layer in-situ. Aluminum (Al) foil sandwiched between the metallic components and a refractory material when heated in an oxidizing gas under a compression load at a selected temperature forms the protective alumina coating on the surface of the metallic components. The alumina coating minimizes evaporation of volatile metals from the metallic substrates, parts, and components in assembled devices that can degrade performance during operation at high temperature.

A cutting tool comprising a base material and a coating arranged on the base material; wherein: the coating comprises an α-Al.sub.2O.sub.3 layer composed of a plurality of α-Al.sub.2O.sub.3 particles; the average particle diameter a of the α-Al.sub.2O.sub.3 particles in a first region of the α-Al.sub.2O.sub.3 layer is 0.10 μm or more and 0.30 μm or less; the average particle diameter b of the α-Al.sub.2O.sub.3 particles in a second region of the α-Al.sub.2O.sub.3 layer is 0.30 μm or more and 0.50 μm or less; the average particle diameter c of the α-Al.sub.2O.sub.3 particles in a third region of the α-Al.sub.2O.sub.3 layer is 0.30 μm or more and 0.50 μm or less; and the ratio b/a is 1.5 or more and 5.0 or less.

A polycrystalline diamond is formed on a substrate to form a polycrystalline diamond compact (PDC) cutter for a tool. The polycrystalline diamond has a cross-sectional dimension of at least 4 millimeters. The substrate includes tungsten carbide. An outer surface of the PDC cutter is at least partially surrounded with at least a single layer of coating by atomic layer deposition. The single layer of coating is configured to protect the PDC cutter from thermal degradation in response to exposure to a temperature greater than 700 degrees Celsius (° C.) and less than about 1050° C.