Coated Tool for Machining of Difficult to Process Materials

Abstract

The present invention relates to a tool (100) for machining workpieces (200), comprising a surface (110) which is at least partially covered by a PVD deposited wear-resistant coating (120), said wear resistant coating (120) comprising one or more wear-resistant layers (121, 122), the coating having a modulus of elasticity, E, which is in a range 300 GPa≤E<350 GPa, and further having a hardness, H, which is greater than 30 GPa.

Claims

1-18. (canceled)

19. A tool for machining workpieces, comprising a surface which is at least partially covered by a PVD deposited wear-resistant coating, said wear resistant coating comprising one or more wear-resistant layers, the coating having a modulus of elasticity, E, which is in a range 300 GPa≤E<350 GPa, and further having a hardness, which is greater than 30 GPa.

20. The tool according to claim 19, wherein each one of the wear-resistant layers having a modulus of elasticity, E, which is in the range 300 GPa≤E<350 GPa, and further having a hardness, H, which is greater than 30 GPa.

21. The tool according to claim 19, wherein at least one of the wear-resistant layers is an aluminium titanium nitride layer, AlTiN layer, having chemical composition in atomic percentage AlxTi1-xN with x in the range 0.5<x≤0.9.

22. The tool according to claim 19, wherein an adhesive layer is applied between the surface and the wear-resistant coating, wherein the adhesive layer improves the adhesion of the wear-resistant coating to the surface and has an adhesion layer thickness between 10 nm and 1 μm.

23. The tool according to claim 19, wherein the wear-resistant coating comprises two or more wear-resistant layers, wherein at least two of the two or more wear-resistant layers are made of materials having the same elements but differing in chemical composition.

24. The tool according to claim 19, wherein the wear-resistant coating comprises two or more wear-resistant layers, wherein at least two of the two or more wear-resistant layers are made of materials having the same elements and same chemical composition but differing in mechanical properties such as modulus of at least elasticity or hardness.

25. The tool according to claim 19, wherein the wear-resistant coating comprises two or more layers, wherein at least two of the two or more wear-resistant layers are made of different materials.

26. The tool according to claim 19, wherein the wear-resistant coating comprises at least: at least one TiAlN layer, or at least one TiSiN layer, or at least one AlCrN layer.

27. The tool according to claim 19, wherein the wear-resistant coating comprises at least one nitride layer.

28. The tool according to claim 19, wherein the wear-resistant coating comprises at least one carbonitride layer or at least one carboxynitride layer or at least one oxynitride layer.

29. The tool according to claim 19, wherein the wear-resistant coating has a layer thickness of 0.5 to 20 μm.

30. The tool according to claim 19, wherein the wear-resistant coating has a crystalline or polycrystalline structure.

31. The tool according to claim 30, wherein the wear-resistant coating has a variable texture.

32. The tool according to claim 19, wherein the wear-resistant coating comprises at least one wear-resistant layer exhibiting cubic phase.

33. The tool according to claim 19, wherein at least the wear-resistant coating or at least one wear-resistant layer or the adhesive layer is/are deposited with the aid of a physical gas-phase deposition.

34. The tool according to claim 21, wherein the wear-resistant coating is a double layer coating comprising: an AlTiN layer and a TiSiN layer, or an AlTiN layer and an AlCrN layer.

35. A use of the coated tool for machining workpieces, comprising a surface which is at least partially covered by a PVD deposited wear-resistant coating, said wear resistant coating comprising one or more wear-resistant layers, the coating having a modulus of elasticity, E, which is in a range 300 GPa≤E<35. GPa, and further having a hardness, which is greater than 30 GPa for machining difficult to cut materials.

36. The use according to claim 35, wherein the difficult to cut materials are at least partially in the form of stainless steel or a nickel-based alloys.

37. The use according to claim 35, wherein the for machining difficult to cut materials are for end-milling difficult to cut materials.

38. The tool according to claim 27, wherein the wear-resistant coating consists of one or more nitride layers.

Description

[0043] Further measures to improve the invention result from the following description of some examples of the execution of the invention, which are shown schematically in the figures. All features and/or advantages resulting from the claims, the description or the drawings, including design details, spatial arrangements and process steps, may be essential to the invention both in themselves and in various combinations. It should be noted that the figures are only descriptive and are not intended to restrict the invention in any way. They show schematically:

[0044] FIG. 1: a schematic view of a tool according to the invention,

[0045] FIG. 2: a schematic view of a tool according to the invention, including an adhesion layer

[0046] FIG. 3: a schematic view of a tool according to the invention, showing two wear-resistant layers

[0047] FIG. 4: A diagram with a representative collection of coatings where the modulus of elasticity is shown as a function of hardness

[0048] FIG. 5: A diagram with representative coatings of various thicknesses with mechanical properties according to the state of the art and according to the invention, where the tool life is shown as a function of the thickness of the coating.

[0049] FIG. 6: A diagram with representative coatings with the modulus of elasticity as a function of the wear for machining a workpiece made of 1.3571 SUS316Ti.

[0050] FIG. 7: A diagram with representative coatings with the modulus of elasticity as a function of the wear for machining a workpiece made of Inconel 718.

[0051] In FIGS. 1 to 3, schematic views of examples of a tool according to the invention are shown. In the following, FIGS. 4 to 7 show measured properties of representative tools and coatings to illustrate the advantages of a representative set of tools according to the invention. It should be noted that the advantages shown in the presented examples can also be obtained for other coatings with various chemical compositions, layer systems, thicknesses, etc., as long as the properties according to the invention are maintained.

[0052] FIG. 1 shows an example of a tool 100 according to the invention for machining a workpiece 200, where the surface 110 is coated at least in parts by a wear-resistant coating 120, said wear resistant coating 120 having a modulus of elasticity E which is in a range between 300 and 350 GPa, and further having a hardness H which is greater than 30 GPa. The tool 100 is made of at least one bulk material 101, which may possess other mechanical properties than the wear-resistant coating 120.

[0053] FIG. 2 shows another example of a tool 100 according to the invention, where an adhesive layer 130 is applied between the surface 110 and the wear-resistant coating 120. The adhesive layer 130 improves the adhesion of the wear-resistant coating 120 to the surface 110 and may have an adhesion layer thickness between 10 nm and 1 μm, preferably between 10 nm and 0.5 μm, in particular between 10 nm and 0.25 μm. Alternatively or in addition, the adhesion layer thickness is smaller than that of the wear-resistant coating 120, preferably at least 3 times. A thinner layer thickness may result in a lower adhesion and a thicker thickness may result in a loss of functionality of the wear-resistant coating. Thus, the advantage of an improved machining performance can be obtained.

[0054] FIG. 3 illustrates a further example of a tool 100 according to the invention, where, in addition to an adhesive layer 130, a wear-resistant coating 120 comprising two wear-resistant layers 121, 122 is shown. Each one of the wear-resistant layers 121, 122 has a modulus of elasticity E which is in a range between 300 and 350 GPa, and further has a hardness H which is greater than 30 GPa. In this way, properties of different materials can be combined, e.g. their chemical resistance, which ultimately leads to a higher service life.

[0055] The following FIGS. 4 to 7) show measured properties of a representative set of tools 100 and coatings to illustrate the advantages of the tool 100 according to the invention.

[0056] For all coatings shown in FIG. 4 being in the above-mentioned inventive ranges of elastic modulus and hardness, excellent results in machining, in particular end milling of materials, in particular difficult to cut materials, were obtained. The results were much better than when using the coatings with elastic modulus and hardness without the inventive ranges.

[0057] FIG. 4 shows the combination of ranges of values of elastic modulus and hardness of AlTiN coatings deposited by using cathodic arc deposition techniques, thereby using for each coating deposition four AlTi-targets as metal material sources, wherein the targets were operated in a known manner, each one as the cathode in a respective arc evaporator, and nitrogen gas was used as reactive gas. The same trends were also observed for other coating materials, in particular AlCrN, TiSiN and combinations of layers containing at least two metals and/or at least one nitride layer or at least one carbonitride layer or at least one carboxynitride layer or at least one oxynitride layer.

[0058] A tool 100 according to the invention may be provided, in which the wear-resistant coating 120 comprises at least one TiAlN layer or at least one TiSiN layer or at least

[0059] one AlCrN layer. Alternatively or in addition, the wear-resistant coating 120 may comprise at least one nitride layer or at least one carbonitride layer or at least one carboxynitride layer or at least one oxynitride layer. As a further alternative or in addition, the chemical composition of at least one wear-resistant layer 121, 122 comprised in the wear-resistant coating 120 may comprise at least two metals, in particular aluminium and titanium.

[0060] It may be provided for a tool 100 according to the invention that the chemical composition of at least one layer 121, 122 comprised in the wear-resistant coating 120 is AlxTi1-xN, wherein x has a value between 0.5 and 0.9, preferably, between 0.6 and 0.8 particularly preferably 0.66. Alternatively or in addition, the chemical composition of at least one wear-resistant layer 121, 122 comprised in the wear-resistant coating 120 may comprise at least titanium and silicon, in particular additionally nitrogen.

[0061] For obtaining the different values of elastic modulus and hardness for the coatings as displayed in FIG. 4, the coating parameters (e.g. substrate temperature, bias voltage, etc.) were varied.

[0062] All values of elastic modulus and hardness of wear-resistant coatings that have been used in the context of the description of the present invention have been measured by using a Fisherscope H100C. The applied loading force was 10 mNw. The measurements were carried out warranting maximal indentation depth of 1% of the total thickness of the wear-resistant coating 120. For the measurements, polished surfaces of steel samples were coated with the respective coating to be examined, wherein the thickness of the coating was at least 2 μm for making possible a reliable examination of the mechanical properties as well as further coating properties.

[0063] For showing the considerable improvement attained by the present invention, the inventor has, among others, deposited different aluminium titanium nitride (AlTiN) coatings by using PVD (physical vapor deposition techniques) of the type arc evaporation.

[0064] AlTiN were deposited exhibiting hardness values higher than 30 GPa but not exhibiting elastic modulus values between 300 GPa and 350 GPa at the same time. Following, some examples of the invention as well as comparative examples will be described in more detail for explaining better the present invention and the technical improvements attained by the present invention. These examples should not be understood as a limitation of the invention but only as showcases of the present invention.

EXAMPLE 1

Non-Inventive Example

[0065] A monolayer AlTiN coating according to the state of the art was deposited as a wear-resistant coating on end milling tools by reactive arc cathodic evaporation of AlTi-targets, wherein the targets were operated as cathodes of corresponding arc evaporators for producing vapor of Al and Ti, in the presence of nitrogen gas, which was introduced in the coating chamber as reactive gas for reacting with Al and Ti for forming the AlTiN coating. This AlTiN coating was produced having a chemical composition in atomic percentage corresponding to Al.sub.xTi.sub.1-xN with x=0.66, elastic modulus value corresponding to 400 GPa and hardness value corresponding to 40 GPa. The same trends were also observed for other coating materials, in particular AlCrN, TiSiN and combinations of layers containing at least two metals and/or at least one nitride layer or at least one carbonitride layer or at least one carboxynitride layer or at least one oxynitride layer.

[0066] End milling tools were coated with coating according to this Example 1, wherein the coating thickness of the AlTiN was varied in order to produce tools having AlTiN coating with coating thickness of 1 μm, 2 μm and 3 μm respectively. The same trend was also observed for other coating materials.

EXAMPLE 2

Inventive Example

[0067] A monolayer AlTiN coating according to the present invention was deposited as wear-resistant coating 120 on end milling tools 100 by reactive arc cathodic evaporation of AlTi-targets, wherein the targets were operated as cathodes of corresponding arc evaporators for producing vapor of Al and Ti, in presence of nitrogen gas, which was introduced in the coating chamber as reactive gas for reacting with Al and Ti for forming the AlTiN coating. This AlTiN coating 120 was produced having a chemical composition in atomic percentage corresponding to Al.sub.xTi.sub.1-xN with x=0.66, elastic modulus value corresponding to 304 GPa and hardness value corresponding to 35 GPa. The same trends and advantages according to the invention could also be obtained by using another deposition process, such as physical gas-phase deposition.

[0068] Both above-mentioned examples 1 and 2 were deposited having a monolayer architecture (i.e. comprising only one layer). However, as mentioned before, the present invention is not limited to wear-resistant coatings 120 having a monolayer architecture but also includes wear-resistant coatings 120 having a multilayer architecture (i.e. comprising two or more layers deposited on one another).

[0069] The wear-resistant coatings provided on tools 100, particularly endmills for machining, particularly end-milling, of materials, particularly, difficult-to-cut materials, according to the present invention exhibits elastic modulus and hardness values in the inventive range as mentioned above, i.e. 300 GPa<350 GPa and H>30 GPa. In case a wear-resistant coating 120 according to the invention comprises one or more wear-resistant layers 121, 122, each one of the wear-resistant layers 121, 122 may have a modulus of elasticity which is in a range between 300 and 350 GPa, and further may have a hardness which is greater than 30 GPa.

[0070] An adhesion layer 130 can be deposited between the surface of the tool 110 and the wear-resistant coating 120. Such an adhesion layer 130 can be used for improving adhesion between the surface of the tool 110 to be coated and the wear-resistant coating 120. The adhesion layer 130 can be provided having elastic modulus and hardness in a different value range than the layers (or the layer) forming the wear-resistant coating 120.

[0071] If an adhesion layer 130 is provided, the thickness of the adhesion layer should preferably not exceed 1 μm. Furthermore, if using an adhesion layer 130, the thickness of the adhesion layer 130 should preferably not exceed the thickness of the wear-resistant coating 120.

[0072] The attained tool service life of end milling tools coated with non-inventive coatings according to Example 1 as well as the attained tool service life of end milling tools coated with inventive coatings according to Example 2 are shown in FIG. 5.

[0073] For generating the results presented in FIG. 5 the end milling tools 100 coated with wear-resistant coatings 120 having different coating thicknesses according to the Examples 1 and 2 as described above, were tested in cutting tests by using following set of cutting test parameters: [0074] Workpiece material: 1.4571 SUS316Ti [0075] Kind of tool: End-mill having diameter d=10 mm [0076] Cutting parameters: Vc=110 m/min, f.sub.t=0.04 mm, ap=8 mm, ae=4 mm, wet conditions

[0077] FIG. 5 (on the right) shows how the AlTiN coatings produced according to the inventive Example 2 lead to increased tool life, when these coatings are used as wear-resistant coatings for end milling tools during machining of 1.4571 SUS316Ti, which is a difficult material to cut. Furthermore, it can be observed that the higher the wear-resistant coating thicknesses the higher the attained tool life.

[0078] FIG. 5 (on the left) shows also that contrariwise, the non-inventive AlTiN coatings do not lead to an increased tool life. For these non-inventive wear-resistant coatings, the effect of the coating thickness is completely the opposite, i.e. the higher wear-resistant coating thicknesses the lower tool life.

[0079] From the results displayed in FIG. 5, it can be concluded that for machining, in particular cutting operations, in which adhesive wear is dominating (like machining—in particular end-milling—of stainless steel or Inconel machining), it is possible to increase considerably the tool performance and hence the tool service life by increasing wear resistant coating thickness. However, a higher wear resistant coating thickness can be beneficial only if the wear resistant coating is provided according to the present invention. In other words, only if the wear resistant coating 120 is provided having values of elastic modulus and hardness within the inventive ranges as mentioned above.

[0080] The inventor found that surprisingly the coating properties of the wear resistant layer 120 regarding for example chemical composition, (poly)crystalline structure and (variable) texture can be varied for attaining further additional benefits, but the above described effect will be provided by maintaining a combination of elastic modulus and hardness in the inventive range as described above and claimed in claim 1 of the present patent application, i.e. 300 GPa≤E<350 GPa and H>30 GPa. Thus, the same trends can also observed for other coating materials, in particular AlCrN, TiSiN and combinations of layers containing at least two metals and/or at least one nitride layer or at least one carbonitride layer or at least one carboxynitride layer or at least one oxynitride layer.

[0081] According to a preferred embodiment of the present invention, the wear-resistant coating 120 may have a crystalline or polycrystalline structure. Alternatively or in addition, the wear-resistant coating 120 may have a variable texture and/or exhibit a cubic phase.

[0082] According to a preferred embodiment of the present invention, the wear-resistant coating 120 comprises at least one layer consisting of AlTiN or mainly comprising AlTiN.

[0083] According to a preferred embodiment of the present invention, the wear-resistant coating 120 comprises at least two wear-resistant layers 121, 122, wherein one layer of the two layers consists of AlTiN or mainly comprises AlTiN and the other one layer consists of TiSiN or mainly comprises TiSiN. Also, the wear-resistant coating 120 may comprise two or more wear-resistant layers 121, 122, wherein at least two of the two or more wear-resistant layers 121, 122 are made of materials having the same elements and same chemical composition but differing in mechanical properties such as modulus of elasticity and/or hardness. Alternatively or in addition, the wear-resistant coating 120 may comprise two or more layers 121, 122, wherein at least two of the two or more wear-resistant layers 121, 122 are made of different materials. According to a further preferred embodiment of the present invention, the wear-resistant coating 120 comprises two or more layers 121, 122 differing in at least one of the material properties comprised in the following group: chemical composition, crystalline structure and texture.

[0084] According to a further preferred embodiment of the present invention, the thickness of the wear-resistant coating is between 0.5 μm and 20 μm, for example between 1 μm and 7 μm as shown in FIG. 3, maybe preferably between 5 and 20 μm.

[0085] Desired coating properties regarding combination of E-Modulus and Hardness according to the present invention can be achieved by selecting the appropriate combination of coating parameters depending of the kind of coating process that is intended to be used.

[0086] The inventor found that for example in the case of deposition of AlTiN coatings, the selection of an appropriate combination of bias voltage and substrate temperature has a big influence on the attained combination of E-modulus and hardness. The appropriate combination of coating parameters for depositing AlTiN coatings according to the present will however also depend on the Al-content.

[0087] In FIG. 6 it is possible to observe the wear behavior of tools 100 coated according to representative examples according the present invention, which exhibit a combination of hardness higher than 30 GPa and an elastic modulus as indicated in FIG. 6 (vertical axis—indicator scale on the left). The coated tools were tested by machining of stainless steel. The wear was measured from wear pictures after 24 m cutting distance.

[0088] For generating the results presented in FIG. 6, following set of cutting parameters were used: [0089] Workpiece material: 1.4571 SUS316Ti [0090] Kind of tool: End-mill with diameter d=10 mm [0091] Cutting parameters: Vc=110 m/min, f.sub.t=0.04 mm, ap=8 mm, ae=4 mm, wet conditions

[0092] These obtained results are only representative examples. The same trends were also observed for other coating materials, in particular AlCrN, TiSiN and combinations of layers containing at least two metals and/or at least one nitride layer or at least one carbonitride layer or at least one carboxynitride layer or at least one oxynitride layer. Also, other deposition processes, workpiece materials and layer systems could be used.

[0093] In FIG. 7 it is possible to observe the wear behaviour of a representative example of tools coated according to the present invention, which exhibit a combination of hardness higher than 30 GPa and an elastic modulus as indicated in FIG. 7 (vertical axis—indicator scale on the left). The coated tools were tested by machining of Inconel. The wear was measured after 6.8 m cutting distance. For generating the results presented in FIG. 7, following set of cutting parameters were used: [0094] Workpiece material: Inconel 718 [0095] Kind of tool: End-mill with diameter d=10 mm [0096] Cutting parameters: Vc=50 m/min, ft=0.06 mm, ap=5 mm, ae=0.5 mm, wet conditions

[0097] These obtained results are only representative examples. The same trends were also observed for other coating materials, in particular AlCrN, TiSiN and combinations of layers containing at least two metals and/or at least one nitride layer or at least one carbonitride layer or at least one carboxynitride layer or at least one oxynitride layer. Also, other deposition processes, workpiece materials and layer systems could be used.

[0098] The preceding explanation of the forms of execution describes the present invention exclusively in the context of examples. Of course, individual features of the design forms can be freely combined with each other, if technically reasonable, without leaving the scope of the present invention.