Multi-layer coating with cubic boron nitride particles

Abstract

A physical configuration of multiple-layer coatings formed with at least one layer of coating containing cubic born nitride (cBN) particles with one or more layers in composite form containing cBN particles may have a thickness of each individual layer as thin as in the nanometer range, or as thick as in the range of a few microns and even up to tens of microns. The chemistry of the composite layer consists of any individual phase of (a) nitrides such as titanium nitride (TiN), titanium carbonitride (TiCN), and hafnium nitride (HfN); (b) carbides such as titanium carbide (TiC); and (c) oxides such as aluminum oxide (AI.sub.2O.sub.3) or any combination of the above phases, in addition to cBN particles. The coating or film can be stand-alone or on a substrate.

Claims

1. A multi-layer coated substrate, consisting of: a. a substrate formed of a substrate material chosen from the set consisting of carbides, ceramics, polycrystalline cubic boron nitride (PCBN) compacts, PCBN tips, cermets, carbon, and steels; b. a composite layer deposited on the substrate, the composite layer consisting of cubic boron nitride (cBN) particles and a second material chosen from the set consisting of nitrides, carbides, carbonitrides, borides, and oxides; c. a first stacked ceramic layer deposited on the composite layer, the first stacked ceramic layer consisting of a third material chosen from the set consisting of nitrides, carbides, carbonitrides, oxides, or any combination thereof; and d. a second stacked ceramic layer deposited on the first stacked ceramic layer, the second stacked ceramic layer consisting of a fourth material chosen from the set consisting of nitrides, carbides, carbonitrides, oxides, or any combination thereof, wherein the third material and fourth material are different.

2. The multi-layer coated substrate of claim 1, wherein the cBN particles in the composite layer make up 20% to 60% of the composite layer.

3. The multi-layer coated substrate of claim 2, wherein each of the composite layer, first stacked ceramic layer, and second stacked ceramic layer comprise a thickness in the range of 200 nm to 10 m.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) FIG. 1 is an illustration of a substrate with multiple coatings according to a first preferred embodiment of a coated substrate according to the present invention.

(2) FIG. 2 is an illustration of a substrate with multiple coatings according to a second preferred embodiment of a coated substrate according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

(3) According to various embodiments of the present invention as used in connection with a coated substrate, the coating configuration may be: (1) a cBN-based composite coating in repetitive units with a ceramic layer as interfacial layer; (2) a cBN-based composite coating with different binder phases stacked in layered form on the composite coating; and (3) a cBN-based composite coating together with other layers of individual or combinatorial ceramic phases. In each case, the inventors have found that the resulting coated substrate provides enhanced performance with respect to wear resistance and tool life compared to previous coated substrates that incorporate cBN as a coating material, particular such tools as are used for cutting steel.

(4) With reference to FIG. 1, a first preferred embodiment of the present invention for use in connection with a cutting tool insert may be described. Substrate 10 may be any material appropriate to the application, such as a ceramic material, a carbide, PCBN compacts or tips, cermet, or steel. For carbides, they can be any substrate with particle size from nano- to micro-sized range with 2%14% Co or Ni as binder. Further, the carbides include any substrates with alloy phases such as TaC and TiC. For ceramics, they can be nitrides such as Si.sub.3N.sub.4 of alpha and beta phases, oxides such as Al.sub.2O.sub.3 with or without TiC, and enhancing agents such as SiC whiskers. The first coating layer on substrate 10 is layer 12, which is a composite layer comprising cBN particles, ranging from nanometer to microns, preferably in the range of 100 nm to 4000 nm. The composite may include, in addition to the cBN particles, various nitrides, carbides, carbonitrides, borides, and oxides in ratio of materials ranging from 20% to 60%, depending upon applications. Layer 14 is first stacked ceramic layer, which may be formed of nitrides, carbides, carbonitrides, oxides, or any combination of these materials. Layer 16 is a second stacked ceramic layer. It should be understood that in various embodiments, there may be only a single stacked ceramic layer, or there may be more than two of these layers. Further, the invention also includes in other embodiments multiple repetitions of this structure, such as, for example, two groupings of layers one over the other, where each grouping comprises a composite cBN layer 12 and first and second stacked ceramic layers, with the thickness of each layer ranging from 200 nm to 10 microns.

(5) Referring now to FIG. 2, a second preferred embodiment of the invention may be described where the ordering of layers has been modified. In this embodiment, the composite cBN layer 12 has been deposited between the first and second ceramic layers 14 and 16. The composite cBN layer 12 thus serves as an interfacial layer between first and second ceramic layers 14 and 16. Depending on the coating chemistry, with this coating configuration, it can modify the tool wear profile.

(6) The coating configuration form can be produced by sequential processes including, but not limited to, (A) spray deposition of cBN particles as a coating preform, and followed by chemical vapor infiltration of ceramic phase(s), then repeating the deposition and infiltration process; (B) vapor deposition (either physical vapor deposition or chemical vapor deposition or both) to create layers of ceramic phases, then spray or deposition of cBN particles, followed by chemical vapor infiltration of ceramic phase(s); (C) molding or compacting method at HP-HT conditions. In spray deposition of cBN particles of 100 nm to 5000 nm, coating preform thickness can be up to a few tens of microns. In chemical vapor infiltration, the temperature is in the range of 850 C. to 1100 C., with infiltration time between 120 minutes and 2400 minutes. Each layer may be bonded by microwave sintering, infrared (IR) heating, laser radiation, or any combination of the above.

(7) This invention, as illustrated and described herein, can be used for cutting tools, such as for inserts used for cutting tools and machines. It may also, however, be applied to other applications, where wear resistance, erosion prevention, or corrosion protection, or thermal protection are desired qualities.

(8) As used herein, comprising is synonymous with including, containing, or characterized by, and is inclusive or open-ended and does not exclude additional, unrecited elements or method steps. As used herein, consisting of excludes any element, step, or ingredients not specified in the claim element. As used herein, consisting essentially of does not exclude materials or steps that do not materially affect the basic and novel characteristics of the claim. Any recitation herein of the term comprising, particularly in a description of components of a composition or in a description of elements of a device, is understood to encompass those compositions and methods consisting essentially of and consisting of the recited components or elements. The invention illustratively described herein suitably may be practiced in the absence of any element or elements, limitation or limitations which is not specifically disclosed herein.

(9) When a Markush group or other grouping is used herein, all individual members of the group and all combinations and subcombinations possible of the group are intended to be individually included in the disclosure.

(10) The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims. Thus, additional embodiments are within the scope of the invention and within the following claims.

(11) In general the terms and phrases used herein have their art-recognized meaning, which can be found by reference to standard texts, journal references and contexts known to those skilled in the art. The preceding definitions are provided to clarify their specific use in the context of the invention.

(12) All patents and publications mentioned in the specification are indicative of the levels of skill of those skilled in the art to which the invention pertains. All references cited herein are hereby incorporated by reference to the extent that there is no inconsistency with the disclosure of this specification.

(13) The present invention has been described with reference to certain preferred and alternative embodiments that are intended to be exemplary only and not limiting to the full scope of the present invention as set forth in the appended claims.