Coated cutting tool

Abstract

A coated cutting tool includes a body and a hard and wear resistant PVD coating on the body, wherein the body is made from a cemented carbide, cermet, ceramics, polycrystalline diamond or polycrystalline cubic boron nitride based materials. The coating includes a first (Ti,Al)-based nitride sub-coating and a second (Ti,Al)-based nitride sub-coating. The first (Ti,Al)-based nitride sub-coating can be a single layer, and the second (Ti,Al)-based nitride sub-coating can be a laminated structure, wherein the first (Ti,Al)-based nitride sub-coating includes a (Ti.sub.1-xAl.sub.x)N.sub.z-layer where 0.1<x<0.4, 0.6<z<1.2, and wherein the second (Ti,Al)-based nitride sub-coating includes a (Ti.sub.1-x1-y1Al.sub.x1Cr.sub.y1)N.sub.z1 layer where 0.5<x1<0.75, 0.05<y1<0.2, 0.6<z1<1.2.

Claims

1. A coated cutting tool comprising: a body, wherein the body comprises cemented carbide, cermet, ceramics, polycrystalline diamond or polycrystalline cubic boron nitride based materials; and a hard and wear resistant PVD coating disposed on the body, the coating having a plurality of sub-coatings including a (Ti,Al)N sub-coating and a (Ti,Al,Cr)N sub-coating, the (Ti,Al)N sub-coating being a single layer, and the (Ti,Al,Cr)N sub-coating being a laminated structure, wherein the (Ti,Al)N sub-coating includes a (Ti.sub.1-xAl.sub.x)N.sub.z-layer where 0.1<x<0.4, 0.6<z<1.2, and wherein the (Ti,Al,Cr)N sub-coating includes a (Ti.sub.1-x1-y1Al.sub.x1Cr.sub.y1)N.sub.z-layer where 0.5<x1<0.75, 0.05<y1<0.2, 0.6<z1<1.2, the (Ti,Al,Cr)N sub-coating being a laminated structure having alternating A and B layers: A/B/A/B/A/B/ . . . , where layer A is (Ti.sub.1-xAlx)N.sub.z, 0.1<x<0.4, 0.6<z<1.2, and layer B is (Ti.sub.1-x1-y1Al.sub.x1Cr.sub.y1)N.sub.z, 0.5<x1<0.75, 0.05<y1<0.2, 0.6<z1<1.2, wherein the A and B layers have an average individual layer thickness between 1 nm and 100 nm.

2. The coated cutting tool according to claim 1, wherein said (Ti,Al)N sub-coating has a thickness between 0.1 m and 2 m.

3. The coated cutting tool according to claim 1, wherein 0.15<x<0.35.

4. The coated cutting tool according to claim 1, wherein 0.55<x1<0.75.

5. The coated cutting tool according to claim 1, wherein 0.05y1<0.15.

6. The coated cutting tool according to claim 1, wherein 0.8<z11.1.

7. The coated cutting tool according to claim 1, wherein the (Ti,Al,Cr)N sub-coating has a thickness between 0.5 m and 10 m.

8. The coated cutting tool according to claim 1, wherein the coated cutting tool includes an innermost single or laminated layer structure arranged on and in contact with said body, the innermost layer structure being disposed between the body and the hard and wear resistant coating and including at least one of the following compositions: TiN, TiC, Ti(C,N) or (Ti,Al)N.

9. The coated cutting tool according to claim 8, wherein the coated cutting tool includes an outermost single or laminated layer structure arranged on said coating, and including at least one of the following compositions: TiN, TiC, Ti(C,N) and (Ti,Al)N.

10. The coated cutting tool according to claim 9, wherein the total thickness of the coating, and any innermost or outermost layer structures is between 0.8 m and 15 m.

11. The coated cutting tool according to claim 9, wherein the average composition of the coating including any innermost or outermost layer structures is 55 at %<% Ti<62 at %, 32 at %<% Al<40 at %, 1 at %<% Cr<9 at %, % Ti+% Al+% Cr=100 at % and balanced with N.

12. The coated cutting tool according to claim 1, wherein said body is cemented carbide including WC and 4-15 wt % Co.

13. The coated cutting tool according to claim 1, wherein the body is polycrystalline cubic boron nitride (PCBN) containing at least 25 vol % of cubic boron nitride (cBN) in a binder, and the binder including at least one nitride, boride, oxide, carbide or carbonitride compound selected from one or more of the following group of elements: Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W and Al.

14. The coated cutting tool according to claim 1, wherein the body is polycrystalline cubic boron nitride (PCBN) containing 30 vol %<cBN<75 vol %, in a binder, and with an average cBN grain size between 0.5 m and 10 m, the binder contains 80 wt %<Ti(C,N)<95 wt % and the rest of the binder including compounds from two or more of the following group of elements: Ti, N, B, Ni, Cr, Mo, Nb, Fe, Al and O.

15. The coated cutting tool according to claim 1, wherein the body is polycrystalline cubic boron nitride (PCBN) containing 35 vol %<cBN<75 vol % in a binder with a bimodal cBN grain size distribution where at least about 50% of the cBN grains have a grain size<5 m and at least 20% of the grains have a grain size>5 m, and the binder contains at least one compound including Al and at least one compound including Ti.

16. The coated cutting tool according to claim 1, wherein the body is polycrystalline cubic boron nitride (PCBN) containing 30 vol %<cBN<75 vol %, in a binder, with an average cBN grain size between 0.5 m and 5 m, the binder contains 80 wt %<Ti(C,N)<90 wt %; less than 1 wt. % of an alloy containing one or more of the following group of elements: Ni, Co, Cr; less than 10 wt % Mo; and the rest of the binder includes at least one of the following compounds: TiB.sub.2, Al.sub.2O.sub.3.

17. A method for manufacturing a coated cutting tool according to claim 1, by applying physical vapor deposition (PVD) techniques, including cathodic arc evaporation, the method comprising: cleaning of the body prior to deposition; and growing of (Ti,Al)N and (Ti,Al,Cr)N layers by using composite or alloyed (Ti,Al) and (Ti,Al,Cr) cathodes, respectively, applying an evaporation current between 50 A and 200 A, using a reactive gas atmosphere comprising pure N.sub.2 or mixed N.sub.2 and Ar gases at a total gas pressure between 1.0 Pa and 8.0 Pa, applying a negative substrate bias between 20 V and 300 V, and applying a deposition temperature between 200 C. and 800 C.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic view of one embodiment of the present disclosure.

(2) FIG. 2 is a schematic view of one embodiment of the present disclosure.

(3) FIG. 3 shows a schematic view of one embodiment of the present disclosure.

(4) FIG. 4 shows an X-ray diffractogram of one embodiment of the present disclosure.

DETAILED DESCRIPTION

(5) According to one embodiment of the present disclosure, schematically shown in FIG. 1, there is provided a coated cutting tool including a body 1 and a hard and wear resistant coating 4 on the body. The coating 4 includes a first (Ti,Al)-based nitride sub-coatings 2 being a single (Ti.sub.1-xAl.sub.x)N.sub.z layer with 0.15<x<0.35 or 0.2x<0.3, and 0.9z1.1 with a thickness between 0.3 m and 0.8 m, and a second (Ti,Al)-based nitride sub-coating 3 being a laminated structure having alternating A and B layers: A/B/A/B/A/B . . . where layers A is (Ti.sub.1-xAl.sub.x)N.sub.z where 0.15<x<0.35, or 0.2x<0.3, and 0.9z1.1, and layer B is (Ti.sub.1-x1-y1Al.sub.x1Cr.sub.y1)N.sub.z1 where 0.55<x10.7, 0.05y1<0.15, and 0.9z11.1 with a thickness between 1 m and 3 m. The A and B layers have an average individual layer thickness between, for example, 1 nm and 100 nm, 5 nm and 50 nm, and 5 nm and 30 nm as measured by, e.g., cross sectional transmission electron microscopy of a middle region of the second sub-coating 3, i.e., in a region between 30% to 70% of its thickness. The average layer thickness is the average from measuring the thickness of at least ten adjacent layers.

(6) It should be appreciated that the individual hard and wear resistant coating 4 may be part of a complex coating design and used as an inner, middle and/or an outer layer of a complex coating.

(7) According to one embodiment of the present disclosure, schematically shown in FIG. 2, there is provided a coated cutting tool including a body 1 and a hard and wear resistant coating 4 on the body. The coating 4 has a first (Ti,Al)-based nitride sub-coatings 2 being a single (Ti.sub.1-xAl.sub.x)N.sub.z layer with 0.15<x<0.35 or 0.2x<0.3, and 0.9z1.1 with a thickness between 0.3 m and 0.8 m, a second (Ti,Al) and a based nitride sub-coating 3 being a laminated structure consisting of alternating A and B layers: A/B/A/B/A/B . . . where layers A is (Ti.sub.1-xAl.sub.x)N.sub.z where 0.15<x<0.35, or 0.2x<0.3, and 0.9z1.1, and layer B is (Ti.sub.1-x1-y1Al.sub.x1Cr.sub.y1)N.sub.z1 where 0.55<x10.7, 0.05y1<0.15, and 0.9z11.1 with a thickness between 1 m and 3 m.

(8) An outermost single layer structure 6, arranged on the hard and wear resistant coating 4, can be TiN or (Ti,Al)N of a single layer of (Ti.sub.1-xAl.sub.x)N.sub.z layer with for example, 0.15<x<0.35, 0.2x<0.3, and 0.9z1.1 with a thickness between 0.05 m and 0.3 m.

(9) The A and B layers have an average individual layer thickness between for example, 1 nm and 100 nm, between 5 nm and 50 nm, or 5 nm and 30 nm as measured by, e.g., cross sectional transmission electron microscopy of a middle region of the second sub-coating 3, i.e., in a region between 30% to 70% of its thickness, and the average layer thickness is the average from measuring the thickness of at least ten adjacent layers.

(10) According to one embodiment of the present disclosure, schematically shown in FIG. 3, there is provided a coated cutting tool including a body 1 and an innermost single or laminated layer structure 5 with a thickness between 0.05 and 0.3 m arranged on and in contact with the body 1, of, e.g., TiN, TiC, Ti(C,N) or (Ti,Al)N, a hard and wear resistant coating 4 on the body. The coating 4 can have a first (Ti,Al)-based nitride sub-coatings 2 being a single (Ti.sub.1-xAl.sub.x)N.sub.z layer with for example, 0.15<x<0.35, or 0.2x<0.3, and 0.9z1.1 with a thickness between 0.3 m and 0.8 m, a second (Ti,Al)-based nitride sub-coating 3 being a laminated structure of alternating A and B layers: A/B/A/B/A/B . . . where layers A is (Ti.sub.1-xAl.sub.x)N.sub.z where 0.15<x<0.35, preferably 0.2x<0.3, and 0.9z1.1, and layer B is (Ti.sub.1-x1-y1Al.sub.x1Cr.sub.y1)N.sub.z1 where 0.55<x10.7, 0.05y1<0.15, and 0.9z11.1 with a thickness between 1 m and 3 m.

(11) An outermost single layer structure 6 may be arranged on the hard and wear resistant coating 4 of TiN or (Ti,Al)N, for example, a single layer of (Ti.sub.1-xAl.sub.x)N.sub.z layer with 0.15<x<0.35 or 0.2x<0.3, and 0.9z1.1 with a thickness between 0.05 m and 0.3 m. The A and B layers have an average individual layer thickness between 1 nm and 100 nm, for example, between 5 nm and 50 nm or between 5 nm and 30 nm as measured by, e.g., cross sectional transmission electron microscopy of a middle region of sub-coating 3, i.e., in a region between 30% to 70% of its thickness. The average layer thickness is the average from measuring the thickness of at least ten adjacent layers.

(12) According to one embodiment of the present disclosure, the total thickness, i.e., the sum of the thicknesses for the innermost layer structure 5, if present, the outermost layer structure 6, if present, and coating 4, is between 0.8 m and 15 m, for example, between 1 m and 10 m, or between 1 m and 6 m.

(13) The average composition of the layers was estimated by energy dispersive spectroscopy (EDS) analysis area using a LEO Ultra 55 scanning electron microscope operated at 20 kV and normal incidence to the coated surface equipped with a Thermo Noran EDS. Industrial standards and ZAF correction were used for the quantitative analysis. The metal composition was evaluated using a Noran System Six (NSS ver 2) software.

(14) According to one embodiment of the present disclosure, the hard and wear resistant coating 4 includes a first (Ti,Al)-based nitride sub-coating 2 of a single layer (Ti.sub.1-x-yAl.sub.x)N.sub.z, a second (Ti,Al)-based nitride sub-coating 3 of a laminated (Ti.sub.1-x-yAl.sub.xCr.sub.y)N.sub.z, y=0 and (Ti.sub.1-x1-y1Al.sub.x1Cr.sub.y1)N.sub.z1 layers and an outermost 6 single layer of (Ti.sub.1-x-yAl.sub.xCr.sub.y)N.sub.z, y=0, and has an average composition of 55 at %<% Ti<62 at %, preferably 57 at %<% Ti<62 at; 57 at %<% Ti<60 at %, 32 at %<% Al<40 at %; 34 at %<% Al<40 at %; 34 at %<% Al<38 at %, 1 at %<% Cr<9 at %; or 3 at %<% Cr<9 at %; 3 at %<% Cr<7 at %, % Ti+% Al+% Cr=100 at % and balanced with N as determined by EDS.

(15) Additionally, the coating 4, innermost layer structure 5, and outermost layer structure 6 may contain a sum of oxygen (O) and carbon (C) concentration between 0 and 3 at %, for example, between 0 and 2 at % as determined by EDS.

(16) Coating phase detection was performed by X-ray diffractometry (XRD) using a Bruker AXS D8-advance x-ray diffractometer and Cu K radiation in Bragg-Brentano configuration. Typically, the detection limit for each phase in a polycrystalline mixed phase materials is less than 5 vol %.

(17) According to one embodiment of the present disclosure, the first (Ti,Al)-based nitride sub-coating 2 is a cubic sodium chloride phase.

(18) According to one embodiment of the present disclosure, the first (Ti,Al)-based nitride sub-coating 2 is of mixed cubic sodium chloride and hexagonal phases.

(19) According to one embodiment of the present disclosure, the second (Ti,Al)-based nitride sub-coating 3 is a cubic sodium chloride phase.

(20) According to one embodiment of the present disclosure, the second (Ti,Al)-based nitride sub-coating 3 is of mixed cubic sodium chloride and hexagonal phases.

(21) Additionally, the coating 4 may also contain amorphous phases with small amounts, close to the detection limit of the XRD technique.

(22) The deposition method for the functional hard and wear resistant coating 4 on a body 1 is based on PVD techniques, for example, reactive cathodic arc evaporation, using composite or alloyed (Ti,Al) and (Ti,Al,Cr) cathodes allowing for growth of (Ti,Al)N and (Ti,Al,Cr)N layers, respectively.

(23) Prior to deposition, the body 1 is adequately cleaned by applying established ex-situ and in-situ cleaning procedures. The desired layer compositions are obtained by selecting the appropriate reactive gas atmosphere and composition of the (Ti,Al) and (Ti,Al,Cr) cathodes, respectively. (Ti,Al)N and (Ti,Al,Cr)N layers are grown with an evaporation current between 50 A and 200 A, a higher current for larger cathode size, in a reactive gas atmosphere comprising pure N.sub.2 or mixed N.sub.2 and, e.g., Ar gases at a total gas pressure between 1.0 Pa and 8.0 Pa, for example, between 1.0 Pa and 5.0 Pa, between 2.0 Pa and 5.0 Pa, or between 3.0 Pa and 5.0 Pa, and a negative substrate bias between 20 V and 300 V, for example, between 40 V and 150 V, or between 50 V and 100 V. The deposition temperature can be between 200 C. and 800 C., for example, between 300 C. and 600 C.

(24) Single layers are deposited by allowing the body 1 to pass through the obtained deposition flux solely from one combination of cathodes and growth parameters according to the above, while laminated layers are grown by allowing the body 1 alternating pass through the obtained deposition flux from at least two different combination of cathodes but otherwise common growth parameters according to the above.

(25) FIG. 4 shows an -2 X-ray diffractogram of one embodiment of the present disclosure, verifying the sodium chloride structure of the as-deposited coating having a first (Ti,Al)-based nitride layer (2) of (Ti,Al)N and a second (Ti,Al)-based nitride layer 3 of laminated (Ti,Al)N and (Ti,Al,Cr)N layers with an average coating composition of Ti=58 at %, Al=36 at %, and Cr=6 at %, as determined by EDS operated at 20 kV, on a hardmetal (WC:Co) body (1). The broad diffraction peaks at about 37, 43, and 62.5 in 2 (x-axis) are the (111), (200), and (220) lattice planes, respectively of a sodium chloride structure. The rest of the peaks originate from the WC:Co body 1.

(26) The deposition method for the innermost 5 and outermost layers 6 is based on PVD techniques, for example, reactive cathodic arc evaporation, using pure, composite or alloyed metal cathodes for growth of, e.g., TiN, TiC, Ti(C,N) or (Ti,Al)N layers, respectively. The desired layer compositions are obtained by selecting the appropriate reactive gas atmosphere and cathode composition, respectively. Layers are grown with an evaporation current between 50 A and 200 A, a higher current for larger cathode size, in a reactive gas atmosphere comprising pure N.sub.2 or mixed N.sub.2 and, e.g., Ar gases at a total gas pressure between 1.0 Pa and 8.0 Pa, for example, 1.0 Pa and 5.0 Pa, between 2.0 Pa and 5.0 Pa, or between 3.0 Pa and 5.0 Pa, and a negative substrate bias between 20 V and 300 V, for example, between 40 V and 150 V, or between 50 V and 100 V. The deposition temperature is between 200 C. and 800 C., for example, between 300 C. and 600 C.

(27) According to one embodiment of the disclosure, the body is a cutting insert for machining by chip removal comprising a body 1 of a hard alloy of cemented carbide, cermet, ceramics, cubic boron nitride (cBN) based material or high speed steel. The body may also be other metal cutting tools, e.g., drills and end mills.

(28) According to one embodiment the body is cemented carbide having WC/Co94 wt %/6 wt %.

(29) According to one embodiment the body is cemented carbide having WC/Co95 wt %/5 wt %.

(30) According to one embodiment the body is cemented carbide having WC/Co87 wt %/13 wt %.

(31) According to one embodiment of the disclosure, the body 1 is PCBN material containing 35 vol %<cBN<70 vol % in a binder with a bimodal cBN grain size distribution where at least about 50% of the cBN grains have a grain size<5 m and at least 20% of the grains have a grain size>5 m. The binder contains at least one compound including Al and at least one compound including Ti. An example of such a PCBN material and a method of producing it is described in published PCT application WO2014/177503.

(32) The cBN grain size distribution and the grain size of the PCBN materials according to the disclosure is estimated according to the method described in published PCT application WO2014/177503.

EXAMPLES

(33) For Tables 2-9 below, N is the number of A+B layers (bilayers) in the laminated sub-coating and at % is referring to the metallic part of the coating.

Example 1

(34) Cemented carbide inserts, ISO geometry CNMG120408, with compositions WC/Co95/5 wt %, grade A, were used as a body 1 for the layer depositions by cathodic arc evaporation.

(35) Before deposition, the inserts were cleaned in ultrasonic baths of an alkali solution and alcohol. The system was evacuated to a pressure of less than 2.010.sup.3 Pa, after which the inserts, mounted on a rotating fixture, were sputter cleaned with Ar ions.

(36) A first (Ti,Al)-based nitride sub-coating 2 of a single (Ti.sub.1-xAl.sub.x)N.sub.z layer with 0x<0.6 and 0.9z1.1 was deposited directly onto the WC:Co body from (Ti,Al) composite cathodes with compositions selected such to yield the desired coating composition (see Table 1) in 4.5 Pa pure N.sub.2 atmosphere, a bias of 25 V, growth temperature of about 500 C. and an evaporation current of 150 A to a total sub-coating thickness of about 0.5 m.

(37) A second (Ti,Al)-based nitride sub-coating 3 of a laminated structure having alternating A and B layers: A/B/A/B/A/B . . . where layer A is (Ti.sub.1-xAl.sub.x)N.sub.z, 0x<0.6, and layer B is (Ti.sub.1-x1-y1Al.sub.x1Cr.sub.y1)N.sub.z1, 0.55<x1<0.65, 0.05<y1<0.15, and 0.9z11.1 was deposited from (Ti,Al) and (Ti,Al,Cr) composite cathodes with compositions selected such to yield the desired metallic compositions of the coatings (see Table 1) in 4.5 Pa pure N.sub.2 atmosphere, a bias of 40 V, growth temperature of about 500 C. and an evaporation current of 150 A to a total sub-coating thickness of about 2.0 m. Generally, a laminated coating structure could be obtained by allowing the coating body to alternately pass through the deposition flux from at least two different cathode compositions used for growth of the different layers, at otherwise fixed deposition conditions.

(38) Here this is realized by placing the cathodes for growth of (Ti.sub.1-xAl.sub.x)N.sub.z and the cathodes for growth of (Ti.sub.1-x1-y1Al.sub.x1Cr.sub.y1)N.sub.z1 opposite to and facing each other in the deposition system. Through fixture rotation, the inserts will alternately pass through the deposition flux from each cathode whereby two consecutive layers (so called bi-layer) will form from the condensing vapor during a full turn. The average individual thickness of these layers, controlled through the speed of rotation of the fixture, was between 1 nm and 100 nm.

(39) TABLE-US-00001 TABLE 1 Cathode composition Ti Al Cr Layer (at %) (at %) (at %) TiN 100 (Ti.sub.0.77Al.sub.0.23)N 75 25 (Ti.sub.0.44Al.sub.0.56)N 45 55 (Ti.sub.0.32Al.sub.0.58Cr.sub.0.10)N 30 60 10

(40) The as-grown coatings metallic composition as obtained by EDS operated at 20 kV are shown in Table 2.

(41) TABLE-US-00002 TABLE 2 2nd Functional Coating - Laminate 1st Functional (Ti, Al)N/(Ti, Al, Cr)N Average Metal Coating - (Ti, Al)N (Ti, Al)N layer (Ti, Al, Cr)N Layer Composition Ti Al Ti Al Ti Al Cr Ti Al Cr (at (at (at (at d (at (at (at d (at (at (at Sample Body %) %) %) %) (nm) %) %) %) (nm) N %) %) %) 1 (invention) grade A 77 23 77 23 25 32 58 10 25 40 59 37 4 2 (invention) grade A 77 23 77 23 12 32 58 10 12 83 59 37 4 3 grade A 44 56 44 56 12 32 58 10 12 83 39 57 4 4 grade A 100 100 12 32 58 10 12 83 73 23 4 5 (invention) grade A 77 23 77 23 8 32 58 10 8 125 59 37 4 Comparative 6 grade A 100 7 grade A 44 56 8 grade A 77 23 9 grade A 32 58 10

Example 2

(42) In example 1, also cemented carbide inserts, ISO geometry TPUN160308, with composition WC/Co94/6 wt %, grade B, were deposited at the same time with a coating metallic composition as shown in Table 3.

(43) TABLE-US-00003 TABLE 3 2nd Functional Coating - Laminate 1st Functional (Ti, Al)N/(Ti, Al, Cr)N Average Metal Coating - (Ti, Al)N (Ti, Al)N layer (Ti, Al, Cr)N Layer Composition Ti Al Ti Al Ti Al Cr Ti Al Cr (at (at (at (at d (at (at (at d (at (at (at Sample Body %) %) %) %) (nm) %) %) %) (nm) N %) %) %) 10 (invention) grade B 77 23 77 23 25 32 58 10 25 40 59 37 4 11 (invention) grade B 77 23 77 23 12 32 58 10 12 83 59 37 4 12 grade B 44 56 44 56 12 32 58 10 12 83 39 57 4 13 grade B 100 100 12 32 58 10 12 83 73 23 4 14 (invention) grade B 77 23 77 23 8 32 58 10 8 125 59 37 4 Comparative 15 grade B 100 16 grade B 44 56 17 grade B 77 23 18 grade B 32 58 10

Example 3

(44) In example 1, also cemented carbide inserts, ISO geometry XOMX120408TR-ME12, with composition WC/Co87/13 wt %, grade C, were deposited at the same time with a coating metallic composition as shown in Table 4.

(45) TABLE-US-00004 TABLE 4 2nd Functional Coating - Laminate 1st Functional (Ti, Al)N/(Ti, Al, Cr)N Average Metal Coating - (Ti, Al)N (Ti, Al)N layer (Ti, Al, Cr)N Layer Composition Ti Al Ti Al Ti Al Cr Ti Al Cr (at (at (at (at d (at (at (at d (at (at (at Sample Body %) %) %) %) (nm) %) %) %) (nm) N %) %) %) 19 (invention) grade C 77 23 77 23 25 32 58 10 25 40 59 37 4 20 (invention) grade C 77 23 77 23 12 32 58 10 12 83 59 37 4 21 grade C 44 56 44 56 12 32 58 10 12 83 39 57 4 22 grade C 100 100 12 32 58 10 12 83 73 23 4 23 (invention) grade C 77 23 77 23 8 32 58 10 8 125 59 37 4 Comparative 24 grade C 100 25 grade C 44 56 26 grade C 77 23 27 grade C 32 58 10

Example 4

(46) Example 1 was repeated using PCBN inserts containing at least 30 vol % of cBN in a binder, grade D. The binder included at least one nitride, boride, oxide, carbide or carbonitrides compound selected from one or more of the elements belonging to the groups 4, 5 and 6 of the periodic table and Al, e.g., Ti(C,N) and AN.

(47) In addition to the layers grown in example 1, an outermost top layer 6 of a single (Ti.sub.1-x-yAl.sub.x)N.sub.z, layer with 0x<0.6 and 0.9y1.1 was deposited from (Ti,Al) composite cathodes with compositions selected such to yield the desired coating composition (see Table 1) in 4.5 Pa pure N.sub.2 atmosphere, a bias of 40 V, growth temperature of about 500 C. and an evaporation current of 150 A to a total sub-coating thickness of about 0.1 m.

(48) The as-grown coatings and their deposition parameters as well as their metallic composition as obtained by EDS operated at 20 kV are shown in Table 5.

(49) TABLE-US-00005 TABLE 5 2nd Functional Coating - Laminate 1st Functional (Ti, Al)N/(Ti, Al, Cr)N Outermost Top Average Metal Coating - (Ti, Al)N (Ti, Al)N layer (Ti, Al, Cr)N Layer Layer (Ti, Al)N Composition Ti Al Ti Al Ti Al Cr Ti Al Ti Al Cr (at (at (at (at d (at (at (at d (at (at (at (at (at Sample Body %) %) %) %) (nm) %) %) %) (nm) N %) %) %) %) %) 28 (invention) grade D 77 23 77 23 25 32 58 10 25 40 77 23 60 36 4 29 (invention) grade D 77 23 77 23 12 32 58 10 12 83 77 23 60 36 4 30 grade D 44 56 44 56 12 32 58 10 12 83 44 56 39 57 4 31 grade D 100 100 12 32 58 10 12 83 100 74 22 4 32 (invention) grade D 77 23 77 23 8 32 58 10 8 125 77 23 60 36 4 Comparative 33 grade D 100 34 grade D 44 56 35 grade D 77 23 36 grade D 32 58 10

Example 5

(50) In example 4, also PCBN inserts containing 30 vol %<cBN<70 vol %, preferably 40 vol %<cBN<65 vol % in a binder with an average cBN grain size between 0.5 m and 4 m, grade E, were deposited at the same time with a coating metallic composition as shown in Table 6. The binder contains 80 wt %<Ti(C,N)<95 wt % and the rest comprising compounds from two or more of the following group of elements: Ti, N, B, Ni, Cr, Mo, Nb, Fe, Al and O, e.g., TiB.sub.2 and Al.sub.2O.sub.3.

(51) TABLE-US-00006 TABLE 6 2nd Functional Coating - Laminate 1st Functional (Ti, Al)N/(Ti, Al, Cr)N Outermost Top Average Metal Coating - (Ti, Al)N (Ti, Al)N layer (Ti, Al, Cr)N Layer Layer (Ti, Al)N Composition Ti Al Ti Al Ti Al Cr Ti Al Ti Al Cr (at (at (at (at d (at (at (at d (at (at (at (at (at Sample Body %) %) %) %) (nm) %) %) %) (nm) N %) %) %) %) %) 37 (invention) grade E 77 23 77 23 25 32 58 10 25 40 77 23 60 36 4 38 (invention) grade E 77 23 77 23 12 32 58 10 12 83 77 23 60 36 4 39 grade E 44 56 44 56 12 32 58 10 12 83 44 56 39 57 4 40 grade E 100 100 12 32 58 10 12 83 100 74 22 4 41 (invention) grade E 77 23 77 23 8 32 58 10 8 125 77 23 60 36 4 Comparative 42 grade E 100 43 grade E 44 56 44 grade E 77 23 45 grade E 32 58 10

Example 6

(52) In example 4, also PCBN inserts having 45 vol %<cBN<70 vol %, for example, 55 vol %<cBN<65 vol % in a binder with an average cBN grain size between 0.5 m and 4 m, for example, between 1 m and 3 m, grade F, were deposited at the same time with a coating metallic composition as shown in Table 7. The binder contained 80 wt %<Ti(C,N)<90 wt %, less than 1 wt. % of an alloy having one or more of the elements: (Ni, Co, and Cr); less than 10 wt % Mo; and rest of mainly TiB.sub.2 and Al.sub.2O.sub.3.

(53) TABLE-US-00007 TABLE 7 2nd Functional Coating - Laminate 1st Functional (Ti, Al)N/(Ti, Al, Cr)N Outermost Top Average Metal Coating - (Ti, Al)N (Ti, Al)N layer (Ti, Al, Cr)N Layer Layer (Ti, Al)N Composition Ti Al Ti Al Ti Al Cr Ti Al Ti Al Cr (at (at (at (at d (at (at (at d (at (at (at (at (at Sample Body %) %) %) %) (nm) %) %) %) (nm) N %) %) %) %) %) 46 (invention) grade F 77 23 77 23 25 32 58 10 25 40 77 23 60 36 4 47 (invention) grade F 77 23 77 23 12 32 58 10 12 83 77 23 60 36 4 48 grade F 44 56 44 56 12 32 58 10 12 83 44 56 39 57 4 49 grade F 100 100 12 32 58 10 12 83 100 74 22 4 50 (invention) grade F 77 23 77 23 8 32 58 10 8 125 77 23 60 36 4 Comparative 51 grade F 100 52 grade F 44 56 53 grade F 77 23 54 grade F 32 58 10

Example 7

(54) In example 4, also PCBN inserts containing more than 70 vol % cBN, for example, 80 vol %<cBN<95 vol % in a binder with a bimodal cBN grain size distribution where part of the cBN grains have a grain size<10 m, for example, between 0.5 m and 10 m, or between 1 m and 6 m, and another part of the cBN grains have a grain size>10 m, for example, between 10 m and 25 m or between 15 m and 25 m, grade G, were deposited at the same time with a coating metallic composition as shown in Table 8. The binder included compounds of two or more of the elements Al, B, N, W, Co, Ni, Fe, Al and/or O.

(55) TABLE-US-00008 TABLE 8 2nd Functional Coating - Laminate 1st Functional (Ti, Al)N/(Ti, Al, Cr)N Outermost Top Average Metal Coating - (Ti, Al)N (Ti, Al)N layer (Ti, Al, Cr)N Layer Layer (Ti, Al)N Composition Ti Al Ti Al Ti Al Cr Ti Al Ti Al Cr (at (at (at (at d (at (at (at d (at (at (at (at (at Sample Body %) %) %) %) (nm) %) %) %) (nm) N %) %) %) %) %) 55 (invention) grade G 77 23 77 23 25 32 58 10 25 40 77 23 60 36 4 56 (invention) grade G 77 23 77 23 12 32 58 10 12 83 77 23 60 36 4 57 grade G 44 56 44 56 12 32 58 10 12 83 44 56 39 57 4 58 grade G 100 100 12 32 58 10 12 83 100 74 22 4 59 (invention) grade G 77 23 77 23 8 32 58 10 8 125 77 23 60 36 4 Comparative 60 grade G 100 61 grade G 44 56 62 grade G 77 23 63 grade G 32 58 10

Example 8

(56) In example 4, also PCBN inserts containing 35 vol %<cBN<70 vol % in a binder with a bimodal cBN grain size distribution where at least about 50% of the cBN grains have a grain size<5 m and at least 20% of the grains have a grain size>5 m, Grade H, were deposited at the same time with a coating metallic composition as shown in Table 9. The binder contains at least one compound including Al and at least one compound including Ti.

(57) TABLE-US-00009 TABLE 9 2nd Functional Coating - Laminate 1st Functional (Ti, Al)N/(Ti, Al, Cr)N Outermost Top Average Metal Coating - (Ti, Al)N (Ti, Al)N layer (Ti, Al, Cr)N Layer Layer (Ti, Al)N Composition Ti Al Ti Al Ti Al Cr Ti Al Ti Al Cr (at (at (at (at d (at (at (at d (at (at (at (at (at Sample Body %) %) %) %) (nm) %) %) %) (nm) N %) %) %) %) %) 64 (invention) grade H 77 23 77 23 25 32 58 10 25 40 77 23 60 36 4 65 (invention) grade H 77 23 77 23 12 32 58 10 12 83 77 23 60 36 4 66 grade H 44 56 44 56 12 32 58 10 12 83 44 56 39 57 4 67 grade H 100 100 12 32 58 10 12 83 100 74 22 4 68 (invention) grade H 77 23 77 23 8 32 58 10 8 125 77 23 60 36 4 Comparative 69 grade H 100 70 grade H 44 56 71 grade H 77 23 72 grade H 32 58 10

Example 9

(58) For a cutting test, the samples from Table 2 (coated grade A in example 1) were used in a turning operation with the following data:

(59) Geometry: CNMG120412-MF5

(60) Application: Facing

(61) Work piece material: 34CrNiMo6, 48-52 HRc

(62) Cutting speed: 130 m/min

(63) Feed: 0.25 mm/rev.

(64) Depth of cut: 0.3 mm

(65) Cooling No

(66) Performance criterion: Crater wear resistance

(67) Table 10 shows the relative cutting performance of the disclosure indicating a performance boost for sample 2.

(68) TABLE-US-00010 TABLE 10 Sample # Relative performance (%) 2 90-100 7 85-95 9 70-80 3 60-70

Example 10

(69) For a cutting test the samples from Table 3 (coated grade B in example 2) were used in a turning operation with the following data:

(70) Geometry: TPUN160308

(71) Application: Facing

(72) Work piece material: 100Cr6

(73) Cutting speed: 320 m/min

(74) Feed: 0.25 mm/rev.

(75) Depth of cut: 2 mm

(76) Cooling Yes

(77) Performance criterion: Crater wear resistance

(78) TABLE-US-00011 TABLE 11 Sample # Performance 11 good 12 ok 16 ok 18 ok

(79) Table 11 shows the relative cutting performance of the disclosure indicating a performance boost for coating 11.

Example 11

(80) For a cutting test the samples from Table 4 (coated grade C in example 3) were used in a turning operation with the following data:

(81) Geometry: XOMX120408TR-M12

(82) Application: Side milling

(83) Work piece material: 42CrMo4

(84) Cutting speed: 400 m/min

(85) Feed: 0.3 mm/rev

(86) Depth of cut: 3 mm

(87) D (a.sub.e) 65 mm (20%)

(88) Cooling No

(89) Performance criterion: Tool life

(90) Table 12 shows the tool life time results of the disclosure indicating a performance boost for samples 21 and 22.

(91) TABLE-US-00012 TABLE 12 Sample # Life time (min) 21 27 22 26 20 23 25 22

Example 12

(92) For a cutting test the samples from Table 9 (coated grade H in example 8), including an uncoated PCBN grade H insert, were used in a turning operation with the following data:

(93) Geometry: CNGA 120408S-01525-L1-B

(94) Application: Continuous cutting

(95) Work piece material: SAE 8620, 58-62 HRC

(96) Cutting speed: 250 m/min

(97) Feed: 0.1 mm

(98) Depth of cut: 0.1 mm

(99) Cooling No

(100) Performance criterion: Tool life

(101) Table 13 shows the tool life time results of the disclosure indicating a clear performance boost for sample 65.

(102) TABLE-US-00013 TABLE 13 Sample # Tool life (km) 65 11.47 66 9.4 67 7.26 uncoated Grade H 6.67

Example 13

(103) For a cutting test the samples from Table 9 (coated grade H in example 8), were used in a turning operation with the following data:

(104) Geometry: CNGA 120408S-01525-L1-B

(105) Application: Continuous cutting

(106) Work piece material: SAE 8620, 58-62 HRC

(107) Cutting speed: 250 m/min

(108) Feed: 0.1 mm

(109) Depth of cut: 0.1 mm

(110) Cooling No

(111) Performance criterion: Material ratio, Rmr 50% after 50 passes.

(112) Rmr is a standard measure for material ratio of a surface roughness profile and often used to evaluate wear resistance. Table 14 shows a reduced material ratio, Rmr 50% depth after 50 passes for samples 65 and 67 compared to for sample 66.

(113) TABLE-US-00014 TABLE 14 Sample # Rmr 50% depth 65 1.55 66 3.95 67 1.28

Example 14

(114) For a cutting test the samples from Table 9 (coated grade H in example 8), were used in a turning operation with the following data:

(115) Geometry: CNGA 120408S-01525-L1-B

(116) Application: Continuous cutting

(117) Work piece material: SAE 8620, 58-62 HRC

(118) Cutting speed: 250 m/min

(119) Feed: 0.1 mm

(120) Depth of cut: 0.1 mm

(121) Cooling No

(122) Performance criterion: Crater wear/crater depth

(123) Table 15 shows best crater wear resistance for sample 65 compared to samples 66, 67 and uncoated grade H.

(124) TABLE-US-00015 TABLE 15 Sample # Crated depth 65 17.04 66 18.37 67 20.04 Uncoated Grade H 17.7

Example 15

(125) For a cutting test the samples from Table 9 (coated grade H in example 8), were used in a turning operation with the following data:

(126) Geometry: TCGW110208S-01015-11-C

(127) Application: ID Turning, diameter 24.69 mm, length 7.6 mm

(128) Work piece material: 100Cr6, 60 HRc

(129) Cutting speed: 143 m/min

(130) Feed: 0.15 mm/rev

(131) Depth of cut: 0.15 mm

(132) Cooling: Yes, but only for chip evacuation

(133) Performance criterion: Tool life

(134) Table 16 shows increased performance for sample 65 compared to the prior art sample.

(135) TABLE-US-00016 TABLE 16 Sample # Relative performance (%) 65 150-200 Prior art sample 90-100

Example 16

(136) For a cutting test the samples from Table 9 (coated grade H in example 8), were used in a turning operation with the following data:

(137) Geometry: DNGA150612S-01525-L1-B

(138) Application: OD Turning, diameter 45 mm, length 26 mm

(139) Work piece material: 25MoCr4E, 58-64 HRc

(140) Cutting speed: 260 m/min

(141) Feed: 0.15 mm/rev

(142) Depth of cut: 0.2 mm

(143) Cooling: No

(144) Performance criterion: Tool life

(145) Table 17 shows increased performance for sample 65 compared to the prior art sample.

(146) TABLE-US-00017 TABLE 17 Sample # Relative performance (%) 65 180-200 Prior art sample 90-100

(147) Although the present embodiment(s) has been described in relation to particular aspects thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred therefore, that the present embodiment(s) be limited not by the specific disclosure herein, but only by the appended claims.