Cermet tool

Abstract

A cermet tool includes from 75-95 volume % of a hard phase and from 5-25 volume % of a binder phase. The hard phase has a first hard phase with a core portion of (Ti, Nb, Mo) (C, N) and a peripheral portion of (Ti, Nb, Mo, W) (C, N) or (Ti, Nb, Mo, W, Zr) (C, N), a second hard phase with both a core portion and a peripheral portion of (Ti, Nb, Mo, W) (C, N) or (Ti, Nb, Mo, W, Zr) (C, N), and a third hard phase of (Ti, Nb, Mo) (C, N). The ratio of Nbs/Nbi is from 0.8 to 1.2, where Nbs is a maximum Nb amount in a surface region and Nbi is an internal Nb amount in an internal region. The ratio of Ws/Wi is from 1.0 to 1.5, where Ws is a maximum W amount in the surface region and Wi is an internal W amount in the internal region. The area ratios A1, A2, and A3 of the respective hard phases are from 75 to 95 area % for A1, from 4 to 24 area % for A2, and from 1 to 24 area % for A3.

Claims

1. A cermet tool, comprising: not less than 75 volume % and not more than 95 volume % of a hard phase; and not less than 5 volume % and not more than 25 volume % of a binder phase, wherein the hard phase is composed of (a) a first hard phase with a core-rim structure composed of a core portion with a composite carbonitride phase of Ti, Nb, and Mo and a peripheral portion with a composite carbonitride phase of Ti, Nb, Mo, W, and Zr, hereinafter, referred to as (Ti, Nb, Mo, W, Zr) (C, N), or a composite carbonitride phase of Ti, Nb, Mo, and W, hereinafter, referred to as (Ti, Nb, Mo, W)(C, N), (b) a second hard phase with a core-rim structure composed of both a core portion and a peripheral portion with the (Ti, Nb, Mo, W, Zr) (C, N) phase or the (Ti, Nb, Mo, W) (C, N) phase, and (c) a third hard phase composed of a composite carbonitride phase of Ti, Nb, and Mo, the binder phase is composed of an element having at least one selected from the group consisting of Co, Ni, and Fe as a main component, when a maximum content of a concentration of the Nb element in a surface region that is within a range from a surface of the cermet tool to a depth of 300 m is Nbs and an internal content of a concentration of the Nb element in an internal region that is deeper inside from the surface region is Nbi, Nbs/Nbi is not less than 0.8 and not more than 1.2, when a maximum content of a concentration of the W element in the surface region is Ws and an internal content of a concentration of the W element in the internal region is Wi, Ws/Wi is not less than 1.0 and not more than 1.5, and, in the hard phase, in a cross section of the internal region of the cermet tool, when an area ratio of the first hard phase is A1, an area ratio of the second hard phase is A2 , an area ratio of the third hard phase is A3, and an entirety of the area of the hard phase is 100% of the area, A1 is not less than 75% of the area and not more than 95% of the area, A2 is not less than 4% of the area and not more than 24% of the area, and A3 is not less than 1% of the area and not more than 16% of the area.

2. The cermet tool according to claim 1, wherein, when Vickers hardness in the surface region is Hs and Vickers hardness in the internal region is Hi, Hs/Hi is not less than 1.1 and not more than 1.3.

3. The cermet tool according to claim 1, wherein, when an area ratio of the core portion in the first hard phase in the surface region is C1s and an area ratio of the core portion in the first hard phase in the internal region is C1i, C1s/C1i is not less than 0.3 and not more than 0.9.

4. The cermet tool according to claim 1, wherein, when an average particle size of the hard phase in the surface region is ds and an average particle size of the hard phase in the internal region is di, ds/di is not less than 1.0 and not more than 2.0.

5. The cermet tool according to claim 1, wherein an average particle size of the hard phase is not less than 1.0 m and not more than 3.0 m.

6. The cermet tool according to claim 1, further comprising Ta in the hard phase.

7. A coated cermet tool, comprising: the cermet tool according to claim 1; and a coating layer formed on a surface of the cermet tool.

8. The cermet tool according to claim 1, the surface region of the tool is considered to be within 300 m of the tool's outer surface; and the internal region of the tool is considered to be deeper than 300 m of the tool's outer surface.

9. A cermet tool, comprising: not less than 75 volume % and not more than 95 volume % of a hard phase; and not less than 5 volume % and not more than 25 volume % of a binder phase, wherein the hard phase is composed of (a) a first hard phase with a core-rim structure composed of a core portion with a composite carbonitride phase of Ti, Nb, and Mo and a peripheral portion with a composite carbonitride phase of Ti, Nb, Mo, W, and Zr, hereinafter, referred to as (Ti, Nb, Mo, W, Zr)(C, N), or a composite carbonitride phase of Ti, Nb, Mo, and W, hereinafter, referred to as (Ti, Nb, Mo, W) (C, N), (b) a second hard phase with a core-rim structure composed of both a core portion and a peripheral portion with the (Ti, Nb, Mo, W, Zr) (C, N) phase or the (Ti, Nb, Mo, W) (C, N) phase, and (c) a third hard phase composed of a composite carbonitride phase of Ti, Nb, and Mo, the binder phase is composed of an element having at least one selected from the group consisting of Co and Ni as a main component, a surface region of the tool is considered to be within 300 m of the tool's outer surface; an internal region of the tool is considered to be deeper than 300 m of the tool's outer surface; a ratio of Nbs/Nbi is from 0.8 to 1.2, where Nbs is a maximum Nb amount in the surface region and Nbi is an internal Nb amount in the internal region; a ratio of Ws/Wi is from 1.0 to 1.5, where Ws is a maximum W amount in the surface region and Wi is an internal W amount in the internal region; and in the hard phase, in a cross section of the internal region of the cermet tool, when an area ratio of the first hard phase is A1, an area ratio of the second hard phase is A2, an area ratio of the third hard phase is A3, and an entirety of the area of the hard phase is 100% of the area, A1 is not less than 75% of the area and not more than 95% of the area, A2 is not less than 4% of the area and not more than 24% of the area, and A3 is not less than 1% of the area and not more than 16% of the area.

10. The cermet tool according to claim 9, wherein: a ratio Hs/Hi is not less than 1.1 and not more than 1.3, Hs being Vickers hardness in the surface region and Hi being Vickers hardness in the internal region.

11. The cermet tool according to claim 10, wherein: a ratio C1s/C1i is not less than 0.3 and not more than 0.9, C1s being an area ratio of the core portion in the first hard phase in the surface region and C1i being an area ratio of the core portion in the first hard phase in the internal region.

12. The cermet tool according to claim 11, wherein: a ratio ds/di is not less than 1.0 and not more than 2.0, ds being an average particle size of the hard phase in the surface region and di being an average particle size of the hard phase in the internal region.

13. The cermet tool according to claim 12, wherein: an average particle size of the hard phase is not less than 1.0 m and not more than 3.0 m.

14. The cermet tool according to claim 13, further comprising Ta in the hard phase.

15. The cermet tool according to claim 9, wherein: a ratio Hs/Hi is not less than 1.1 and not more than 1.3, Hs being Vickers hardness in the surface region and Hi being Vickers hardness in the internal region; and a ratio ds/di is not less than 1.0 and not more than 2.0, ds being an average particle size of the hard phase in the surface region and di being an average particle size of the hard phase in the internal region.

16. The cermet tool according to claim 15, wherein: an average particle size of the hard phase is not less than 1.0 m and not more than 3.0 m.

17. The cermet tool according to claim 16, further comprising Ta in the hard phase.

18. The cermet tool according to claim 9, wherein: a ratio C1s/C1i is not less than 0.3 and not more than 0.9, C1s being an area ratio of the core portion in the first hard phase in the surface region and C1i being an area ratio of the core portion in the first hard phase in the internal region; and a ratio ds/di is not less than 1.0 and not more than 2.0, ds being an average particle size of the hard phase in the surface region and di being an average particle size of the hard phase in the internal region.

19. The cermet tool according to claim 18, wherein: an average particle size of the hard phase is not less than 1.0 m and not more than 3.0 m.

20. The cermet tool according to claim 19, further comprising Ta in the hard phase.

Description

EXAMPLES

(1) Subsequently, a method of manufacturing a cermet tool of the present invention is described using specific examples. The method of manufacturing a cermet tool of the present invention is not limited in particular as long as the structure (the hard phase and the binder phase) of the cermet tool is achieved.

(2) For example, a method of manufacturing a cermet tool of the present invention includes:

(3) step (A): a step of blending 30 to 90 mass % of titanium niobium molybdenum carbonitride powder or titanium niobium tantalum molybdenum carbonitride powder having an average particle size of 0.5 to 4.0 m, 5 to 40 mass % of at least one type of powder, having an average particle size of 0.5 to 4.0 m, selected from the group consisting of a carbide, a nitride, and a carbonitride of at least one metal element selected from the group consisting of Ti, Zr, Nb, Mo, and W except titanium niobium molybdenum carbonitride and titanium niobium tantalum molybdenum carbonitride powder, and 5 to 30 mass % of at least one type of powder selected from the group consisting of Co, Ni, and Fe having an average particle size of 0.5 to 3.0 m (note that they are 100 mass % in total);

(4) step (B): a mixing step of blending the raw material powder and mixing in a wet ball mill in 5 to 35 hours to prepare a mixture;

(5) step (C): a pressing step of obtaining a pressed body by pressing the mixture to form a predetermined shape of a tool;

(6) step (D): a first temperature-increasing step of increasing temperature of the pressed body obtained in the step (C) to a predetermined temperature within a range between 1200 and 1400 C. in vacuum at 67 Pa or less;

(7) step (E): a second temperature-increasing step of increasing temperature of the pressed body after the step (D) to a sintering temperature within a range between 1400 and 1600 C., from the predetermined temperature within a range between 1200 and 1400 C., (the sintering temperature is higher than the predetermined temperature) in a nitrogen atmosphere from 50 to 1330 Pa;

(8) step (F): a first sintering step of maintaining the pressed body after the step (E) at a sintering temperature within the range between 1400 and 1600 C. in a nitrogen atmosphere at the pressure same as the pressure in the step (E) for a predetermined period of time for sintering;

(9) step (G): a first cooling step of cooling the pressed body after the step (F) to a temperature within a range between 1000 and 1200 C. at a rate of 1 to 50 C./min from the range between 1400 and 1600 C. in a nitrogen pressure from 1 to 50 Pa that is lower than the pressure in the step (F);

(10) step (H): a second sintering step of maintaining the pressed body after the step (G) at a sintering temperature within a range between 1000 and 1200 C. in a nitrogen atmosphere at the pressure same as the pressure in the step (G) for a predetermined period of time for sintering; and

(11) step (I): a second cooling step of cooling the pressed body after the step (H) from the predetermined temperature within the range between 1000 and 1200 C. to normal temperature.

(12) The raw material powder used in the step (A) has an average particle size measured by Fisher method (Fisher Sub-Sieve Sizer (FSSS)) in accordance with American Society for Testing Materials (ASTM) standard B330.

(13) Each step of the method of manufacturing a cermet tool of the present invention has the following significance.

(14) In the step (A), the use of titanium niobium molybdenum carbonitride powder or titanium niobium tantalum molybdenum carbonitride powder and at least one type of powder selected from the group consisting of a carbide, a nitride, and a carbonitride of at least one metal element selected from the group consisting of Ti, Zr, Nb, Mo, and W enables constitution of the first hard phase, the second hard phase, and the third hard phase.

(15) In the step (B), it is possible to adjust the average particle size of the hard phase and uniformly mix the mixed powder with predetermined composition. This is pressed, sintered, and cooled in the following steps to obtain the cermet tool of the present invention having a hard phase and a binder phase with specific composition.

(16) In the step (C), the mixture thus obtained is pressed to form a predetermined shape of a tool. The pressed body thus obtained is sintered in the following sintering step.

(17) In the step (D), the temperature of the pressed body is increased in vacuum at 67 Pa or less to accelerate degasification before appearance of a liquid phase and immediately after appearance of a liquid phase, and thus the sinterability in the following sintering step is improved.

(18) In the step (E), sintering at a temperature within a range between 1400 and 1600 C. enables an increase in the concentration of the W element in the surface region of the cermet tool. In addition, in the steps (E) and (F), the process is performed in the nitrogen atmosphere to prevent denitrification from the surfaces of the pressed body. Therefore, reduction of smoothness on the as-sintered surface accompanied by denitrification and reduction in the hard phase, such as (Ti, Nb, Mo) (C, N), near the as-sintered surface are inhibited.

(19) In the step (G), cooling at a nitrogen pressure of 1 to 50 Pa that is lower than the steps (E) and (F) and at a cooling rate from 1 to 50 C./min enables inhibition of movement of Nb elements to the surfaces of the pressed body.

(20) In the step (H), by holding at a temperature lower than that in the step (F), the area ratios of the first to third hard phases become arbitrary.

(21) Then, in the step (I), the sintered body is cooled to room temperature to obtain the cermet tool of the present invention.

(22) The cermet tool obtained through the steps from (A) to (I) may be subjected to grinding and honing on the edge, as needed.

Example 1

(23) [Production of Cermet Tool]

(24) As raw material powders that were commercially available, (Ti, Nb, Mo) (C, N) powder having an average particle size of 2.0 m (mass ratio of TiC/TiN=50/50), (Ti, Nb, Ta, Mo) (C, N) powder having an average particle size of 2.0 m (mass ratio of TiC/TiN=50/50), WC powder having an average particle size of 1.5 m, ZrC powder having an average particle size of 1.5 m, Co powder having an average particle size of 1.0 m, and Ni powder having an average particle size of 1.0 m were prepared. The average particle sizes of the raw material powders were measured by Fisher method (Fisher Sub-Sieve Sizer (FSSS)) in accordance with American Society for Testing Materials (ASTM) standard B330. The expression (Ti, Nb, Mo) (C, N) means composite carbonitride of Ti, Nb, and Mo and (Ti, Nb, Ta, Mo) (C, N) means composite carbonitride of Ti, Nb, Ta, and Mo.

(25) The prepared raw material powders were weighed to be at the blending composition in Table 1 below, and the weighed raw material powders were put in a stainless steel pot together with an acetone solvent and cemented carbide balls for mixing and grinding in the wet ball mill Time periods for mixing and grinding in the wet ball mill are shown in Table 2. After the mixing and grinding in the wet ball mill, the mixture obtained by evaporating the acetone solvent was pressed at a pressure of 196 MPa in a mold to be, after sintering, a shape of an insert shape of SDKN1203 with a breaker in JIS B 4120, and a pressed body of the mixture was obtained.

(26) TABLE-US-00001 TABLE 1 Sample No. Composition (mass %) Present 60% (Ti.sub.0.80Nb.sub.0.10Mo.sub.0.10) (C.sub.0.5N.sub.0.5), 21% WC, Product 1 1% ZrC, 9% Co, 9% Ni Present 70% (Ti.sub.0.80Nb.sub.0.10Mo.sub.0.10) (C.sub.0.5N.sub.0.5), 11% WC, Product 2 1% ZrC, 9% Co, 9% Ni Present 50% (Ti.sub.0.80Nb.sub.0.10Mo.sub.0.10) (C.sub.0.5N.sub.0.5), 33% WC, Product 3 1% ZrC, 8% Co, 8% Ni Present 60% (Ti.sub.0.70Nb.sub.0.20Mo.sub.0.10) (C.sub.0.5N.sub.0.5), 21% WC, Product 4 1% ZrC, 9% Co, 9% Ni Present 60% (Ti.sub.0.90Nb.sub.0.08Mo.sub.0.02) (C.sub.0.5N.sub.0.5), 21% WC, Product 5 1% ZrC, 9% Co, 9% Ni Present 65% (Ti.sub.0.80Nb.sub.0.10Mo.sub.0.10) (C.sub.0.5N.sub.0.5), 22% WC, Product 6 1% ZrC, 6% Co, 6% Ni Present 53% (Ti.sub.0.80Nb.sub.0.10Mo.sub.0.10) (C.sub.0.5N.sub.0.5), 22% WC, Product 7 1% ZrC, 12% Co, 12% Ni Present 60% (Ti.sub.0.80Nb.sub.0.10Mo.sub.0.10) (C.sub.0.5N.sub.0.5), 22% WC, Product 8 1% ZrC, 12% Co, 5% Ni Present 60% (Ti.sub.0.80Nb.sub.0.10Mo.sub.0.10) (C.sub.0.5N.sub.0.5), 22% WC, Product 9 1% ZrC, 5% Co, 12% Ni Present 60%(Ti.sub.0.70Nb.sub.0.10 Ta.sub.0.10Mo.sub.0.10) (C.sub.0.5N.sub.0.5), Product 10 20% WC, 1% ZrC, 10% Co, 9% Ni Comparative 60% (Ti.sub.0.800Nb.sub.0.10Mo.sub.0.10) (C.sub.0.5N.sub.0.5), 21% WC, Product 1 1% ZrC, 9% Co, 9% Ni Comparative 60% (Ti.sub.0.80Nb.sub.0.10Mo.sub.0.10) (C.sub.0.5N.sub.0.5), 21% WC, Product 2 1% ZrC, 9% Co, 9% Ni Comparative 50%Ti(C.sub.0.5N.sub.0.5), 22% WC, 8%NbC, 1%Mo, 2%C, Product 3 1% ZrC, 9% Co, 9% Ni Comparative 60% (Ti.sub.0.80Nb.sub.0.10Mo.sub.0.10) (C.sub.0.5N.sub.0.5), 21% WC, Product 4 1% ZrC, 9% Co, 9% Ni Comparative 60% (Ti.sub.0.80Nb.sub.0.10Mo.sub.0.10) (C.sub.0.5N.sub.0.5), 21% WC, Product 5 1% ZrC, 9% Co, 9% Ni Comparative 60% (Ti.sub.0.80Nb.sub.0.10Mo.sub.0.10) (C.sub.0.5N.sub.0.5), 21% WC, Product 6 1% ZrC, 9% Co, 9% Ni

(27) TABLE-US-00002 TABLE 2 Sample No. Time Period In Wet Ball Mill (hours) Present Product 1 13 Present Product 2 12 Present Product 3 15 Present Product 4 13 Present Product 5 13 Present Product 6 12 Present Product 7 15 Present Product 8 13 Present Product 9 14 Present Product 10 14 Comparative Product 1 13 Comparative Product 2 30 Comparative Product 3 15 Comparative Product 4 13 Comparative Product 5 14 Comparative Product 6 13

(28) After the pressed body of the mixture was put in a sintering furnace, the temperature was increased to a nitrogen introduction temperature T1 ( C.) shown in Table 3(a) from room temperature in vacuum at 67 Pa or less. When the temperature in the furnace reached the nitrogen introduction temperature T1 ( C.), nitrogen gas was introduced into the sintering furnace until a pressure in the furnace reached a furnace pressure P1 (Pa) shown in Table 3(b). In the nitrogen atmosphere at the furnace pressure P1 (Pa), the temperature was increased from the nitrogen introduction temperature T1 ( C.) to the sintering temperature T2 ( C.) shown in Table 3(c). When the temperature in the furnace reached the sintering temperature T2 ( C.), the sintering temperature T2 ( C.) was maintained in the nitrogen atmosphere at the furnace pressure P1 (Pa) for 60 min for sintering. Then, the nitrogen gas was discharged until the furnace pressure P1 (Pa) reached a furnace pressure P2 (Pa) shown in Table 3(d), and then it was cooled from the sintering temperature T2 ( C.) to a sintering temperature T3 ( C.) shown in Table 3(f) with a cooling rate R1 ( C./min) When the temperature in the furnace reached the sintering temperature T3 ( C.), the sintering temperature T3 ( C.) was maintained in the nitrogen atmosphere at the furnace pressure P2 (Pa) for 60 min for sintering. Then, the nitrogen was discharged and replaced by an argon atmosphere. The argon atmosphere was cooled from the sintering temperature T3 ( C.) to room temperature.

(29) TABLE-US-00003 TABLE 3 (a) (e) Nitrogen (b) (c) (d) Cooling (f) Introduction Pressure in Sintering Pressure in Rate Sintering Temperature Furnace Temperature Furnace R1 Temperature Sample No. T1 ( C.) P1 (Pa) T2 ( C.) P2(Pa) ( C./min) T3 ( C.) Present 1350 200 1550 30 10 1150 Product 1 Present 1300 200 1500 30 10 1100 Product 2 Present 1400 200 1600 30 10 1200 Product 3 Present 1350 200 1550 30 10 1150 Product 4 Present 1350 200 1550 30 50 1150 Product 5 Present 1350 200 1550 30 5 1150 Product 6 Present 1350 200 1550 5 10 1150 Product 7 Present 1350 500 1550 30 10 1150 Product 8 Present 1350 200 1550 50 10 1150 Product 9 Present 1380 200 1550 40 10 1170 Product 10 Comparative 1400 200 1650 30 10 1250 Product 1 Comparative 1250 200 1380 30 10 1150 Product 2 Comparative 1350 200 1550 30 10 1150 Product 3 Comparative 1400 200 1650 100 10 1150 Product 4 Comparative 1400 200 1650 1 100 1250 Product 5 Comparative 1350 200 1550 Product 6

(30) The cermet tool obtained by sintering was subjected to honing at the edge of the cermet tool by a wet brush honing machine.

(31) The cermet tools of Present Products and Comparative Products thus prepared were polished by tilting at 10 degrees relative to surfaces of the cermet tools. Cross-sections of the polished surfaces were observed with an SEM to measure each composition of Nbs and Ws in the surface region and Nbi and Wi in the internal region, respectively, using the EDS attached to the SEM. From the compositions thus measured, Nbs/Nbi and Ws/Wi were obtained. The results are shown in Table 4.

(32) TABLE-US-00004 TABLE 4 Sample No. Nbs/Nbi Ws/Wi Present Product 1 0.9 1.1 Present Product 2 1.0 1.0 Present Product 3 0.8 1.4 Present Product 4 0.9 1.1 Present Product 5 0.9 1.0 Present Product 6 1.0 1.1 Present Product 7 1.1 1.1 Present Product 8 1.1 1.5 Present Product 9 1.0 1.0 Present Product 10 1.0 1.1 Comparative Product 1 1.1 1.4 Comparative Product 2 1.1 0.9 Comparative Product 3 1.5 1.5 Comparative Product 4 1.1 1.3 Comparative Product 5 0.9 1.6 Comparative Product 6 1.4 1.3

(33) For the polished surface polished by tilting at 10 degrees relative to a surface of the cermet tool, an image of a cross-section of the polished surface enlarged at a magnification of 5000 with an SEM was taken. From the image thus taken, the average particle size ds in the surface region of the hard phase and the average particle size di in the internal region were measured using Fullman's expression (1) and ds/di was obtained. The average particle size of the hard phase was defined as an average value of the average particle size ds in the surface region and the average particle size di in the internal region. The ds/di and the average particle size of the hard phase are shown in Table 5. Further, from the image thus taken, the area ratio C1s of the core portion in the first hard phase in the surface region and the area ratio C1i of the core portion in the first hard phase in the internal region were measured using Fullman's expression (1). C1s/C1i was obtained from C1s and C1i that were measured. The results are shown in Table 5.

(34) TABLE-US-00005 TABLE 5 Average Particle Size Sample No. ds/di of Hard Phase (m) C1s/C1i Present Product 1 1.3 1.5 0.8 Present Product 2 1.1 1.2 0.9 Present Product 3 1.6 1.8 0.5 Present Product 4 1.3 1.4 0.8 Present Product 5 1.4 1.6 0.7 Present Product 6 1.7 1.7 0.8 Present Product 7 1.2 1.3 0.7 Present Product 8 1.5 1.7 0.3 Present Product 9 1.0 1.3 0.9 Present Product 10 1.3 1.6 0.7 Comparative Product 1 1.8 3.2 0.5 Comparative Product 2 1.7 0.9 0.7 Comparative Product 3 2.1 1.4 0.4 Comparative Product 4 1.0 1.2 1.0 Comparative Product 5 2.2 2.2 0.5 Comparative Product 6 2.5 1.8 1.1

(35) For the polished surface polished by tilting at 10 degrees relative to the surface of the cermet tool, Vickers hardness at an applied load of 4.9 N was measured using a micro-Vickers hardness tester with intervals of 10 m in a vertical direction from the surface of the cermet tool. The maximum hardness within a range within 300 m from the surface of the cermet tool was defined as Hs. Vickers hardness in 5 spots in positions of 500 m from the surface of the cermet tool was measured and the maximum hardness in the 5 spots was defined as Hi. The results are shown in Table 6.

(36) TABLE-US-00006 TABLE 6 Sample No. Hs/Hi Present Product 1 1.1 Present Product 2 1.1 Present Product 3 1.3 Present Product 4 1.1 Present Product 5 1.1 Present Product 6 1.3 Present Product 7 1.1 Present Product 8 1.3 Present Product 9 1.1 Present Product 10 1.1 Comparative Product 1 1.4 Comparative Product 2 1.0 Comparative Product 3 1.4 Comparative Product 4 1.3 Comparative Product 5 1.4 Comparative Product 6 1.3

(37) The cermet tools of Present Products and Comparative Products were polished vertically to the surfaces of the cermet tools, and from the cross-sections of the polished surfaces, the composition of each hard phase was identified by the SEM with an EDS. Further, an image of the cross-section of the internal region of the cermet tool enlarged at a magnification of 10000 with the SEM was taken. From the image thus taken, the area ratios A1, A2, and A3 of the respective hard phases were obtained using commercially available image analysis software. The results are shown in Table 7. Then, a cross-section to 500 m inside in the depth direction from the surface of the cermet tool was observed with an SEM with an EDS to identify the composition of the binder phase. Further, the cross-section was chemically etched using aqua regia to observe the chemically etched cross-section with the SEM with an EDS. Then, from these two types of cross-section, an area ratio of the hard phase that was not chemically etched and an area ratio of binder phase that was chemically etched were measured. From the results, the proportion of volume % of the hard phase and volume % of the binder phase in the cermet tool were obtained. The results are shown in Table 8.

(38) TABLE-US-00007 TABLE 7 Hard Phase First Hard Phase Second Hard Phase Composition A1 Composition Sample No. Core Portion Peripheral Portion (area %) Core Portion Present (Ti, Nb, Mo) (C, N) (Ti, Nb, Mo, W, Zr) (C, N) 85 (Ti, Nb, Mo, W) (C, N) Product 1 Present (Ti, Nb, Mo) (C, N) (Ti, Nb, Mo, W, Zr) (C, N) 80 (Ti, Nb, Mo, W) (C, N) Product 2 Present (Ti, Nb, Mo) (C, N) (Ti, Nb, Mo, W, Zr) (C, N) 88 (Ti, Nb, Mo, W) (C, N) Product 3 Present (Ti, Nb, Mo) (C, N) (Ti, Nb, Mo, W, Zr) (C, N) 84 (Ti, Nb, Mo, W) (C, N) Product 4 Present (Ti, Nb, Mo) (C, N) (Ti, Nb, Mo, W, Zr) (C, N) 86 (Ti, Nb, Mo, W) (C, N) Product 5 Present (Ti, Nb, Mo) (C, N) (Ti, Nb, Mo, W, Zr) (C, N) 91 (Ti, Nb, Mo, W) (C, N) Product 6 Present (Ti, Nb, Mo) (C, N) (Ti, Nb, Mo, W, Zr) (C, N) 83 (Ti, Nb, Mo, W) (C, N) Product 7 Present (Ti, Nb, Mo) (C, N) (Ti, Nb, Mo, W, Zr) (C, N) 84 (Ti, Nb, Mo, W) (C, N) Product 8 Present (Ti, Nb, Mo) (C, N) (Ti, Nb, Mo, W, Zr) (C, N) 85 (Ti, Nb, Mo, W) (C, N) Product 9 Present (Ti, Nb, Ta, Mo) (C, (Ti, Nb, Ta, Mo, W, Zr) (C, 82 (Ti, Nb, Ta, Mo, W) (C, Product 10 N) N) N) Comparative (Ti, Nb, Mo) (C, N) (Ti, Nb, Mo, W, Zr) (C, N) 73 (Ti, Nb, Mo, W) (C, N) Product 1 Comparative (Ti, Nb, Mo) (C, N) (Ti, Nb, Mo, W, Zr) (C, N) 66 (Ti, Nb, Mo, W) (C, N) Product 2 Comparative Hard Phase having Core Portion of Ti (C, N) and Peripheral Portion of (Ti, Nb, Mo, W, Zr) Product 3 (C, N): 78 area % Hard Phase having Core Portion of (Ti, Nb, Mo, W) (C, N) and Peripheral Portion of (Ti, Nb, Mo, W, Zr) (C, N): 11 area % Hard Phase of Ti (C, N): 11 area % Comparative (Ti, Nb, Mo) (C, N) (Ti, Nb, Mo, W, Zr) (C, N) 91 (Ti, Nb, Mo, W) (C, N) Product 4 Comparative (Ti, Nb, Mo) (C, N) (Ti, Nb, Mo, W, Zr) (C, N) 70 (Ti, Nb, Mo, W) (C, N) Product 5 Comparative (Ti, Nb, Mo) (C, N) (Ti, Nb, Mo, W, Zr) (C, N) 85 (Ti, Nb, Mo, W) (C, N) Product 6 Hard Phase Third Hard Phase Second Hard Phase Composition Composition A2 Single Phase A3 Sample No. Peripheral Portion (area %) Particle (area %) Present (Ti, Nb, Mo, W, Zr) (C, N) 6 (Ti, Nb, Mo) (C, N) 9 Product 1 Present (Ti, Nb, Mo, W, Zr) (C, N) 4 (Ti, Nb, Mo) (C, N) 16 Product 2 Present (Ti, Nb, Mo, W, Zr) (C, N) 10 (Ti, Nb, Mo) (C, N) 2 Product 3 Present (Ti, Nb, Mo, W, Zr) (C, N) 7 (Ti, Nb, Mo) (C, N) 9 Product 4 Present (Ti, Nb, Mo, W, Zr) (C, N) 6 (Ti, Nb, Mo) (C, N) 8 Product 5 Present (Ti, Nb, Mo, W, Zr) (C, N) 7 (Ti, Nb, Mo) (C, N) 2 Product 6 Present (Ti, Nb, Mo, W, Zr) (C, N) 10 (Ti, Nb, Mo) (C, N) 7 Product 7 Present (Ti, Nb, Mo, W, Zr) (C, N) 6 (Ti, Nb, Mo) (C, N) 10 Product 8 Present (Ti, Nb, Mo, W, Zr) (C, N) 7 (Ti, Nb, Mo) (C, N) 8 Product 9 Present (Ti, Nb, Ta, Mo, W, Zr) (C, 8 (Ti, Nb, Ta, Mo) (C, 10 Product 10 N) N) Comparative (Ti, Nb, Mo, W, Zr) (C, N) 27 0 Product 1 Comparative (Ti, Nb, Mo, W, Zr) (C, N) 34 0 Product 2 Comparative Hard Phase having Core Portion of Ti (C, N) and Peripheral Portion of Product 3 (Ti, Nb, Mo, W, Zr) (C, N): 78 area % Hard Phase having Core Portion of (Ti, Nb, Mo, W) (C, N) and Peripheral Portion of (Ti, Nb, Mo, W, Zr) (C, N): 11 area % Hard Phase of Ti (C, N): 11 area % Comparative (Ti, Nb, Mo, W, Zr) (C, N) 9 0 Product 4 Comparative (Ti, Nb, Mo, W, Zr) (C, N) 30 0 Product 5 Comparative (Ti, Nb, Mo, W, Zr) (C, N) 6 (Ti, Nb, Mo) (C, N) 9 Product 6

(39) TABLE-US-00008 TABLE 8 Hard Phase Binder Phase Sample No. (volume %) Composition (volume %) Present Product 1 86.4 (Ti, W) (Co, Ni) 13.6 Present Product 2 86.5 (Ti, W) (Co, Ni) 13.5 Present Product 3 86.1 (Ti, W) (Co, Ni) 13.9 Present Product 4 86.4 (Ti, W) (Co, Ni) 13.6 Present Product 5 86.4 (Ti, W) (Co, Ni) 13.6 Present Product 6 90.3 (Ti, W) (Co, Ni) 9.7 Present Product 7 80.8 (Ti, W) (Co, Ni) 19.2 Present Product 8 86.2 (Ti, W) (Co, Ni) 13.8 Present Product 9 86.4 (Ti, W) (Co, Ni) 13.6 Present Product 10 86.3 (Ti, W) (Co, Ni) 13.7 Comparative Product 1 86.5 (Ti, W) (Co, Ni) 13.5 Comparative Product 2 86.6 (Ti, W) (Co, Ni) 13.4 Comparative Product 3 86.9 (Ti, W, Nb) 13.1 (Co, Ni) Comparative Product 4 86.1 (Ti, W) (Co, Ni) 13.9 Comparative Product 5 86.8 (Ti, W) (Co, Ni) 13.2 Comparative Product 6 86.5 (Ti, W) (Co, Ni) 13.5

(40) Using the samples thus obtained, Cutting Test 1, Cutting Test 2, and Cutting Test 3 were performed. Cutting Test 1 is a test for evaluation of fracture resistance, Cutting Test 2 for evaluation of wear resistance, and Cutting Test 3 for evaluation of a machined surface of a work piece material. The results of Cutting Tests are shown in Table 9.

(41) [Cutting Test 1] Processing mode: Milling, Tool shape: SDKN1203, Work piece material: SCM440, Shape of work piece material: 200 mm80 mm200 mm (shape: board material with six holes of 30 mm size), Cutting speed: 150 m/min, Feed: 0.25 mm/tooth, Depth of cut: 2.0 mm, Coolant: Not used, Point of evaluation: the tool life was defined as the time when the sample has a fracture, and the length of process until tool life was measured.

(42) [Cutting Test 2] Processing mode: Milling, Tool shape: SDKN1203, Work piece material: SCM440, Shape of work piece material: 200 mm80 mm200 mm, Cutting speed: 250 m/min, Feed: 0.15 mm/tooth, Depth of cut: 2.0 mm, Coolant: Not used, and Point of evaluation: the tool life was defined as the time when the sample has a fracture or the sample has 0.3 mm of maximum flank wear width or the corner wear width, and the length of process until tool life was measured.

(43) [Cutting Test 3] Processing mode: Milling, Tool shape: SDKN1203, Work piece material: SS400, Shape of work piece material: 150 mm70 mm150 mm, Cutting speed: 150 m/min, Feed: 0.15 mm/tooth, Depth of cut: 0.3 mm, Coolant: Not used, and Point of evaluation: the arithmetic mean roughness Ra of the process surface of the work piece material was evaluated when the length of process was 5.0 m.

(44) TABLE-US-00009 TABLE 9 Cutting Cutting Test 3 Test 1 Machined surface Fracture Evaluation Test Resistance Cutting Test 2 Surface Roughness Test Wear Resistance Test of Work Piece Tool Life Tool Life Mode of Material Ra Sample No. (m) (m) Damage (m) Present 3.5 12.8 Flank Wear 0.12 Product 1 Present 3.0 13.5 Flank Wear 0.11 Product 2 Present 3.8 11.4 Flank Wear 0.16 Product 3 Present 3.2 11.2 Flank Wear 0.13 Product 4 Present 3.3 12.4 Flank Wear 0.14 Product 5 Present 2.9 14.1 Flank Wear 0.11 Product 6 Present 4.2 9.8 Flank Wear 0.14 Product 7 Present 3.0 13.0 Flank Wear 0.12 Product 8 Present 3.6 9.5 Flank Wear 0.14 Product 9 Present 3.7 12.9 Flank Wear 0.12 Product 10 Comparative 2.1 9.2 Flank Wear 0.26 Product 1 Comparative 1.8 6.3 Flank Wear 0.17 Product 2 Comparative 0.7 5.8 Fracture 0.32 Product 3 Comparative 2.2 2.7 Flank Wear 0.37 Product 4 Comparative 0.8 11.2 Flank Wear 0.22 Product 5 Comparative 1.1 13.0 Flank Wear 0.19 Product 6

(45) The length of process in Cutting Test 1 was evaluated as for 3 m or more, O for not less than 2 m and less than 3 m, for not less than 1 m and less than 2 m, and X for less than 1 m. The length of process in Cutting Test 2 was evaluated as for 10 m or more, O for not less than 7 m and less than 10 m, for not less than 3 m and less than 7 m, and X for less than 3 m. The arithmetic mean roughness Ra of the process surface of the work piece material in Cutting Test 3 was evaluated as for less than 0.15 m, O for not less than 0.15 m and less than 0.25 m, for not less than 0.25 m and less than 0.35 m, and X for 0.35 m or more. The evaluation is in the order of (excellent) >O>>X (poor), and and O show better cutting performances. The results of evaluation thus obtained are shown in Table 10.

(46) TABLE-US-00010 TABLE 10 Cutting Cutting Cutting Sample No. Test 1 Test 2 Test 3 Present Product 1 Present Product 2 Present Product 3 Present Product 4 Present Product 5 Present Product 6 Present Product 7 Present Product 8 Present Product 9 Present Product 10 Comparative Product 1 Comparative Product 2 Comparative Product 3 X Comparative Product 4 X X Comparative Product 5 X Comparative Product 6

(47) All of the evaluations of Present Products were or O, and it is understood that they were excellent in wear resistance and fracture resistance and were capable of reducing the machined surface roughness. In contrast, the evaluations of Comparative Products have or X, and it is understood that they did not satisfy at least one of the performances among wear resistance, fracture resistance, and machined surface roughness.

Example 2

(48) The surfaces of the cermet tools of Present Products 1 to 10 in Example 1 were coated using a PVD apparatus. Present Products 1 to 10 and Comparative Products 1 to 6 were coated with a TiAlN layer having an average layer thickness of 2.5 m on the surfaces and they are defined as Present Products 11 to 20 and Comparative Products 7 to 12. The cermet tool of Present Product 1 was coated with a Ti (C, N) layer having an average layer thickness of 2.5 m on the surface and it is defined as Present Product 21. In addition, the cermet tool of Present Product 1 was coated with an alternate lamination in which TiAlN with 2 nm per layer and TiAlNbWN with 3 nm per layer were alternately laminated 500 layers each and it is define as Present Product 22. Present Products 11 to 22 and Comparative Products 7 to 12 were subjected to Cutting Tests 1, 2, and 3, which are the same as the Tests in Example 1. The results are shown in Table 11.

(49) TABLE-US-00011 TABLE 11 Cutting Cutting Test 3 Test 1 Machined surface Fracture Evaluation Test Resistance Cutting Test 2 Surface Roughness Test Wear Resistance Test of Work Piece Tool Life Tool Life Mode of Material Ra Sample No. (m) (m) Damage (m) Present 3.1 17.4 Flank Wear 0.19 Product 11 Present 2.8 19.0 Flank Wear 0.18 Product 12 Present 3.2 13.5 Flank Wear 0.24 Product 13 Present 2.5 13.5 Flank Wear 0.17 Product 14 Present 2.8 15.4 Flank Wear 0.19 Product 15 Present 2.2 16.8 Flank Wear 0.14 Product 16 Present 3.1 11.1 Flank Wear 0.15 Product 17 Present 2.5 14.2 Flank Wear 0.17 Product 18 Present 3.1 10.8 Flank Wear 0.21 Product 19 Present 3.3 17.6 Flank Wear 0.19 Product 20 Present 2.8 18.2 Flank Wear 0.19 Product 21 Present 3.3 19.8 Flank Wear 0.15 Product 22 Comparative 1.4 11.2 Flank Wear 0.33 Product 7 Comparative 0.9 8.7 Flank Wear 0.25 Product 8 Comparative 0.3 7.4 Fracture 0.42 Product 9 Comparative 1.2 3.3 Flank Wear 0.47 Product 10 Comparative 0.2 13.3 Flank Wear 0.36 Product 11 Comparative 0.1 15.0 Flank Wear 0.55 Product 12

(50) The length of process in Cutting Test 1 was evaluated as for 3 m or more, O for not less than 2 m and less than 3 m, for not less than 1 m and less than 2 m, and X for less than 1 m. The length of process in Cutting Test 2 was evaluated as for 10 m or more, O for not less than 7 m and less than 10 m, for not less than 3 m and less than 7 m, and X for less than 3 m. The arithmetic mean roughness Ra of the process surface of the work piece material in Cutting Test 3 was evaluated as for less than 0.15 m, O for not less than 0.15 m and less than 0.25 m, for not less than 0.25 m and less than 0.35 m, and X for 0.35 m or more. The evaluation is in the order of (excellent) >O>>X (poor), and and O show better cutting performances. The results of evaluation thus obtained are shown in Table 12.

(51) TABLE-US-00012 TABLE 12 Cutting Cutting Cutting Sample No. Test 1 Test 2 Test 3 Present Product 11 Present Product 12 Present Product 13 Present Product 14 Present Product 15 Present Product 16 Present Product 17 Present Product 18 Present Product 19 Present Product 20 Present Product 21 Present Product 22 Comparative Product 7 Comparative Product 8 X Comparative Product 9 X X Comparative Product 10 X Comparative Product 11 X X Comparative Product 12 X X

(52) All Present Products of the evaluations of Present Products were or O, and it is understood that they were excellent in wear resistance and fracture resistance and were capable of reducing machined surface roughness. In contrast, the evaluations of Comparative Products have or X, and it is understood that they did not satisfy at least one of the performances among wear resistance, fracture resistance, and machined surface roughness. In the wear resistance test, the tool life of Present Products without coating a coating layer was 9.5 m or more, whereas the tool life of Present Products with coating a coating layer was 10.8 m or more. Therefore, it is understood that the tool life became longer. Present Products 11 to 22 with coating a coating layer had smaller surface roughness compared to that of Comparative Products 7 to 12 and enabled that life time in wear resistance was longer than that of Present Products 1 to 10 without coating a coating layer.

INDUSTRIAL APPLICABILITY

(53) The coated cutting tool of the present invention is capable of reducing machined surface roughness of a work piece material and is excellent in fracture resistance and chipping resistance without reducing wear resistance. Therefore, the tool is capable of extending tool life more than conventional ones, so that the coated cutting tool of the present invention is highly industrially applicable.