Multi-layer coating with cubic boron nitride particles

• US 10,639,768 B2
• Filed: 05/29/2012
• Issued: 05/05/2020
• Est. Priority Date: 05/27/2011
• Status: Active Grant

• Current Assignee: P&S Global Holdings, LLC
• Original Assignee: P&S Global Holdings, LLC
• Inventors: Jiang, Wenping, Malshe, Ajay P.
• Primary Examiner(s): Huang, Cheng Yuan
• Application Number:
  US14/119,799
• Publication Number:
  US 20140308511A1
• Time in Patent Office: 2,898 Days
• CPC Class Codes: B23B 2200/081 with projections chip breaking projections in general B23B2200/321
• CPC Class Codes: B23B 2200/087 for chip breaking chip breaking depressions in general B23B2200/323, multiple chip breaking grooves B23B2200/325
• CPC Class Codes: B23B 2200/204 with discontinuous cutting edge
• CPC Class Codes: B23B 2200/205 with cutting edge having a wave form
• CPC Class Codes: B23B 2228/10 Coatings
• CPC Class Codes: B23B 27/141 Specially shaped plate-like cutting inserts, i.e. length greater or equal to width, width greater than or equal to thickness with specially shaped plate-like exchangeable cutting inserts, e.g. chip-breaking groove, B23B27/1603; with removable plate-like milling cutting inserts of special shape B23C5/202
• CPC Class Codes: B23B 27/143 characterised by having chip-breakers
• CPC Class Codes: B23B 27/148 Composition of the cutting inserts
• CPC Class Codes: B24D 18/0009 using moulds or presses
• CPC Class Codes: B24D 3/06 metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
• CPC Class Codes: C04B 2235/3217 Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
• CPC Class Codes: C04B 2235/3843 Titanium carbides
• CPC Class Codes: C04B 2235/3856 Carbonitrides, e.g. titanium carbonitride, zirconium carbonitride
• CPC Class Codes: C04B 2235/3886 Refractory metal nitrides, e.g. vanadium nitride, tungsten nitride
• CPC Class Codes: C04B 2235/604 Pressing at temperatures other than sintering temperatures
• CPC Class Codes: C04B 2235/614 Gas infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/665 Local sintering, e.g. laser sintering
• CPC Class Codes: C04B 2235/667 Sintering using wave energy, e.g. microwave sintering
• CPC Class Codes: C04B 35/5831 based on cubic boron nitrides or Wurtzitic boron nitrides, including crystal structure transformation of powder
• CPC Class Codes: C23C 28/044 coatings specially adapted for cutting tools or wear applications
• CPC Class Codes: C23C 30/005 : on hard metal substrates
• CPC Class Codes: Y10T 407/24 : with chip breaker, guide or deflector
• CPC Class Codes: Y10T 407/27 : comprising tool of specific chemical composition
• CPC Class Codes: Y10T 428/265 : 1 mil or less

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 (AI₂O₃) 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 μ

m.