Coated tool

• US 10,640,864 B2
• Filed: 04/10/2015
• Issued: 05/05/2020
• Est. Priority Date: 04/10/2014
• Status: Active Grant

• Current Assignee: Tungaloy Corporation (Berkshire Hathaway Incorporated)
• Original Assignee: Tungaloy Corporation (Berkshire Hathaway Incorporated)
• Inventors: Hirano, Yusuke, Metoki, Kenji
• Primary Examiner(s): Sheikh, Humera N
• Assistant Examiner(s): Ivey, Elizabeth D
• Application Number:
  US15/302,209
• Publication Number:
  US 20170029931A1
• Time in Patent Office: Days
• CPC Class Codes: B23B 2228/105 with specified thickness
• CPC Class Codes: B23B 27/14 Cutting tools of which the bits or tips or cutting inserts are of special material
• CPC Class Codes: B23B 27/148 Composition of the cutting inserts
• CPC Class Codes: B23B 51/00 Tools for drilling machines
• CPC Class Codes: B23C 5/16 characterised by physical features other than shape
• CPC Class Codes: C23C 14/06 characterised by the coating material C23C14/0021 , C23C14/04 take precedence
• CPC Class Codes: C23C 14/0641 Nitrides C23C14/0617 takes precedence
• CPC Class Codes: C23C 14/0664 Carbonitrides
• CPC Class Codes: C23C 14/081 of aluminium, magnesium or beryllium
• CPC Class Codes: C23C 14/083 of refractory metals or yttrium
• CPC Class Codes: C23C 14/32 by explosion; by evaporation and subsequent ionisation of the vapours , e.g. ion-platingC23C14/34 - C23C14/48 take precedence
• CPC Class Codes: C23C 28/042 including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides
• CPC Class Codes: C23C 28/044 coatings specially adapted for cutting tools or wear applications
• CPC Class Codes: C23C 28/42 characterized by the composition of the alternating layers
• CPC Class Codes: C23C 28/44 characterized by a measurable physical property of the alternating layer or system, e.g. thickness, density, hardness
• CPC Class Codes: C23C 30/005 on hard metal substrates

Abstract

The coated tool has a substrate and a coating layer. The coating layer contains alternating first and second laminated structures. The first laminated structure contains at least two kinds of alternating layers having different compositions. An average thickness of the layers contained in the first laminated structure is 60 nm or more and 500 nm or less. The second laminated structure contains at least two kinds of alternating layers having different compositions. An average thickness of the layers contained in the second laminated structure is 2 nm or more and less than 60 nm. The layers contained in the first laminated structure and the second laminated structure contain a compound having one or more specific metals and at least one or more of carbon, nitrogen, oxygen and boron. Average thickness(es) of the first and second laminated structure is/are continuously or stepwisely increased in a direction away from the substrate.

Claims

1. A coated tool which comprises a substrate, and a coating layer formed onto a surface of the substrate, wherein the coating layer contains a first laminated structure and a second laminated structure, each of the first laminated structure and the second laminated structure are laminated alternately and continuously twice or more, the first laminated structure contains at least two kinds of layers having different compositions, and the two kinds of layers contained in the first laminated structure are alternately laminated twice or more, an average thickness of the layers contained in the first laminated structure is 60 nm or more and 500 nm or less, the second laminated structure contains at least two kinds of layers having different compositions, and the two kinds of layers contained in the second laminated structure are alternately laminated twice or more, an average thickness of the layers contained in the second laminated structure is 2 nm or more and less than 60 nm, the layers contained in the first laminated structure and the second laminated structure contain a compound comprising at least one metal element selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Al, Si, Sr, Y, Sn and Bi, and at least one non-metal element selected from the group consisting of carbon, nitrogen, oxygen and boron, and an average thickness of the first laminated structure and an average thickness of the second laminated structure are both stepwisely increased from a substrate side toward a surface side of the coating layer, such that an outermost portion of the first laminated structure and an outermost portion of the second laminated structure have a greater average thickness than remaining portions of the first and second laminated structures;

wherein when an average thickness of the first laminated structure nearest to the substrate is given by TA1, and an average thickness of the first laminated structure nearest to the surface of the coating layer is given by TB1, then a ratio of TA1 to TB1 is 5% or more and 50% or less;

wherein when an average thickness of the second laminated structure nearest to the substrate is given by TA2, and an average thickness of the second laminated structure nearest to the surface of the coating layer is given by TB2, then a ratio of TA2 to TB2 is 5% or more and 50% or less;

wherein when an average thickness of the layers contained in the first laminated structure nearest to the substrate is given by TC1, and an average thickness of the layers contained in the first laminated structure nearest to the surface of the coating layer is given by TD1, then a ratio of TC1 to TD1 is 12% or more and 70% or less;

wherein when an average thickness of the layers contained in the second laminated structure nearest to the substrate is given by TC2, and an average thickness of the layers contained in the second laminated structure nearest to the surface of the coating layer is given by TD2, then a ratio of TC2 to TD2 is 5% or more and 70% or less; and

wherein a grain size of the first laminated structure is increased with the increase of the average thicknesses of the first laminated structure and the second laminated structure.

2. The coated tool according to claim 1, wherein an average thickness of the first laminated structure is 0.2 μ

m or more and 6 μ

m or less.

3. The coated tool according to claim 2, wherein:

the layers contained in the first laminated structure and the layers contained in the second laminated structure contain a compound comprising;

at least two metal elements selected from the group consisting of Ti, Nb, Ta, Cr, W, Al, Si, Sr and Y, and

at least one non-metal element selected from the group consisting of carbon, nitrogen, oxygen and boron.

4. The coated tool according to claim 1, wherein an average thickness of the second laminated structure is 0.02 μ

m or more and 6 μ

m or less.

5. The coated tool according to claim 1, wherein an average thickness of the whole coating layer is 0.22 μ

m or more and 12 μ

m or less.

6. The coated tool according to claim 1, wherein the layers contained in the first laminated structure and the layers contained in the second laminated structure contain a compound comprising at least two metal elements selected from the group consisting of Ti, Nb, Ta, Cr, W, Al, Si, Sr and Y, and at least one non-metal element selected from the group consisting of carbon, nitrogen, oxygen and boron.

7. The coated tool according to claim 1, wherein:

an average thickness of the first laminated structure is 0.2 μ

m or more and 6 μ

m or less; and

an average thickness of the second laminated structure is 0.02 μ

m or more and 6 μ

m or less.

8. The coated tool according to claim 7, wherein:

an average thickness of the whole coating layer is 0.22 μ

m or more and 12 μ

m or less.

9. The coated tool according to claim 1, wherein:

an average thickness of a first laminated structure closest to the substrate is thinner than an average thickness of a first laminated structure farther from the substrate;

an average thickness of a second laminated structure closest to the substrate is thinner than an average thickness of a second laminated structure farther from the substrate, at least three first laminated structures and at least three second laminated structures are laminated alternately;

the total number of layers in each of the first laminated structures increases, with increasing distance from the substrate;

the total number of layers in each of the second laminated structures increases, with increasing distance from the substrate; and

the total number of layers in any of the first laminated structures is less than the total number of layers in any of the second laminated structures.

10. A coated tool which comprises a substrate, and a coating layer formed onto a surface of the substrate, wherein the coating layer contains a first laminated structure and a second laminated structure, each of the first laminated structure and the second laminated structure are laminated alternately and continuously twice or more, the first laminated structure contains at least two kinds of layers having different compositions, and the two kinds of the layers contained in the first laminated structure are alternately laminated twice or more, an average thickness of the layers contained in the first laminated structure is 60 nm or more and 500 nm or less, the second laminated structure contains at least two kinds of layers having different compositions, and the two kinds of the layers contained in the second laminated structure are alternately laminated twice or more, an average thickness of the layers contained in the second laminated structure is 2 nm or more and less than 60 nm, the layers contained in the first laminated structure and the second laminated structure contain a compound comprising at least one metal element selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Al, Si, Sr, Y, Sn and Bi, and at least one nonmetal element selected from the group consisting of carbon, nitrogen, oxygen and boron, an average thickness of a first laminated structure closest to the substrate is thinner than an average thickness of a first laminated structure farther from the substrate;

an average thickness of a second laminated structure closest to the substrate is thinner than an average thickness of a second laminated structure farther from the substrate;

the average thickness of the first laminated structure and the average thickness of the second laminated structure are both stepwisely increased from a substrate side toward a surface side of the coating layer, such that an outermost portion of the first laminated structure and an outermost portion of the second laminated structure have a greater average thickness than remaining portions of the first and second laminated structures;

wherein when an average thickness of the first laminated structure nearest to the substrate is given by TA1, and an average thickness of the first laminated structure nearest to the surface of the coating layer is given by TB1, then a ratio of TA1 to TB1 is 5% or more and 50% or less;

wherein when an average thickness of the second laminated structure nearest to the substrate is given by TA2, and an average thickness of the second laminated structure nearest to the surface of the coating layer is given by TB2, then a ratio of TA2 to TB2 is 5% or more and 50% or less;

wherein when an average thickness of the layers contained in the first laminated structure nearest to the substrate is given by TC1, and an average thickness of the layers contained in the first laminated structure nearest to the surface of the coating layer is given by TD1, then a ratio of TC1 to TD1 is 12% or more and 70% or less;

wherein when an average thickness of the layers contained in the second laminated structure nearest to the substrate is given by TC2, and an average thickness of the layers contained in the second laminated structure nearest to the surface of the coating layer is given by TD2, then a ratio of TC2 to TD2 is 5% or more and 70% or less; and

wherein a grain size of the first laminated structure is increased with the increase of the average thicknesses of the first laminated structure and the second laminated structure.

11. The coated tool according to claim 10, wherein:

at least three first laminated structures and at least three second laminated structures are laminated alternately;

the total number of layers in each of the first laminated structures increases, with increasing distance from the substrate; and

the total number of layers in each of the second laminated structures increases, with increasing distance from the substrate.

12. The coated tool according to claim 11, wherein:

the total number of layers in any of the first laminated structures is less than the total number of layers in any of the second laminated structures.