Coating method and coated element

• US 20060099422A1
• Filed: 09/26/2003
• Published: 05/11/2006
• Est. Priority Date: 09/27/2002
• Status: Abandoned Application

• Current Assignee: CemeCon AG
• Original Assignee: CemeCon AG
• Inventors: Lemmer, Oliver, Gussone, Joachim, Breidt, Dirk
• Application Number:
  US10/529,258
• Publication Number:
  US 20060099422A1
• Time in Patent Office: Days
• US Class Current: 428/408
• CPC Class Codes: C23C 16/0227 by cleaning or etching
• CPC Class Codes: C23C 16/27 Diamond only
• CPC Class Codes: C23C 30/005 on hard metal substrates
• CPC Class Codes: Y10T 428/30 Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

Disclosed are an element comprising a hard metal substrate (10) and a diamond layer (30), and a method for coating a hard metal substrate (10). Said hard metal substrate is provided with hard material particles (20) and surrounding binder material (22). The hard material particles (20) are surrounded by binding material (22) in a first area (24) comprising intact hard metal. The transition region of the first area (24) encompasses a deep profile having recesses (18) and elevations (16). The diamond layer (30) is braced with the substrate material (10) with the aid of said deep profile, portions of the diamond layer (30) being disposed deeper within the substrate (10) than elevations (16) of the first area (24). Said structure is obtained by means of a pretreatment process in which a hard metal substrate (10) is first subjected to selective etching in order to remove the binding material (22). A porous zone having a deep profile is formed. The hard material particles located within the porous zone (12) are removed by means of microbeams or a second, WC-selective etching step. A cobalt concentration on the surface is finally removed in a Co-selective etching step, and the substrate (10) is coated with a diamond layer by means of CVD.

Claims

1. Element having

a substrate of a hard metal or cermet comprising hard material particles and binding material

and a diamond layer,

wherein the diamond layer is disposed over a first region of intact substrate material within which hard material particles are surrounded by binding material

wherein the transition region of the first region, which is disposed towards the diamond layer, comprises a depth profile having indents and elevations,

and wherein the diamond layer is braced with the substrate material such that portions of the diamond layer are disposed deeper in the substrate than elevations of the first region

characterised in that:

between the first region and the diamond layer there is disposed a porous zone in which hard material particles are free of binding material and

wherein the hard material particles form an intact hard material particle structure within the porous zone and are not weakened at the grain edges by etching.

2. Element according to claim 1 wherein the porous zone comprises an average thickness of 3-7 μ

m.

3. Element according to claim 1 wherein the porous zone comprises an average thickness d, the depth profile of the transition region of the first region comprises an average peak-to-valley height Rz and a maximum peak-to-valley height Rmax and wherein d is less than or equal to Rmax and preferably d is less than or equal to Rz.

4. Element according to claim 1 wherein the substrate material contains WC hard material particles and a binder containing Co, and wherein the grain size of the hard material particles is less than 0.8 μ

m and preferably less than 0.5 μ

m.

5. Element according to claim 1 wherein the binding material contains 3 to 12% and preferably more than 6% and particularly preferably 8 to 10% cobalt.

6. Element according to claim 1 wherein the transition region of the first region comprises an average peak-to-valley height Rz of 1 to 20 μ

m, preferably 2 to 10 μ

m and particularly preferably 3 to 7 μ

m.

7. Element according to claim 1 wherein the average peak-to-valley height Rz of the transition region of the first region is greater than the grain size of the hard metal, preferably more than five times the grain size of the hard metal.

8. Method for coating a substrate material with a diamond layer wherein the substrate material contains hard material particles and binding material wherein

a binding material-selective etching is executed in a first step, wherein the binding material in a border zone of the substrate is removed,

a hard material-selective etching is executed in a second step, wherein the hard material particles in the border zone are completely removed so that a surface profile with elevations and indents is created,

a binding material-selective etching is executed in a third step, wherein a binding material concentration on the surface is removed,

and the substrate is coated with a diamond layer thereafter.

9. Method according to claim 8 wherein the etching executed in the third step comprises a lesser etching depth than the etching executed in the first step.

10. Method according to claim 8 wherein in the second step the etching is executed with one of the following chemicals:

compounds of potassium permanganate and caustic soda, compounds of potassium ferricyanide and caustic soda, caustic soda, caustic potash solution and/or sodium carbonate.

11. Method according to claim 8 wherein in the third step the etching is executed as electrochemical etching with sulphuric acid and/or hydrochloric acid or as chemical etching with HCl/H₂O₂ or H₂SO₄/H₂O₂.

16. Method according to claim 8 wherein in the first step an average etching depth of 1 to 20 μ

m, preferably 2 to 10 μ

m and particularly preferably 3 to 7 μ

m is achieved.

17. Method according to claim 8 wherein in the first step the etching is executed with one of the following chemicals:

HCL, HNO₃, compounds of H₂SO₄ and H₂O₂, compounds of HCl and H₂O₂.

18. Method according to claim 8 wherein the diamond layer is applied by means of CVD.

12. Method for coating a substrate material with a diamond layer (wherein the substrate material comprises hard material particles and surrounding binding material wherein

in a first step a selective etching of the binding material is executed,

hard material particles are removed in a subsequent mechanical removal step by means of a blasting process with blasting particles,

and the substrate is afterwards coated with a diamond layer.

13. Method according to claim 12 wherein a binding material-selective etching step is executed after the mechanical removal step.

14. Method according to claim 12 wherein a cleaning step is executed before the coating.

15. Method according to claim 12 wherein the blasting particles consist of SiC and comprise a grain size of less than 100 μ

m.

19. Method according to claim 12 wherein in the first step an average etching depth of 1 to 20 μ

m, preferably 2 to 10 μ

m and particularly preferably 3 to 7 μ

m is achieved.

20. Method according to claim 12 wherein in the first step the etching is executed with one of the following chemicals:

HCL, HNO₃, compounds of H₂SO₄ and H₂O₂, compounds of HCl and H₂O₂.

21. Method according to claim 12 wherein the diamond layer is applied by means of CVD.