THICK THERMAL BARRIER COATING FOR SUPERABRASIVE TOOL

• US 20110020081A1
• Filed: 03/03/2010
• Published: 01/27/2011
• Est. Priority Date: 03/03/2009
• Status: Active Grant

• Current Assignee: Diamond Innovations Incorporated (Sandvik AB)
• Original Assignee: Diamond Innovations Incorporated (Sandvik AB)
• Inventors: Selinder, Torbjörn, Webb, Steven W.
• Granted Patent: US 8,652,638 B2
• Time in Patent Office: Days
• US Class Current: 407/115
• CPC Class Codes: B22F 2005/001 Cutting tools, earth boring or grinding tool other than table ware
• CPC Class Codes: B22F 7/06 of composite workpieces or articles from parts, e.g. to form tipped tools B22F7/002 takes precedence
• CPC Class Codes: B22F 7/08 with one or more parts not made from powder B22F7/062 takes precedence
• CPC Class Codes: B23B 2200/00 Details of cutting inserts
• CPC Class Codes: B23B 2200/08 Rake or top surfaces
• CPC Class Codes: B23B 2200/12 Side or flank surfaces
• CPC Class Codes: B23B 2200/242 bevelled or chamfered
• CPC Class Codes: B23B 2222/04 Aluminium
• CPC Class Codes: B23B 2222/16 Cermet
• CPC Class Codes: B23B 2224/28 Titanium carbide
• CPC Class Codes: B23B 2224/36 Titanium nitride
• CPC Class Codes: B23B 2226/12 Boron nitride
• CPC Class Codes: B23B 2226/125 cubic [CBN]
• CPC Class Codes: B23B 2226/31 Diamond
• CPC Class Codes: B23B 2226/315 polycrystalline [PCD]
• CPC Class Codes: B23B 2228/04 applied by chemical vapour deposition [CVD]
• CPC Class Codes: B23B 2228/08 applied by physical vapour deposition [PVD]
• CPC Class Codes: B23B 2228/10 Coatings
• CPC Class Codes: B23B 2228/105 with specified thickness
• 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 27/148 : Composition of the cutting inserts
• CPC Class Codes: B24D 3/007 : the constituent being used as bonding agent between different parts of an abrasive tool
• 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 408/81 : Tool having crystalline cutting edge
• CPC Class Codes: Y10T 428/30 : Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

The present disclosure relates to cutting tool edges that include on a rake face a superabrasive layer and a HPHT sintered or HPHT bonded cap layer. The cap layer improves adhesion between the superabrasive layer and an optional coating system for the cutting insert and acts as a thick anti-friction layer and/or a thermal barrier coating.

Claims

1. A cutting insert, comprising:

a superabrasive layer on a rake face of the cutting insert; and

a cap layer high pressure/high temperature (HPHT) sintered or high pressure/high temperature (HPHT) bonded to the superabrasive layer on the rake face;

wherein the cap layer includes one or more layers each having a composition including a cermet, a ceramic or a metal, and

wherein a thickness of the cap layer is about 20 μ

m or thicker.

2. The cutting insert according to claim 1, comprising a support body, wherein the superabrasive layer is sintered to a first surface of the support body.

3. The cutting insert according to claim 1, comprising a coating system deposited onto the cap layer on the rake face and onto a flank face of the cutting insert.

4. The cutting insert according to claim 1, wherein the superabrasive layer has a composition including polycrystalline boron nitride (PCBN) or polycrystalline diamond (PCD).

5. The cutting insert according to claim 1, wherein the thickness of the cap layer is about 30 μ

m to about 200 μ

m.

6. The cutting insert according to claim 5, wherein the thickness of the cap layer is less than about 150 μ

m.

7. The cutting insert according to claim 1, wherein the cermet includes WC/Co or TiCN/Co and has a metal content of 0.5 w/w to 25 w/w.

8. The cutting insert according to claim 1, wherein the ceramic includes a nitride, boride, carbide or an oxide.

9. The cutting insert according to claim 8, wherein the ceramic is alumina, AlN, or ZrO₂.

10. The cutting insert according to claim 1, wherein the metal includes Ta, Nb, Mo, or refractory metals.

11. The cutting insert according to claim 3, wherein the coating system includes at least one ceramic layer.

12. The cutting insert according to claim 11, wherein the at least one ceramic layer has a composition including TiN, TiC, TiCN, TiSiN, SiN, alumina, AlN, ZrO₂, ZrN, chromia and combinations and/or alloys thereof.

13. The cutting insert according to claim 1, wherein the cutting insert includes a chamfer and wherein the thickness of the cap layer is equal to or less than a height of the chamfer.

14. A cutting insert, comprising:

a rake face and an opposing base surface; and

a plurality of flank faces interconnect the rake face and the base surface,

wherein an intersection of the plurality of flank faces and the rake face form a cutting edge,

wherein the rake face of the cutting insert includes the following, in order from an outermost surface inward to a substrate;

a coating system, a cap layer, a superabrasive layer, and the substrate,

wherein the cap layer has a composition including a cermet, a ceramic or a metal, and

wherein a thickness of the cap layer is about 20 μ

m to about 200 μ

m.

15. The cutting insert according to claim 14, wherein the cap layer is HPHT sintered or HPHT bonded to the superabrasive layer and the superabrasive layer is sintered to the substrate.

16. The cutting insert according to claim 14, wherein at least one of the flank faces of the cutting insert includes the following, in order from an outermost surface inward:

the coating system.

17. The cutting insert according to claim 14, wherein the coating system includes at least one ceramic layer having a composition including a nitride, boride, carbide or an oxide.

18. A method of manufacturing a cutting insert, the method comprising:

bonding a cap layer to a surface of a superabrasive layer of a substrate structure by a high pressure/high temperature (HPHT) process;

shaping the substrate structure with the bonded cap layer to a shape of a cutting insert; and

coating a rake face and a flank face of the cutting insert with a coating system, the coating system including at least one ceramic layer,

wherein the cap layer has a composition including a cermet, a ceramic or a metal, and

wherein a thickness of the cap layer is about 20 μ

m to about 200 μ

m.

19. The method according to claim 18, wherein the coating system includes at least one ceramic layer having a composition including a nitride, boride, carbide or an oxide.

20. The method according to claim 19, wherein the at least one ceramic layer has a composition including TiN, TiC, TiCN, TiSiN, SiN, alumina, AlN, ZrO₂, ZrN, chromia and combinations and/or alloys thereof.

21. A cutting insert, comprising:

a superabrasive layer on a rake face of the cutting insert; and

a cap layer high pressure/high temperature (HPHT) sintered or high pressure/high temperature (HPHT) bonded to the superabrasive layer on the rake face;

wherein the cap layer includes one or more layers each having a composition including a cermet, a ceramic or a metal, further comprising a coating system deposited onto the cap layer on the rake face and onto a flank face of the cutting insert and

wherein a thickness of the cap layer is about 20 μ

m or thicker.

22. The cutting insert according to claim 21, comprising a support body, wherein the superabrasive layer is sintered to a first surface of the support body.

23. The cutting insert according to claim 21, wherein the superabrasive layer has a composition including polycrystalline boron nitride (PCBN) or polycrystalline diamond (PCD).

24. The cutting insert according to claim 21, wherein the thickness of the cap layer is about 30 μ

m to about 200 μ

m.

25. The cutting insert according to claim 24, wherein the thickness of the cap layer is less than about 150 μ

m.

26. A superabrasive tool, comprising:

a superabrasive layer on a face of the cutting insert; and

a cap layer high pressure/high temperature (HPHT) sintered or high pressure/high temperature (HPHT) bonded to the superabrasive layer on the face;

wherein the cap layer includes one or more layers each having a composition including a cermet, a ceramic or a metal, and

wherein a thickness of the cap layer is about 20 μ

m or thicker.

27. The tool according to claim 26, comprising a support body, wherein the superabrasive layer is sintered to a first surface of the support body.

28. The tool according to claim 26, comprising a coating system deposited onto the cap layer.

29. The method according to claim 28, wherein the coating system includes at least one ceramic layer having a composition including a nitride, boride, carbide or an oxide.

30. The method according to claim 29, wherein the at least one ceramic layer has a composition including TiN, TiC, TiCN, TiSiN, SiN, alumina, AlN, ZrO₂, ZrN, chromia and combinations and/or alloys thereof.