Kennametal Inc.

Yamawa Manufacturing Limited

Anakkavur T Santhanam

Rajendra V Godse

Prem C Jindal

Dennis T Quinto

Kenneth E Undercoffer

George P Grab

Mark S Greenfield

Edward V Conley

Willard E Henderer

Sadayuki Akaki

William D Ewald

Roger A Baillargeon

A coated carbide tap comprises a substrate consisting of tungsten carbide cemented with 12 to 16% by weight cobalt with additions of small amounts of transition metal carbides added to restrain grain growth, and may also contain low levels of impurities that might be picked up during processing. The substrate is coated with a layer of metal nitrides, carbides, carbonitrides, borides and/or oxides, the metal being chosen from one or more of the following: aluminum, silicon and the transition metals from Groups IV, V, and VIof the Periodic Chart. The coating may comprise a monolayer and/or alternating layers optionally with varying chemical composition. To reduce friction, a top outer layer comprised of molybdenum disulphide; molybdenum disulphide and transition metals, or any combination thereof; carbon; carbon and transition metal carbides, or any combination thereof; carbon and a transition metal, or any combination thereof; and/or carbon nitride may be either co-deposited as a single layer or deposited in multiple or alternating layers to the coating. The coated carbide tap of the invention can be used at cutting speeds at least three times faster than conventional taps without chipping or breaking the tap.

Coated carbide tap

A coated cemented (binder alloy, e.g., cobalt-chromium alloy) tungsten carbide cutting insert that comprises a substrate and a coating. The substrate contains at least about 70 weight percent tungsten and carbon, between about 3 weight percent and about 12 weight percent cobalt, and at least 0.09 weight percent chromium. The substrate presents a surface zone of binder alloy enrichment that begins near (or at) and extends inwardly from a peripheral surface of the substrate. The coating includes a base layer that contains chromium.

Chromium-containing cemented carbide body having a surface zone of binder enrichment

Provided is a coated cutting tool having a coating and a substrate. The coating includes at least one CVD layer which may have a residual tensile stress and at least one layer having a high residual compressive stress. The outermost layer of the coating is preferably the one containing residual compressive stresses. The substrate is a composite having hard refractory grains.

Coated cutting tools

Provided is a coated cutting tool having a coating and a substrate. The coating includes at least one chemical vapor deposited (CVD) layer and at least one physical vapor deposited (PVD) layer. The outermost layer of the coating is a PVD layer, containing residual compressive stresses. The substrate is a composite having hard refractory grains bonded together by a binder material.

CVD and PVD coated cutting tools

Provided is a coated cutting tool having a coating and a substrate. The coating includes at least one CVD layer which may have a residual tensile stress and at least one layer having a high residual compressive stress. The outermost layer of the coating is preferably the one containing residual compressive stresses. The substrate is a composite having hard refractory grains. The cutting tool has been found to be particularly useful in the machining of titanium alloys and superalloys.

Method of machining using coated cutting tools

Provided is a coated cutting tool having a binder enriched substrate. The coating includes at least one CVD layer which may be in a state of residual tensile stress and at least one layer in a state of residual compressive stress.

Binder enriched coated cutting tool

Provided is a coated cutting tool having a binder enriched substrate. The coating includes at least one chemical vapor deposited (CVD) layer and at least one physical vapor deposited (PVD) layer. The PVD layer contains residual compressive stresses.

Binder enriched CVD and PVD coated cutting tool

A coated indexable cutting insert for wet and dry milling of cast irons is provided. The substrate of the insert is composed of a cemented tungsten carbide based composition containing about 5.7 to about 6.4 weight percent cobalt and about 2.9 to about 3.6 weight percent tantalum. The coating includes two coatings of differing composition. The first coating is selected from titanium carbide, titanium carbonitride, and titanium nitride. The second coating is alumina.

Coated cutting insert

A cermet cutting tool is provided having a composition containing the following: about 3.5 to about 6.5 w/o (weight percent) nickel; about 4.5 to about 7.5 w/o cobalt, wherein the sum of nickel plus cobalt is between about 8 to 11 w/o; about 20 to about 25 w/o tungsten; about 5 to about 11 w/o molybdenum; up to about 6 w/o tantalum plus niobium; up to about 0.05 w/o chromium; up to about 1 w/o aluminum; and up to about 3 w/o vanadium; with the remainder being essentially titanium, carbon, and nitrogen, wherein at least substantially all the carbon and nitrogen are present as metal compounds selected from the group consisting of metal carbonitrides and mixtures of metal carbonitrides and metal carbides where said metal is selected from the group consisting of tungsten, molybdenum, titanium, tantalum, niobium, vanadium, chromium, their solid solutions and there mixtures.

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Monroeville, PA, United States of America

Anakkavur T Santhanam