Kennametal Inc.

Kennamtetal Inc.

Oerlikon Trading Ltd.

Ronald Penich

Yixiong Liu

Vineet Kumar

Wangyang Ni

Mark S Greenfield

Peter Rudolf Leicht

Aharon Inspektor

Parag L Hegde

Zhenyu Liu

Nicholas F Waggle, Jr

Chen Chen

Zhigang Ban

Dennis T Quinto

Charles Erik Bauer

Michael Frank Beblo

Fengting Xu

Volker-Hermann Derflinger

Qian Ding

In one aspect, coatings are described herein employing composite architectures providing high aluminum content and high hardness for various cutting applications. For example, a coated cutting tool comprises a substrate and a coating comprising a refractory layer deposited by physical vapor deposition adhered to the substrate, the refractory layer comprising a plurality of sublayer groups, a sublayer group comprising a titanium aluminum nitride sublayer and an adjacent composite sublayer comprising alternating nanolayers of titanium silicon nitride and titanium aluminum nitride.

Multilayer nitride hard coatings

In one aspect, coated cutting tools are described herein comprising a substrate and a coating comprising a refractory layer deposited by physical vapor deposition adhered to the substrate, the refractory layer comprising MAlN wherein x&#x2265;0.68 and M is titanium, chromium or zirconium, the refractory layer including a cubic crystalline phase and having hardness of at least 25 GPa.

Low stress hard coatings and applications thereof

A coated cutting insert includes a substrate that is either a ceramic substrate or polycrystalline cubic boron nitride-containing substrate and has a substrate surface. A base coating scheme is applied by chemical vapor deposition to the substrate surface wherein the base coating scheme includes the following coating layers: an inner coating layer adjacent to the substrate surface wherein the inner coating layer is a nitride selected from the group consisting of titanium nitride, zirconium nitride and hafnium nitride; an inner mediate coating layer deposited to the inner coating layer wherein the inner mediate coating layer is a carbonitride selected from the group consisting of titanium carbonitride, zirconium carbonitride and hafnium carbonitride; an outer mediate coating layer deposited to the inner mediate coating layer and wherein the outer mediate coating layer is a carbonitride selected from the group consisting of titanium carbonitride, zirconium carbonitride and hafnium carbonitride; and an outer coating layer deposited on the outer mediate coating layer wherein the outer coating layer is a carbide selected from the group consisting of titanium carbide, zirconium carbide and hafnium carbide. An exterior coating scheme is deposited on the base coating scheme by physical vapor deposition.

PVD-coated cutting tools and method for making the same

In one aspect, coated cutting tools are described herein comprising a substrate and a coating comprising a refractory layer deposited by physical vapor deposition adhered to the substrate, the refractory layer comprising MAlN wherein x&#x2267;0.68 and M is titanium, chromium or zirconium, the refractory layer including a cubic crystalline phase and having hardness of at least 25 GPa.

In one aspect, coated cutting tools are described herein. In some embodiments, a coated cutting tool comprises a substrate and a refractory layer deposited by PVD adhered to the substrate, the refractory layer comprising MAlN wherein x&#x2267;0.4 and M is titanium, chromium or zirconium, the refractory layer having a thickness greater than 5 &#x3bc;m, hardness of at least 25 GPa and residual compressive stress less than 2.5 GPa.

Refractory coatings for cutting tool applications and methods of making the same are described herein which, in some embodiments, permit incorporation of increased levels of aluminum into nitride coatings while reducing or maintaining levels of hexagonal phase in such coatings. Coatings and methods described herein, for example, employ cubic phase forming compositions for limiting hexagonal phase in nitride coatings of high aluminum content.

Hard coatings comprising cubic phase forming compositions

A coated wear-resistant member, as well as a method for making the same, includes a substrate and a coating scheme. The coating scheme has a region of alternating coating sublayers. One coating sublayer is TiAlSiN wherein 40 atomic percent&#x2266;x&#x2266;80 atomic percent; 15 atomic percent&#x2266;y&#x2266;55 atomic percent; 4 atomic percent&#x2266;100&#x2212;x&#x2212;y&#x2266;15 atomic percent. The other coating sublayer is TiAlN wherein 45 atomic percent&#x2266;p&#x2266;100 atomic percent. The method for making a coated wear-resistant member includes the steps of providing the substrate, and depositing the region of alternating coating sublayers.

Multilayer coated wear-resistant member and method for making the same

A wear resistant multilayer nitride hard coating for substrates. The hard coating includes a first layer of titanium aluminum nitride and a second layer comprising a plurality of sublayer groups. Each sublayer group includes a first sublayer of titanium silicon nitride and a second sublayer of titanium aluminum nitride. The composition of the titanium aluminum nitride, both in the first layer and in the sublayer groups, is (TiAl)N, wherein 0.4&#x2266;x&#x2266;0.6. The composition of the titanium silicon nitride sublayers is (TiSi)N, wherein 0.85&#x2266;y&#x2266;0.98, and all of the silicon is in solid solution in the titanium silicon nitride such that no silicon phase or silicon nitride phase exists in this sublayer. The combined amount of aluminum and silicon present in the sublayer groups being narrowly controlled such that the sum of x and y is in the range of 1.38 to 1.46.

A nanolayered coated cutting tool that includes a substrate that has a surface with a coating on the surface thereof. The coating comprises a plurality of coating sets of alternating nanolayers of titanium nitride and titanium aluminum nitride wherein each coating set has a thickness up to about 100 nanometers. The coating includes a bonding region and an outer region. The bonding region comprises a plurality of the coating sets wherein the thickness of each coating set increases as the set moves away from the surface of the substrate. The outer region comprises a plurality of the coating sets wherein the thickness of each coating set is about equal.

Nanolayered coated cutting tool and method for making the same

A coated article has a substrate and a coating scheme, which has a PVD coating region. The PVD coating region contains aluminum, yttrium, nitrogen and at least one element selected from the group of titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten and silicon. The sum of the aluminum and yttrium contents is between about 3 atomic percent and about 55 atomic percent of the sum of aluminum, yttrium and the other elements. The yttrium content is between about 0.5 atomic percent and about 5 atomic percent of the sum of aluminum, yttrium and the other elements. There is also a method of making the coated article that includes steps of providing the substrate and depositing the above coating scheme with the PVD coating region.

Coated article having yttrium-containing coatings applied by physical vapor deposition and method for making the same

Coated cutting tools are disclosed which have a hard coating that includes at least one aluminum titanium nitride layer having a single phase structure of B1 cubic phase and a composition of (AlTi)N, where x is in the range of about 0.46 to about 0.52 moles. The hard coatings also have a residual stress in the range of from about &#x2212;0.4 to about &#x2212;3 GPa as measured by the XRD Sin&#x3a8; method, and a crystallographic orientation characterized by an x-ray diffraction (200) to (111) peak intensity ratio in the range of about 1 to about 14. Preferably the aluminum titanium nitride layer has an average crystallite size in the range of about 15 to about 50 nanometers. Methods of making such coated cutting tools are also disclosed.

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Greensburg, PA, United States of America

Ronald Penich