Kennametal Inc.

Zhenyu Liu

Yixiong Liu

Peter Rudolf Leicht

Rodrigo Alejandro Cooper

Mark S Greenfield

Chen Chen

Ronald Penich

Vineet Kumar

Nicholas F Waggle, Jr

Qingjun Zheng

Kimaya Prakash Vyavhare

In one aspect, cutting tools are described herein comprising wear resistant coatings employing one or more refractory layers of polycrystalline α-AlO. Briefly, a coated cutting tool described herein comprises a substrate, and a coating adhered to the substrate, the coating comprising a layer of polycrystalline α-AlOdeposited by chemical vapor deposition (CVD), wherein at least 5% of all grain boundaries in the polycrystalline α-AlOlayer have a misorientation angle less than 15 degrees as determined using a field-emission scanning electron microscope (FESEM) and an electron backscatter diffraction (EBSD) detector.

Surface coated cutting tools

In one aspect, a coated cutting tool described herein comprises a substrate and a coating adhered to the substrate, the coating including a refractory layer comprising AlON, the AlON layer exhibiting a peak in a range of 33-35° 2θ in an XRD, wherein the peak has a FWHM of 0.1°-0.7° 2θ. In some embodiments, the AlON layer can exhibit a ribbon-like crystallites, needle-like crystallites, or rice-like crystallites and associated surface texture.

Aluminum oxynitride coatings with enhanced crystallinity

In one aspect, methods of making coated articles are described herein. A method, in some embodiments, comprises providing a substrate, and depositing a coating by chemical vapor deposition (CVD) and/or physical vapor deposition (PVD) over a surface of the substrate, the coating comprising at least one polycrystalline layer, wherein one or more CVD and/or PVD conditions are selected to induce one or more properties of the polycrystalline layer. The presence of the one or more properties in the polycrystalline layer is quantified by two-dimensional (2D) X-ray diffraction analysis.

Quantitative textured polycrystalline coatings

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

A coating includes a layer having an alumina matrix and at least one of zirconia grains and hafnia grains in the alumina matrix. An average grain size of the at least one of the zirconia grains and hafnia grains is 100 nm or less. A coated cutting tool includes a substrate and the coating bonded to the substrate. The substrate has a rake face, a flank face, and a cutting edge formed at the intersection of the rake face and the flank face.

Coating and coated cutting tool comprising the coating

CVD Alumina coating has been one of the most important materials for wear resistant application for many years. Recently, texture control in &#x3b1;-AlOhas attracted increasing attention due to the possibility to further improve the anisotropic properties such as thermal conductivity and mechanical properties. The influence of process parameters on textures is complex. In the present application, the influence of nucleation surface condition and HS on the texture in CVD &#x3b1;-AlOcoatings has been investigated. It has been shown that without the addition of HS, the crystal orientation in the AlOcoatings is primarily dominated by the nucleation surface condition, whereas the effect of reactant composition on texture is minimal. On the other hand, in the presence of HS during growth, reactant composition also plays an important role in affecting the crystal orientation. This effect is likely due to the strong interaction between the AlOsurface and the HS.

Control and characterization of texture in CVD &#x3b1;-AlOcoatings

Cutting tools are described having coatings which can demonstrate desirable wear resistance and increased cutting lifetimes. A coated cutting tool described herein has a substrate and a coating with a plurality of alternating layers of a first layer of AlOand a second layer of at least one of MeAlOand MeAlO/MeOcomposite, wherein Me is Zr, Hf, Ti or a combination thereof. The coating has a superlattice-like structure.

Multilayer structured coatings for cutting tools

In one aspect, articles are described herein comprising refractory coatings employing an inter-anchored multilayer architecture. Articles having refractory coatings described herein, in some embodiments, are suitable for high wear and/or abrasion applications such as metal cutting operations. A coated article described herein comprises a substrate and a coating deposited by CVD adhered to the substrate, the coating including a refractory layer comprising a plurality of sublayer groups, a sublayer group comprising a Group IVB metal nitride sublayer and an adjacent layer alumina sublayer, the Group IVB metal nitride sublayer comprising a plurality of nodules interfacing with the alumina sublayer.

Inter-anchored multilayer refractory coatings

A coated cutting insert for a chipforming material removal operation wherein the coated insert has a substrate and a coating scheme on the substrate. The coating scheme includes a CVD transition coating layer. The coating scheme further includes a CVD multi-layered coating scheme having a plurality of coating sets. Each one of the coating sets has an aluminum oxide coating layer and a nitrogen-containing coating layer.

CVD coated cutting insert and method of making the same

A coated cutting insert and a method for making the same. The coated cutting insert has a substrate with a substrate surface. There is a backing coating scheme on the substrate surface, and a TiAlOcoating layer wherein the TiAlOcoating layer is deposited using chemical vapor deposition from a gaseous composition including AiCl, H, TiCl, COand HCl.

[object Object]

In one aspect, articles are described herein comprising refractory coatings employing alumina-based hybrid nanocomposite architectures. A coated article described herein comprises a substrate and a coating deposited by CVD adhered to the substrate, the coating including a composite refractory layer having a matrix phase comprising alumina and at least one particulate phase within the matrix phase, the particulate phase comprising nanoscale to submicron particles formed of at least one of an oxycarbide and oxycarbonitride of one or more metals selected from the group consisting of aluminum and Group IVB metals.

Hybrid nanocomposite coatings and applications thereof

In one aspect, articles employing CVD coatings deposited at low temperatures are described herein. Briefly, a coated article described herein comprises a substrate and a refractory coating adhered to the substrate, the refractory coating including a layer of TiN deposited by thermal CVD, the layer of TiN having an average crystallite size of 0.05 &#x3bc;m to 0.5 &#x3bc;m and residual tensile stress of 100 MPa to 700 MPa.

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Greensburg, PA, United States of America

Zhenyu Liu