Nanolaminated coated cutting tool

[0001] The present invention relates to a cutting tool insert coated with a hard and wear resistant coating comprising a nanolaminated structure based on (Ti,Al)N and (Ti,Si)N layers, respectively. This insert is particularly useful in metal cutting applications generating high temperatures, e.g., machining of super alloys, stainless steels and hardened steels. The coating is grown by physical vapour deposition (PVD) and preferably by cathodic arc evaporation.

[0002] U.S. Pat. No. 7,056,602 discloses a cutting tool insert coated with a cubic structured (Ti_yAl_xMe_1-x-y)N based layer where Me is one of the elements: Zr, Hf, V, Nb, Ta, Cr, Mo, W or Si, and: x is between 0.50 and 0.80; the ratio, x/(x+y), is between 0.50 and 0.85; the sum of Ti and Al subscripts, x+y, is between 0.7 and 1.0.

[0003] EP 1736565 discloses a cutting tool cubic boron nitride based insert coated with a cubic structured (Me,Si)X phase, where Me is one or more of the elements Ti, V, Cr, Zr, Nb, Mo, Hf, Ta and Al, and X is one or more of the elements N, C, O or B

[0004] EP 0588350 discloses a hard layer of Ti—Si—N composite material on a body, the layer being deposited using a source of evaporation possessing a composition of Ti_aSi_b with a in the range of 75-85 at % and b 15-25 at %.

[0005] Coating optimization has also been obtained by applying different concepts of multilayers as; alternating Ti and Al containing layers (U.S. Pat. No. 6,309,738), oxygen and non-oxygen containing layers (U.S. Pat. No. 6,254,984), one of the layers stacked in the multilayer consists itself of a multilayer (U.S. Pat. No. 6,077,596), alternating nitrogen content (U.S. Pat. No. 5,330,853) or using one metastable compound (U.S. Pat. No. 5,503,912) or as aperiodic multilayer (U.S. Pat. No. 6,103,357).

[0006] Further improvements in thermal stability and hardness have been achieved by the introduction of Si into TiN- or TiAlN-based coatings. JP 2000-334607 discloses a coated tool with laminated layers comprising TiSi (layer a) and TiAl (layer b) compounds. The (a) layer is selected among nitride, carbonitride, oxynitride and oxycarbonitride containing 10%<Si<60% with a NaCl type crystalline structure. Layer (b) is selected among nitride, carbonitride, oxynitride and oxycarbonitride containing 40%<Al<75% with a NaCl type crystalline structure. The (a) layer and (b) layers are applied alternately and the (b) layer is located just above the surface of the base material.

[0007] EP 1939327 discloses a cutting tool comprising a hard coating giving improved crater and flank wear resistance, said coating comprising an aperiodic multilayer X+Y+X+Y+ . . . with average layer thickness of X and Y layers of between 0.1 and 100 nm and with average chemical composition Al_aTi_bSi_cCr_dC_eN_1-e, where 0<a<0.5, 0.1<b<0.9, 0.01<c<0.17, 0≦d<0.06, a+b+c+d=1, and 0≦e<1.

[0008] The trends towards dry-work processes for environmental protection, i.e., metal cutting operation without using cutting fluids (lubricants) and accelerated machining speed with improved process put even higher demands on the characteristics of the tool materials due to an increased tool cutting-edge temperature. In particular, coating stability at high temperatures, e.g., oxidation- and wear-resistance have become even more crucial.

[0009] It is an object of the present invention to provide a coated cutting tool yielding improved performance in metal cutting applications at elevated temperatures.

[0010] It is a further object of the present invention to provide a coated cutting tool with improved edge integrity.

[0011] It has been found that combining layers based on (Ti,Si)N and (Ti,Al)N, respectively, in a nanolaminated coating structure onto a cutting tool insert significantly improves the tool life due to increased crater wear resistance, flank wear resistance and edge integrity, especially in machining operations generating high tool temperatures.

[0015] According to the present invention, there is provided a cutting tool for machining by chip removal comprising a body of a hard alloy of cemented carbide, cermet, ceramics, cubic boron nitride based material or high speed steel, preferably cemented carbide and cermet, onto which is deposited a hard and wear resistant coating comprising a polycrystalline nanolaminated structure of alternating A and B layers with a thickness between 0.5 and 20 μm, preferably between 0.5 and 10 μm, most preferably between 0.5 and 5 μm. Preferably the nanolaminated structure has an overall columnar structure with average column width between 20 and 1000 nm, preferably between 20 and 500 nm, as determined by, e.g., cross section scanning electron microscopy of a middle region of the nanolaminated structure, i.e., in a region within 30 to 70% of the thickness in the growth direction, and said average columnar width is the average from measuring the width of at least ten adjacent columns.

[0016] Said layer A is (Ti_1-x-pAl_xMe1_p)N_a, where 0.3<x<0.95, preferably 0.45<x<0.75, and 0.90<a<1.10, preferably 0.96<a<1.04, 0≦p<0.15, and Me1 is one or more of the metal elements from group 3, 4, 5 or 6 in the periodic table, preferably one or more of Zr, Y, V, Nb, Mo and N, most preferably one or more of Zr, Y, V and Nb. Said layer B is (Ti_1-y-zSi_yMe2_z)N_b, where 0.05<y<0.25 preferably 0.05<y<0.18, 0≦z<0.4, 0.9<b<1.1, preferably 0.96<b<1.04, and Me2 is one or more of the metal elements from group 3, 4, 5 or 6 in the periodic table including Al, preferably one or more of Y, V, Nb, Mo, N and Al, most preferably one or more of Y, V, Nb and Al, Layers A and B have an average individual layer thickness between 1 nm and 50 nm, as measured by, e.g., cross sectional transmission electron microscopy of a middle region of the nanolaminated structure, i.e., a region within 30 to 70% of the thickness in the growth direction, and said average layer thickness is the average from measuring the thickness of at least ten adjacent layers. Said nanolaminated structure comprises a phase mixture of cubic and hexagonal phases, preferably only cubic phases, as determined by X-ray diffraction.

[0017] In a first preferred embodiment z=p=0.

[0018] In a second preferred embodiment Me1 is one or more of Zr, Y, V and Nb with 0<p<0.05.

[0019] In a third preferred embodiment Me2 is Y, 0<z<0.15.

[0020] In a fourth preferred embodiment Me2 is one or both of V and Nb with 0<z<0.3.

[0021] In a fifth preferred embodiment Me2 is Al, 0.2<z<0.4.

[0022] Within the nanolaminated structure, Layer A has a stress level of −5.0<a<0 GPa, preferably −3.0<σ<−0.5 GPa.

[0023] Said coating may comprise an inner single- and/or multilayer coating of TiN, TiC, Ti(C,N) or (Ti,Al)N, preferably (Ti,Al)N, and/or an outer single- and/or multilayer coating of TiN, TiC, Ti(C,N), (Ti,Si)N or (Ti,Al)N, preferably (Ti,Si)N or (Ti,Al)N, according to prior art, to a total coating thickness, including the thickness of the nanolaminated structure, of between 0.5 and 30 μm, preferably between 0.5 and 15 μm, and most preferably between 0.5 and 10 μm.

[0024] The deposition method for the coatings of the present invention is physical vapour deposition (PVD), preferably cathodic arc evaporation, using alloy or composite cathodes under the following conditions; (Ti,Al,Me1)N and (Ti,Si,Me2)N layers are grown from cathodes yielding the desired layer composition. The evaporation current is between 50 A and 200 A. The layers are grown in an Ar+N₂ atmosphere, preferably in a pure N₂ atmosphere, at a total pressure of 0.5 Pa to 9.0 Pa, preferably 1.5 Pa to 5.0 Pa. The bias is −10 V to −300 V, preferably −20 V to −200V. The deposition temperature is between 350° C. and 700° C., preferably between 400° C. and 650° C.

[0025] The invention also relates to the use of cutting tool inserts according to the above for machining of stainless steel, super alloys and hardened steel at cutting speeds of 50-500 m/min, preferably 50-300 m/min, with an average feed of 0.08-0.5 mm/rev, preferably 0.1-0.4 mm/rev, depending on cutting speed and insert geometry.

[0026] The coatings of Table 1 were deposited by cathodic arc evaporation onto the following inserts:

• • [0027] S1: Cemented carbide with (90 wt % WC+10 wt % Co)
  • [0028] S2: Cemented carbide with (94 wt % WC+6 wt % Co)
  • [0029] S3: Seco Tools commercial cermet grade, CM

[0030] Before deposition, the inserts were cleaned in ultrasonic baths of an alkali solution and alcohol. The deposition chamber was evacuated to a base pressure of less than 2.0×10⁻³ Pa, after which the inserts were sputter cleaned with Ar ions. The coatings were deposited from alloy or composite cathodes in 99.995% pure N₂ atmosphere at a total pressure of 2-6 Pa, using a bias of −20 to −60 V and an evaporation current of 60-200 A at 450° C. The cathodes were selected to yield the composition of Layer A and Layer B, respectively, and mounted on opposing sides of the deposition chamber in order to obtain the nanolaminated structure by fixture rotation. The average individual layer thickness was varied by altering the cathode current (60-200 A) and the rotation speed of the fixture (1-5 rpm). The total coating thickness was about 2 μm for all inserts as measured on the flank face.

[0031] FIG. 1 shows a scanning electron microscopy (SEM) image of a Ti_0.38Al_0.62N/Ti_0.93Si_0.07N nanolaminated structure (coating 9). The individual layers are clearly seen, indicating minimal intermixing between adjacent layers. The individual layer thickness varies due to a 3-fold fixture rotation and a columnar microstructure extends throughout the nanolaminated structure.

[0032] X-ray diffractograms of as-deposited coatings were obtained using Cu Kα radiation and a θ-2θ configuration. FIG. 2 shows (a) Ti_0.38Al_0.62N single layer (coating 39), (b) Ti_0.86Si_0.14N single layer (coating 41), and (c) Ti_0.38Al_0.62N/Ti_0.86Si_0.14N nanolaminated structure (coating 1). All three coatings display only cubic NaCl crystal structures.

[0033] The average residual stress, σ, is shown in Table 1. The stresses were evaluated by XRD measurements using the sin²ψ method. The measurements were performed using CuKα-radiation on the NaCl (422)-reflections. Data was obtained with eleven Ψ-angles (positive and negative), equidistant within a sin²Ψ range of 0 to 0.75)(Ψ=0-60°. The residual stress values were evaluated using a Poisson's ratio of ν=0.22 and Young's modulus of E=450 GPa. For the nanolaminated structures stress values were measured for the (Ti,Al)N layers.

[0034] The total average composition of the nanolaminated structure was measured by energy dispersive x-ray spectroscopy (EDS) analysis area using a LEO Ultra 55 scanning electron microscope with a Thermo Noran EDS detector operating at 10 kV. The data were evaluated using the Noran System Six (NSS version 2) software.

[0035] Table 1 summarizes the results for the example coatings, both according to the invention and comparative coatings according to prior art.

[0036]

	TABLE 1
	Composition Layer A	Composition Layer B
	(metal at. %)	(metal at. %)
Coating	Description	Ti	Al	Si	Me1	Ti	Al	Si	Me2***
	Inventive
1	TiAlN/TiSiN*	38	62	0	0	86	0	14	0
2	TiAlN/TiSiN*	38	62	0	0	86	0	14	0
3	TiAlN/TiSiN*	38	62	0	0	86	0	14	0
4	TiAlN/TiSiN*	38	62	0	0	86	0	14	0
5	TiAlN/TiSiN*	38	62	0	0	86	0	14	0
6	TiAlN/TiSiN*,**	38	62	0	0	86	0	14	0
7	TiAlN/TiSiN*	50	50	0	0	86	0	14	0
8	TiAlN/TiSiN*	38	62	0	0	93	0	7	0
9	TiAlN/TiSiN*	38	62	0	0	93	0	7	0
10	TiAlN/TiSiN*	50	50	0	0	93	0	7	0
11	TiAlN/TiSiYN*	38	62	0	0	84	0	12	4
12	TiAlN/TiSiYN*	38	62	0	0	83	0	9	8
13	TiAlN/TiSiYN*	38	62	0	0	79	0	7	14
14	TiAlN/TiSiVN*	38	62	0	0	82	0	11	7
15	TiAlN/TiSiVN*	38	62	0	0	76	0	9	15
16	TiAlN/TiSiVN*	50	50	0	0	70	0	7	23
17	TiAlN/TiSiNbN*	38	62	0	0	85	0	10	5
18	TiAlN/TiSiNbN*	38	62	0	0	78	0	8	14
19	TiAlN/TiSiNbN*	38	62	0	0	69	0	6	25
20	TiAlN/TiSiAlN*	38	62	0	0	67	21	12	0
21	TiAlN/TiSiAlN*	38	62	0	0	55	39	6	0
22	TiAlN/TiSiAlN*	38	62	0	0	60	32	8	0
23	TiAlYN/TiSiN*	38	61	0	1	86	0	14	0
24	TiAlYN/TiSiN*	37	59	0	4	86	0	14	0
25	TiAlVN/TiSiN*	38	61	0	1	86	0	14	0
26	TiAlVN/TiSiN*	37	59	0	4	86	0	14	0
27	TiAlNbN/TiSiN*	38	61	0	1	86	0	14	0
28	TiAlNbN/TiSiN*	37	59	0	4	86	0	14	0
29	TiAlZrN/TiSiN*	38	61	0	1	86	0	14	0
30	TiAlZrN/TiSiN*	37	59	0	4	86	0	14	0
31	TiAlZrN/TiSiVN*	38	61	0	1	76	0	9	15
32	TiAlZrN/TiSiYN*	37	59	0	4	84	0	12	4
33	TiAlVN/TiSiAlN*	37	59	0	4	60	32	8	0
	Comparative
34	TiN/TiSiN*	100	0	0	0	86	0	14	0
35	TiAlSiN/TiSiN*	61	32	7	0	93	0	7	0
36	TiAlN/TiSiN*	80	20	0	0	93	0	7	0
37	TiAlN/TiSiN*,**	38	62	0	0	86	0	14	0
38	TiN/TiAlSiN*,**	100	0	0	0	61	32	7	0
39	TiAlN	37.6	62.4	0.0	0.0	0.0	0.0	0.0	0.0
40	TiAlN	49.6	50.4	0.0	0.0	0.0	0.0	0.0	0.0
41	TiSiN	86.4	0.0	13.6	0.0	0.0	0.0	0.0	0.0
42	TiSiN	92.8	0.0	7.2	0.0	0.0	0.0	0.0	0.0
43	TiAlSiN	61.1	32.0	6.9	0.0	0.0	0.0	0.0	0.0
44	TiSiN + TiAlN**	85.9	0.0	14.1	0.0	38.0	62.0	0.0	0.0
45	TiAlN + TiSiN**	38.3	61.7	0.0	0.0	86.0	0.0	14.0	0.0
				σ
		Average composition	Layer thickn.	(GPa)
Coat-		(at. %)	(nm)	Layer
ing	Description	Ti	Al	Si	Me1	Me2***	N	A	B	A
	Inventive
1	TiAlN/TiSiN*	31.9	12.6	4.1	0.0	0.0	51.4	5	8	−0.9
2	TiAlN/TiSiN*	39.1	5.7	5.6	0.0	0.0	49.6	4	17	−0.5
3	TiAlN/TiSiN*	26.1	21.2	2.2	0.0	0.0	50.4	11	5	−1.9
4	TiAlN/TiSiN*	34.3	11.8	4.5	0.0	0.0	49.4	3	5	−0.7
5	TiAlN/TiSiN*	27.9	18.5	2.9	0.0	0.0	50.6	24	17	−2.3
6	TiAlN/TiSiN*,**	31.4	14.4	3.8	0.0	0.0	50.3	7	8	−1.1
7	TiAlN/TiSiN*	33.1	13.1	3.4	0.0	0.0	50.5	10	9	−1.4
8	TiAlN/TiSiN*	35.3	13.6	1.9	0.0	0.0	49.1	6	8	−1.3
9	TiAlN/TiSiN*	32.1	16.3	1.7	0.0	0.0	50.0	9	6	−1.4
10	TiAlN/TiSiN*	38.7	10.4	2.0	0.0	0.0	48.9	5	6	−1.0
11	TiAlN/TiSiYN*	29.5	16.7	2.8	0.0	1.0	50.1	11	10	—
12	TiAlN/TiSiYN*	31.9	12.8	2.6	0.0	2.3	50.4	4	6	—
13	TiAlN/TiSiYN*	28.7	16.7	1.6	0.0	3.3	49.8	8	7	—
14	TiAlN/TiSiVN*	32.5	13.9	3.1	0.0	2.0	48.5	7	9	—
15	TiAlN/TiSiVN*	27.0	17.7	2.1	0.0	3.3	50.0	10	8	—
16	TiAlN/TiSiVN*	32.4	9.5	2.1	0.0	7.1	48.8	5	8	—
17	TiAlN/TiSiNbN*	31.1	13.6	2.9	0.0	1.4	51.0	9	12	—
18	TiAlN/TiSiNbN*	27.9	16 8	1.9	0.0	3.3	50.1	8	7	—
19	TiAlN/TiSiNbN*	26.1	14.3	1.6	0.0	6.6	51.3	5	6	—
20	TiAlN/TiSiAlN*	29.4	18.4	3.6	0.0	0.0	48.6	5	8	—
21	TiAlN/TiSiAlN*	22.3	25.9	1.6	0.0	0.0	50.3	5	6	—
22	TiAlN/TiSiAlN*	24.5	22.6	2.1	0.0	0.0	50.7	6	7	—
23	TiAlYN/TiSiN*	34.0	11.9	4.2	0.4	0.0	49.8	6	9	—
24	TiAlYN/TiSiN*	34.4	12.3	4.2	1.0	0.0	49.1	5	7	—
25	TiAlVN/TiSiN*	32.6	11.7	4.2	0.4	0.0	51.5	5	8	—
26	TiAlVN/TiSiN*	34.7	12.6	3.9	1.0	0.0	48.8	6	8	—
27	TiAlNbN/TiSiN*	34.4	12.5	4.3	0.4	0.0	48.9	6	9	—
28	TiAlNbN/TiSiN*	34.3	11.2	4.2	1.0	0.0	50.3	5	8	—
29	TiAlZrN/TiSiN*	31.7	14.4	3.9	0.5	0.0	50.1	6	7	—
30	TiAlZrN/TiSiN*	32.4	13.3	4.0	1.1	0.0	50.3	7	9	—
31	TiAlZrN/	29.3	13.0	2.6	0.4	4.3	50.8	5	7	—
	TiSiVN*
32	TiAlZrN/	33.8	11.3	3.7	0.9	1.2	49.9	5	8	—
	TiSiYN*
33	TiAlVN/	23.7	22.9	2.1	0.9	0.0	51.3	6	7	—
	TiSiAlN*
	Comparative
34	TiN/TiSiN*	45.4	0.0	4.1	0.0	0.0	50.5	9	12	−3.0
35	TiAlSiN/TiSiN*	36.7	9.5	3.5	0.0	0.0	50.3	10	7	−2.1
36	TiAlN/TiSiN*	44.0	5.0	1.8	0.0	0.0	49.2	9	9	−2.5
37	TiAlN/TiSiN*,**	27.6	19.2	2.7	0.0	0.0	50.6	130	80	−2.6
38	TiN/TiAlSiN*,**	39.3	8.7	1.9	0.0	0.0	50.1	110	130	−3.1/
										−3.3
39	TiAlN	—	—	—	—	—	50.4	—	—	−2.7
40	TiAlN	—	—	—	—	—	50.6	—	—	−2.3
41	TiSiN	—	—	—	—	—	49.5	—	—	−3.1
42	TiSiN	—	—	—	—	—	49.6	—	—	−2.4
43	TiAlSiN	—	—	—	—	—	50.0	—	—	−2.9
44	TiSiN + TiAlN**	N (at. %): 51.1/49.5	1080	1250	—
45	TiAlN + TiSiN**	N (at. %): 50.1/50.5	1140	870	—
*Individual layer compositions are estimated from the corresponding single layers.
**Constant individual layer thicknesses.
***Me2 content excluding Al, which has its own column.

Coatings 1-8, 10, 12, 22, 29, 34-45 on S1 inserts were tested under the following conditions:

Geometry: CNMG120408-MF1

Application: Longitudinal turning

Work piece material: AISI 316L

Cutting speed: 230 m/min

Feed: 0.15 mm/rev

Depth of cut: 1.5 mm

Tool life criteria: Flank wear (vb)>0.3 mm

[0037] The results are presented in Table 2.

[0038] FIG. 3 shows SEM images of used edges after 11 minutes turning with (a) comparative coating 39, (b) comparative coating 43, and (c) inventive coating 8. It is clearly seen that the inventive coating show improved crater and edge wear characteristics.

Coatings 1, 4, 6, 15, 33, 37, 39, 41, 45 on S2 inserts were tested under the following conditions:

Geometry: CNMG120408-MF1

Application: Longitudinal turning

Work piece material: Inconel 718

Cutting speed: 70 m/min

Feed: 0.2 mm/rev

Depth of cut: a_p=0.5 mm

Tool life criteria: Flank wear (vb)>0.3 mm

[0039] The results are presented in Table 2.

Coatings 1, 3, 9, 17, 36, 39-45 on S3 inserts were tested under the following conditions:

Geometry: DCMT11T304-F1

Application: Longitudinal turning

Work piece material: DIN 100Cr6

Cutting speed: 250 m/min

Feed: 0.15 mm/rev

Depth of cut: a_p=0.5 mm

Tool life criteria: Flank wear (vb)>0.2 mm

[0040] The results are presented in Table 2.

[0041]

	TABLE 2
	Example 2	Example 3	Example 4
Coating	Crater	Edge	Life time (min)	Life time (min)	Life time (min)
Inventive
1	Good	Good/Medium	15	8	21
2	Good	Medium	14	—	—
3	Good/Medium	Good	13	—	18
4	Good	Good/Medium	14	8	—
5	Good/Medium	Good/Medium	15	—	—
6	Good	Good/Medium	13	9	—
7	Good/Medium	Good/Medium	12	—	—
8	Good	Good	16	—	—
9	—	—	—	—	21
10	Good/Medium	Good	14	—	—
12	Good/Medium	Good/Medium	15	—	—
15	—	—	—	9	—
17	—	—	—	—	21
22	Good	Good	15	—	—
29	Good	Good/Medium	14	—	—
33	—	—	—	10	—
Comparative
34	Medium	Good/Medium	10	—	—
35	Good	Poor	12	—	—
36	Medium	Good/Medium	12	—	17
37	Good/Medium	Poor	13	7	—
38	Good/Medium	Poor	12	—	—
39	Medium/Poor	Good	11	6	14
40	Poor	Good	8	—	12
41	Good	Poor	9	5	12
42	Good/Medium	Medium/Poor	9	—	15
43	Good/Medium	Medium	12	—	15
44	Medium	Good/Medium	7	—	17
45	Good/Medium	Medium/Poor	10	5	15

[0042] It is obvious from the above examples 2-4 that the inserts according to the invention show an increased tool performance with improved edge and crater wear characteristics.