Cubic boron nitride composition, coating and articles made therefrom, methods of making and using said composition, coating and articles

Abstract

A composition including a first phase selected from nitrides, carbides, carbonitrides, borides, sulphides, chalcogenides, oxides, and suicides, and a second phase selected from nitrides, carbides, carbonitrides, borides, sulphides, chalcogenides, oxides, and suicides, wherein said second phase comprises a multiplicity of discrete portions positioned into the first phase, with these multiplicity of portions comprising a continuous second phase, and made thereof, coatings and articles, especially, machining, cutting and shaping tools, wearparts, and methods of making and using the composition, coating and articles.

We claim:  
     
         1 . A coated article comprising a substrate supporting a coating comprising a first phase selected from nitrides, carbides, carbonitrides, borides, oxides, and suicides, and a second phase selected from nitrides, carbides, carbonitrides, borides, sulphides, chalcogenides, oxides, and suicides, wherein said second phase is continuous, is in contact with the substrate, and in contact with the first phase.  
     
     
         2 . The coating of  claim 1 , wherein the first phase comprises a nitride and the second phase comprises a nitride different that the nitride of the first phase.  
     
     
         3 . The coating of  claim 1 , wherein the first phase comprises cubic boron nitride.  
     
     
         4 . The coating of  claim 1 , wherein the first phase comprises cubic boron nitride, and the second phase comprises titanium nitride.  
     
     
         5 . A method of coating a substrate comprising: 
 (A) forming on the substrate, a first phase comprising at least one of nitrides, carbides, carbonitrides, borides, oxides, and suicides; and    (B) forming on the substrate, a second phase comprising at least one of nitrides, carbides, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides, wherein the second phase is continuous, is in contact with the first phase, and displaces at least a portion of the first phase from the second phase.    
     
     
         6 . The method of  claim 5 , wherein the first phase comprises a nitride and the second phase comprises a nitride different than the nitride of the first phase.  
     
     
         7 . The method of  claim 5 , wherein in step (A) the first phase is formed by electrostatic spray coating, and in step (B) the second phase is formed by chemical vapor infiltration.  
     
     
         8 . The method of  claim 7 , wherein the first phase comprises cubic boron nitride.  
     
     
         9 . The method of  claim 7 , wherein the first phase comprises cubic boron nitride, and the second phase comprises titanium nitride.  
     
     
         10 . A method of shaping a workpiece, comprising contacting the workpiece with a tool work surface, wherein the work surface comprises a first phase selected from nitrides, carbides, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides, and a second phase selected from nitrides, carbides, carbonitrides, borides, sulphides, chalcogenides, oxides, and suicides, wherein said second phase is continuous and is in contact with first phase.  
     
     
         11 . The method of  claim 10 , wherein the first phase comprises a nitride and the second phase comprises a nitride different than the nitride of the first phase.  
     
     
         12 . The method of  claim 10 , wherein the first phase comprises cubic boron nitride.  
     
     
         13 . The method of  claim 10 , wherein the first phase comprises cubic boron nitride, and the second phase comprises titanium nitride.  
     
     
         14 . A tool comprising a work surface, wherein the work surface comprises a first phase selected from nitrides, carbides, carbonitrides, borides, sulphides, chalcogenides, oxides, and suicides, and a second phase selected from nitrides, carbides, carbonitrides, borides, oxides, and silicides, wherein said second phase is continuous and is in contact with the first phase.  
     
     
         15 . The tool of  claim 14 , wherein the first phase comprises a nitride and the second phase comprises a nitride different that the nitride of the first phase.  
     
     
         16 . The tool of  claim 14 , wherein the first phase comprises cubic boron nitride.  
     
     
         17 . The tool of  claim 14 , wherein the first phase comprises cubic boron nitride, and the second phase comprises titanium nitride.