Cemented carbide insert and method of making same

Abstract

The present invention relates to a coated cemented carbide cutting tool particularly for turning applications with high toughness demands, of stainless steels of different compositions and microstructures, and of low and medium alloyed non-stainless steels. The cemented carbide is WC-Co based with a composition of 9-12 wt % Co, 0.2-2.0 wt % cubic carbides from elements from group IVa, Va or VIa of the periodic table and balance WC with a grain size of 1.5-2 μm. The binder phase is W-alloyed with a CW-ratio in the range of 0.77-0.95. The coating includes a multilayered structure of the composition (Ti x Al 1−x ,)N in which x varies repeatedly between the two ranges 0.45<x<0.55 and 0.70<x<0.80, adding up to a total thickness of 2-9 μm.

1. A coated cemented carbide cutting tool comprising:
 a WC—Co based cemented carbide body comprising a composition of 9-12 wt % Co, 0.2-2.0 wt % cubic carbides from elements from group IVa, Va or VIa of the periodic table and balance WC with an average grain size of the WC of 1.5-2 μm and a W-alloyed binder phase with a CW-ratio in the range of 0.77-0.95; and  
 a hard and wear resistant coating deposited on the WC—Co cemented carbide body comprising: 
 a first innermost bonding layer of TiN;  
 a second layer comprising a multilayered structure of 0.05-0.2 μm thick sublayers of the composition (Ti x Al 1−x )N in which x varies repeatedly between the two ranges 0.45<x<0.55 and 0.70<x<0.80, the first sublayer of (Ti x Al 1−x )N adjacent to the TiN bonding layer having an x-value in the range 0.45<x<0.55, the second sublayer of (Ti x Al 1−x )N having an x-value in the range 0.70<x<0.80 and the third sublayer having an x value in the range 0.45<x<0.55 and so forth repeated until 8-30 sublayers are built up;  
 a third at least 0.2 μm thick layer of (Ti x Al 1−x )N, where x is in the range 0.45<x<0.55;  
 a fourth outermost layer of TiN;  
 
 wherein the total coating thickness is in the range of 2-9 μm and the thickness of the second layer constitutes 75-95% of the total coating thickness.  
 
     
     
       2. The cutting tool according to  claim 1 , wherein the Co content is 10-11 wt %. 
     
     
       3. The cutting tool according to  claim 1 , wherein the 0.2-2.0 wt % cubic carbides from elements from group IVa, Va or VIa of the periodic table are 1.2-1.8 wt % cubic carbides of the metals Ta, Nb and Ti. 
     
     
       4. The cutting tool according to  claim 1 , wherein the content of Ta is preferably over 0.8 wt %. 
     
     
       5. The cutting tool according to  claim 1 , wherein the CW-ratio shall preferably over 0.82-0.92. 
     
     
       6. The cutting tool according to  claim 1 , wherein the coating comprises a first innermost 0.1-0.5 μm layer of TiN, a second layer having a multilayered structure of 22-24 sublayers of the composition (Ti x Al 1−x )N in which x varies repeatedly between the two ranges 0.45<x<0.55 and 0.70<x<0.80, a third 0.4-0.8 μm layer of (Ti x Al 1−x )N having an x-value in the range 0.45<x<0.55, and a fourth outermost thin 0.1-0.2 μm layer of TiN. 
     
     
       7. The cutting tool according to  claim 1 , wherein the coating has a total thickness of 3.5-7 μm. 
     
     
       8. The cutting tool according to  claim 1 , wherein the average WC grain size is between 1.6 and 1.8 μm. 
     
     
       9. A method of making a cutting tool, the method comprising:
 forming a powder mixture containing WC, Co and cubic carbides;  
 mixing said powders with pressing agent and W metal such that the desired CW-ratio is obtained;  
 milling and spray drying the mixture to a powder material with the desired properties;  
 pressing and sintering the powder material at a temperature of 1300-1500° C., in a controlled atmosphere of about 50-mbar followed by cooling to form a substrate; and  
 applying a hard, wear resistant coating by PVD techniques comprising: 
 depositing a first innermost bonding layer of TiN;  
 depositing a second layer comprising a 0.05-0.2 μm thick multilayered structure of sublayers of the composition (Ti x Al 1−x )N in which x varies repeatedly between the two ranges 0.45<x<0.55 and 0.70<x<0.80, the first sublayer of (Ti x Al 1−x )N adjacent to the TiN bonding layer having an x-value in the range 0.45<x<0.55, the second sublayer of (Ti x Al 1−x )N having an x-value in the range 0.70<x<0.80 and the third sublayer having an x value in the range 0.45<x<0.55, and so forth repeated until 8-30 sublayers are built up;  
 depositing a third at least 0.2 μm thick layer of (Ti x Al 1−x )N, where x is in the range 0.45<x<0.55;  
 depositing a fourth outermost layer of TiN;  
 wherein the total coating thickness is in the range of 2-9 μm and the thickness of the second layer constitutes 75-95 % of the tool coating thickness.  
 
 
     
     
       10. The cutting tool of  claim 1 , wherein the third layer has a thickness which exceeds the thickness of any of the individual sublayers. 
     
     
       11. The cutting tool of  claim 1 , wherein the third layer has a thickness of 0.4-0.8 μm. 
     
     
       12. The method of  claim 9 , wherein the third layer has a thickness of  0 . 4 -   0 . 8  μm.   
     
     
       13. The method of  claim 9 , wherein the desired CW- ratio is  0 . 77   -   0 . 95 .   
     
     
       14. The method of  claim 13 , wherein the desired CW- ratio is  0 . 82   -   0 . 92 .   
     
     
       15. The method of  claim 9 , wherein the first innermost bonding layer of TiN has a thickness of  0 . 1 -   0 . 5  μm, the multilayered structure of the second layer has  8   -   30  sublayers, the third layer has a thickness of  0 . 4   -   0 . 8  μm, and the fourth outermost layer has a thickness of  0 . 1   -   0 . 2  μm.   
     
     
       16. The cutting tool according to  claim 6 , wherein the Co content is  10 -   11  wt  % .   
     
     
       17. The cutting tool according to  claim 6 , wherein the  0 . 2 -   2 . 0  wt  %  cubic carbides from elements from group IVa, Va or VIa of the periodic table are  1 . 2   -   1 . 8  wt  %  cubic carbides of the metals Ta, Nb and Ti.   
     
     
       18. The cutting tool according to  claim 6 , wherein the content of Ta is preferably over  0 . 8  wt % .   
     
     
       19. The cutting tool according to  claim 6 , wherein the CW- ratio is  0 . 82   -   0 . 92 .   
     
     
       20. The cutting tool according to  claim 6 , wherein the average WC grain size is between  1 . 6  and  1 . 8  μm.