Anchored oxide coatings on hard metal cutting tools

Abstract

A cutting tool insert comprises a hard metal substrate having at least two wear-resistant coatings including an exterior ceramic coating and a coating under the ceramic coating being a metal carbonitride having a nitrogen to carbon-plus-nitrogen atomic ratio between 0.7 and 0.95 which causes the metal carbonitride to form projections into the ceramic coating improving adherence and fatigue strength of the ceramic coating.

1. A cutting tool insert comprising a hard metal substrate having at least two wear-resistant coatings including an exterior ceramic coating and a coating under the ceramic coating being a metal carbonitride having a nitrogen to carbon-plus-nitrogen atomic ratio between 0.7 and 0.95 which causes the metal carbonitride to form projections into the ceramic coating whereby improving adherence and fatigue strength of the ceramic coating. 
     
     
       2. The cutting tool insert as set forth in  claim 1 , wherein the metal carbonitride has a nitrogen content of between 70% and 90% based upon the total nitrogen and carbon content of the metal carbonitride layer. 
     
     
       3. The cutting tool insert as set forth in  claim 1 , wherein the metal carbonitride has a nitrogen to carbon-plus-nitrogen atomic ratio between 0.75 and 0.95 as determined by X-ray diffraction. 
     
     
       4. A cutting tool insert as set forth in  claim 1 , having a coating of titanium nitride 1 to 4 microns thick, a titanium carbonitride coating, 2 to 4 microns thick, and an aluminum oxide coating of 1 to 10 microns thick. 
     
     
       5. A cutting tool insert according to  claim 3 , having a titanium nitride coating 2 microns thick, a titanium carbonitride coating 3 microns thick and an aluminum oxide coating 6 microns thick with an overcoating of Ti (C,N) 2 microns thick. 
     
     
       6. A cutting tool insert as set forth in  claim 1 , wherein the metal in the metal carbonitride coating is selected from one of the groups IVB, VB and VIB in the periodic table of elements. 
     
     
       7. A cutting insert as set forth in  claim 6 , and including a substrate composed of 3% to 30% binder metal from the iron group and between 70% and about 97% carbide selected from the group tungsten carbide, titanium carbide, tantalum carbide, niobium carbide, molybdenum carbide, zirconium carbide and hafnium carbide. 
     
     
       8. A cutting tool insert as set forth in  claim 7 , wherein in the substrate nitrides replace a portion of the carbides. 
     
     
       9. A cutting tool insert as set forth in  claim 6 , wherein the surface layer of the substrate is enriched with the binder metal. 
     
     
       10. A method of making a cutting tool insert comprising the steps of applying a titanium nitride coating, a metal carbonitride coating and a ceramic coating, all by chemical vapor deposition, wherein the reactants during the chemical vapor deposition of the carbonitride layer are controlled to provide a nitrogen to carbon-plus-nitrogen atomic ratio between 0.75 and 0.95 and wherein a ceramic coating is deposited thereover such that the carbonitride layer has fingers which extend into the ceramic coating increasing coating adhesion. 
     
     
       11. A cutting tool insert comprising a hard metal substrate comprising at least two wear-resistant coatings including an exterior ceramic coating and a coating under the ceramic coating being a metal carbonitride having a nitrogen to carbon atomic ratio which causes the metal carbonitride to form projections into the ceramic coating thereby improving adherence and fatigue strength of the ceramic coating,
 wherein the metal carbonitride has a nitrogen content of between 70% and 90% based upon the total nitrogen and carbon content of the metal carbonitride layer.    
     
     
       12. A cutting tool insert comprising a hard metal substrate having at least two wear-resistant coatings including an exterior ceramic coating and a coating under the ceramic coating being a metal carbonitride having a nitrogen to carbon atomic ratio between 0.7 and 0.95 which causes the metal carbonitride to form projections into the ceramic coating whereby improving adherence and fatigue strength of the ceramic coating,
 wherein the metal carbonitride has a nitrogen content of between 70% and 90% based upon the total nitrogen and carbon content of the metal carbonitride layer.    
     
     
       13. The cutting tool insert as set forth in claim 11, wherein the metal carbonitride has a nitrogen content of between 70% and 90% based upon the total nitrogen and carbon content of the metal carbonitride later as determined by X-ray diffraction.  
     
     
       14. The cutting tool insert as set forth in claim 11, having a coating of titanium nitride 1 to 4 microns thick, a titanium carbonitride coating 2 to 4 microns thick, and an aluminum oxide coating of 1 to 10 microns thick.  
     
     
       15. The cutting tool insert according to claim 13, having a titanium nitride coating 2 microns thick, a titanium carbonitride coating 3 microns thick, and an aluminum oxide coating 6 microns thick, with an overcoating of Ti (C,N) 2 microns thick.  
     
     
       16. The cutting tool insert as set forth in claim 11, wherein the metal in the metal carbonitride coating is selected from one of the groups IVB, VB, and VIB in the periodic table of elements.  
     
     
       17. The cutting insert as set forth in claim 16, and including a substrate composed of 3% to 30% binder metal from the iron group and between 70% and about 97% carbide selected from the group tungsten carbide, titanium carbide, tantalum carbide, niobium carbide, molybdenum carbide, zirconium carbide, and hafnium carbide.  
     
     
       18. The cutting tool insert as set forth in claim 17, wherein in the substrate nitrides replace a portion of the carbides.  
     
     
       19. The cutting tool insert as set forth in claim 16, wherein the surface layer of the substrate is enriched with the binder metal.  
     
     
       20. A method of making a cutting tool insert comprising the steps of applying a titanium nitride coating, a metal carbonitride coating, and a ceramic coating, all by chemical vapor deposition, wherein the reactants during the chemical vapor deposition of the carbonitride layer are controlled to provide a nitrogen content of between 70% and 90% based upon the total nitrogen and carbon content of the metal carbonitride layer, and wherein a ceramic coating is deposited thereover such that the carbonitride layer has fingers which extend into the ceramic coating, increasing coating adhesion.  
     
     
       21. The cutting tool insert as set forth in claim 11, wherein the ceramic coating directly overlays the metal carbonitride coating.  
     
     
       22. The cutting tool insert as set forth in claim 1, wherein the ceramic coating directly overlays the metal carbonitride coating.