CN110468387A - 双结构涂层刀具 - Google Patents

双结构涂层刀具 Download PDF

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CN110468387A
CN110468387A CN201910884159.7A CN201910884159A CN110468387A CN 110468387 A CN110468387 A CN 110468387A CN 201910884159 A CN201910884159 A CN 201910884159A CN 110468387 A CN110468387 A CN 110468387A
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coating
double structure
cutting tool
matrix
cvd
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李洪林
吴春涛
薛峰
高见
闫晋予
袁宏辉
赵海波
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CHENGDU TOOL RESEARCH INSTITUTE Co Ltd
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Abstract

本发明为双结构涂层刀具，解决现有刀具的双结构涂层的硬度较低，颗粒较粗，寿命不长，应用领域受到限制的弊端。刀具基体上沿基体表面向外依次有CVD、PVD或PCVD复合涂层，CVD涂层沿基体向外依次为：TiN+MT‑TiCN+过渡层TiAlCNO+细颗粒α‑Al2O3+CVD或PCVD表层，与基体接触的最内层TiN可以保证基体与涂层的结合力，MT‑TiCN依靠其较高的硬度作为耐磨层，同时对后续的α‑Al2O3起到支撑作用，过渡层TiAlCNO保证MT‑TiCN和α‑Al2O3两种涂层的结合力，α‑Al2O3作为隔热层保护基体，细颗粒α‑Al2硬度得到了提升，粗糙度降低。

Description

双结构涂层刀具
技术领域
本发明涉及的是一种用于各种刀具的涂层，具体为：化学涂层（CVD）+物理涂层（PVD）的双结构涂层，广泛用于各种加工领域的刀具。
技术背景
涂层是现代刀具制造业的关键技术之一，制造业的技术进步、新材料的不断出现以及对加工效率更苛刻的要求，对刀具涂层提出了越来越高的要求。切削刀具在切削加工过程中承受极大的机械负荷和热负荷、极易产生磨损，致使其使用寿命急剧下降，尤其是一些难加工材料更是如此。因此，对切削刀具进行表面改性，提高表面性能，对提高切削刀具寿命极其重要，切削刀具采用表面涂层技术能有效地提高其切削性能和使用寿命，使刀具获得优异的综合性能，从而可大幅度提高机械加工效率。
目前刀具涂层主要有三大类，化学气相沉积涂层（CVD）、物理气相沉积涂层（PVD）以及物理化学气相沉积（PCVD）。
CVD涂层是在高温（800-1200度）条件下通过气体化学反应在基体上形成涂层，厚度可以达到40um，在粗加工领域优势非常明显，虽然经过几十年的发展，技术成熟可靠，虽然新技术日新月异，但起主要作用的核心涂层一直没有很大变化，仍然为TiN、TiC、TiCN、α-Al2O3，主流涂层结构主要为TiN+TiCN+过渡层+α-Al2O3+TiCN+TiN，最内层TiN可以保证基体与涂层的结合力，TiCN依靠其较高的硬度作为耐磨层，同时对后续的α-Al2O3起到支撑作用，过渡层保证MT-TiCN和α-Al2O3两种涂层的结合力，α-Al2O3具有目前已知最好的绝热效果，作为隔热层保护基体，TiCN+TiN作为判断刀具磨损情况的标识层，目前主流的CVD涂层加工的材料依然集中在钢、不锈钢、铸铁等相对易加工材料领域，如钛合金、高温合金、硬度超过HRC60的材料，由于其本身硬度高或存在加工硬化、导热差等难题，采用复合硬度只有HV2800左右的CVD涂层确实比较困难，即使CVD-TiC涂层硬度可以达到HV3200，但由于其抗高温氧化性又比较差，在难加工合金高温高热的加工环境下容易造成刀具的过早失效。虽然α-Al2O3是目前抗高温氧化性最好的涂层，但其硬度只有HV2700，硬度稍显不足。
PVD涂层是在温度相对较低（小于600度）的条件下，通过离子轰击靶材，使靶材以原子或分子的形式沉积在基体表面上，由于沉积温度相对较低，几乎不影响基体强度，可开发性强，可以沉积真正意义上的纳米涂层，表面非常光滑及离子轰击使涂层内部为压应力等诸多优点，近些年发展很快，目前开发的TiAlSiN等涂层，涂层硬度超过HV3800，同时由于Al、Si、Cr等元素在加工过程形成了抗氧化的氧化物，一定程度上又保护了基体，相对更适合难加工合金的加工。但是由于PVD涂层一般做的都比较薄，2-5um，最厚一般不超过8um，故其耐磨性又稍显不足。
在刀具涂层领域，国内外对单一CVD或PVD涂层研究非常多，如中国专利ZL201110439260.5描述了一种改善化学涂层结构的方法，美国专利US 6689450 B2描述了一种低温条件下MT-TiCN+γ-Al2O3多层复合涂层生长技术，美国专利US 2016/0053372 A1描述了一种CVD-TiAlCN的制备方法，瑞典专利No.9402543—4描述一种化学涂层后处理的方法，美国专利US 6033768描述了一种含有稀土钇元素的PVD-TiAlYN涂层制备方法等等。虽然改善单一结构涂层性能的研究很多，但将CVD和PVD两种方法结合起来的双结构涂层技术研究非常少，目前只查到国内专利ZL 201010530080.3描述了一种双结构涂层的制备方法，但该专利所述的TiN+MT-TiCN+过渡层+α-Al2O3+TiN+PVD-TiN涂层结构中的CVD涂层，是仅在WC-Co硬质合金基体上沉积的最传统的涂层，存在均匀性差，α-Al2O3颗粒较粗（颗粒尺寸超过2um），加工时易脱落，磨损快，使用寿命不长，同时，该专利表面PVD涂层只涉及到TiN涂层，TiN涂层硬度低，抗氧化能力差，并不适合难加工材料加工，也使专利所述的双结构涂层应用受到更多限制。
发明内容
本发明的目的是提供一种具有具有较高的硬度，使用寿命长的双结构涂层刀具。
本发明是这样实现的：
双结构涂层刀具，刀具基体上有CVD+PVD复合涂层，该涂层结构为：基层为CVD,CVD沿基体表面从内向外依次为：TiN+MT-TiCN+过渡层TiAlCNO+细颗粒α-Al2O3，表层为CVD表层+PVD或PCVD表层。
刀具基体包含各种高速钢、不锈钢等钢制刀具基体，WC基硬质合金基体，ZrO2基体，赛隆基体，Si3N4基体，TiCN基体，Al2O3基体，CBN基体，金刚石基体 。
刀具涂层从最底层到最外层结构为：TiN + MT-TiCN + 过渡层TiAlCNO + 细颗粒α-Al2O3 + CVD表层 + PVD或PCVD表层。
过渡层为TiAlCNO，沉积过程中控制Al含量在0.5-2%，通过在传统的TiCO和TiCNO过渡层中添加Al，使MT-TiCN均匀过度到α-Al2O3涂层，通过成分的连续性，使涂层结合力更好，同时更有利于后续细颗粒α-Al2O3的沉积。
通过降低沉积压力至50-60mbar或打断α-Al2O3的生长，形成α-Al2O3+TiAlCNO的多层叠加结构，使α-Al2O3的颗粒尺寸降低到1.2um以下，同时也使α-Al2O3硬度得到了提升。细颗粒α-Al2O3涂层厚度1-20um，颗粒尺寸0.5-1.2um。
细颗粒α-Al2O3涂层，厚度优选5-10um。
MT-TiCN厚度1-20um。
MT-TiCN涂层厚度优选3-10um。
过渡层为TiAlCNO厚度0.1-1um。
过渡层厚度优选0.5-1um。
CVD表层为IVB族金属的碳化物、氮化物、碳氮化物、碳氮氧化物、硼化物、硼氮化物、碳硼氮化物、氮硅化物、碳氮硅化物、氮铝化物、碳氮铝化物、碳氮硅铝化物中的一种或几种的复合涂层，厚度1-10um。
CVD表层厚度优选1-5um。
化学涂层后需要对产品进行后处理，处理后表面粗糙度小于0.5um。
CVD表层表面粗糙度优选小于0.2um。
PVD或PCVD表层是通过PVD或PCVD方法制备的金刚石涂层、类金刚石涂层、PVD-Al2O3、PVD-Zr2O3、PVD-Cr2O3、IVB族和VB族金属的碳化物、氮化物、碳氮化物、碳氮氧化物、硼化物、硼氮化物、硼碳氮化物、氮硅化物、碳氮硅化物、氮铝化物、碳氮铝化物、碳氮硅铝化物中的一种或几种的复合涂层，厚度0.5-10um。
PVD表层厚度优选0.5-5um。
根据材料的加工特性选择相应的PVD涂层种类，中低速加工普通易加工钢搭配TiN涂层，中高速加工普通易加工钢搭配TiAlN涂层，加工石墨搭配金刚石或DLC涂层，加工硅含量大于12%的铝合金搭配TiCN涂层，加工铜合金搭配CrN涂层，加工不锈钢搭配TiCrAlSiN涂层，加工镍基合金搭配TiAlN+PVD-Al2O3复合涂层，加工铸铁搭配TiCrAlN、TiAlN涂层，加工钛合金搭配AlCrN或CrN涂层，加工非铁合金搭配TiB2涂层等等。
后处理是在不损伤刃口的前提下，通过毛刷或喷砂的方法实现，毛刷法选取由SiC、猪鬃等构成的毛刷，根据CVD表层的厚度进行短时间的处理，单一刀具处理时间5-10秒即可，喷砂法是通过选用金刚砂、硅砂、树脂砂，在2-4Bar的压力下，对涂层表面进行短时间喷砂处理，单一刀具处理时间5-10秒即可，通过后处理达到降低涂层表面粗糙度的目的。
本发明着眼于大幅提高加工效率，尤其是难加工材料领域，将CVD涂层和PVD涂层的优势充分结合起来，形成一种双结构涂层。该涂层中的CVD涂层不单单是传统的MT-TiCN、α-Al2O3以及TiN、TiC、TiCN涂层的复合结构，较已知的专利ZL 201010530080.3，通过在传统的TiCO和TiCNO过渡层中添加Al，使涂层结合力更好，更有利于后续细颗粒α-Al2O3的沉积，通过对α-Al2O3沉积工艺和结构的优化及TiAlCNO过渡层的共同作用，使颗粒尺寸降低到1.2um以下，同时也使α-Al2O3硬度得到了提升，从而使耐磨性大幅改善。在对涂层进行必要的后处理降低表面粗糙度后，再根据需要，选择Ti-Al基、Al-N基、TiB2、TiN、Al2O3等单层或多层复合PVD涂层涂覆于化学涂层之上，利用PVD涂层的高硬度、低摩擦系数等优势改善刀具使用效果，同时，在进行PVD涂层沉积的过程中，离子对于化学涂层的轰击会使局部应力从拉应力改变为压应力，减少化学涂层内部的裂纹，还会提高刃口强度，进一步提升刀具的使用效果。
本发明的关键点之一在于CVD过渡层TiAlCNO工艺的控制，由于在TiCO中加入了Al元素，需要控制Al含量在0.5-2%，如果Al元素加入过量或不足，会导致涂层结合力不良，也有可能造成涂层颗粒过粗或反应不充分，影响后续α-Al2O3颗粒过大，通过Al元素的加入，使MT-TiCN均匀过度到α-Al2O3涂层，通过成分的连续性，使涂层结合力更好，同时更有利于后续细颗粒α-Al2O3的沉积。
本发明的关键点之二在于PVD表层和被加工材料的匹配性，由于材料种类繁多，有钢、不锈钢、铸铁、镍基合金、钛合金、有色金属等等不同类型，加工特性也都不同，加工过程参数也各不相同，必须根据材料的加工特性选择相应的PVD涂层种类，若选择错误，也有可能造成达不到预期的加工效果，如中低速加工普通易加工钢搭配TiN涂层，中高速加工普通易加工钢搭配TiAlN涂层，加工石墨搭配金刚石或DLC涂层，加工硅含量大于12%的铝合金搭配TiCN涂层，加工铜合金搭配CrN涂层，加工不锈钢搭配TiCrAlSiN涂层，加工镍基合金搭配TiAlN+PVD-Al2O3复合涂层，加工铸铁搭配TiCrAlN、TiAlN涂层，加工钛合金搭配AlCrN或CrN涂层，加工非铁合金搭配TiB2涂层等等，故必须由有经验的工程人员进行被加工材料和涂层材料的匹配。
本发明的关键点之三在于后处理，处理的原则是在不损伤刃口的前提下，去除CVD表层表面的大颗粒并降低表面的粗糙度，如果处理工艺不到位或卡具选用不合理，有可能会造成刃口崩刃，如果处理时间过长，去除了CVD涂层的表层并漏出Al2O3涂层，在进行PVD涂层时，有可能因为Al2O3导电性差造成PVD涂层的脱落而起不到应有的作用，故重点应控制后处理的时间，一般5-10秒即可。
本发明所得的双结构涂层不仅具有优异的耐磨性和抗高温氧化性，而且由于PVD涂层的存在和适当的涂层后处理工序，使这种双涂层具有较高的硬度、较低的应力和摩擦系数，能有效提高刀具的使用寿命。该涂层因为结合了CVD涂层和PVD涂层优点，具有优异的性能，可广泛应用于各种材料的切削加工，尤其是难加工材料，具有十分广泛的应用前景，具有极大的应用价值和推广的可能性。
表1专利ZL 201010530080.3与本发明中α-Al2O3硬度和划痕结合力对比对比
附图说明
图1为实施例1中本发明CVD涂层喷砂处理后刃口处SEM形貌。
图2为实施例1中本发明CVD+PVD涂层刃口处SEM形貌。
图3为实施例1中本发明α-Al2O3颗粒尺寸。
图4为实施例1中采用专利ZL 201010530080.3工艺制备的CVD-α-Al2O3涂层断口SEM形貌。
图5为实施例2中本发明CVD涂层断口SEM形貌。
图6为实施例2中本发明CVD-α-Al2O3颗粒尺寸。
图7为实施例1中本发明涂层结构简图。
具体实施方式
实施例1：
在WC—Co硬质合金基体上沉积CVD涂层，其结构从内到外依次为：
TiN + MT-TiCN + 过渡层TiACNO + α—Al2O3 + CVD表层。
沉积工艺如表2所示。
表2 实施例1中CVD涂层沉积参数
CVD表层为TiCN+TiN复合表层，沿α-Al2O3涂层表面向外依次为TiCN、TiN。
α—Al2O3颗粒尺寸1.2um。
用400目的金刚砂对CVD表层进行湿喷砂处理，喷压2.0Bar,时间5秒。
在喷砂处理后的CVD表层表面采用多弧离子镀法沉积一层PVD-TiN（1um）+ PVD-CrN（1μm）的PVD复合表层，之后再次用400目金刚砂对涂层表面进行湿喷砂处理，喷压4.0Kg/cm2，时间30秒。
多弧离子镀工艺参数如下：
1.加热：温度500度，时间180min，氩气流量60sccm
2.离子源刻蚀：氩气流量100sccm，偏压200V，时间30min，离子源5KW，偏流5A
3.电弧轰击刻蚀：时间30min，氩气100sccm，偏压800V，偏流30A
4.镀膜：时间120min，氮气流量500-1800sccm，压力1-4Pa，弧靶电流50-180A，
偏流5-40A，偏压40-150V，时间60min
切削参数如下：
本发明刀片型号：SNMM250724-F。
对比例1：商品CVD涂层刀具（15um）： TiN+MT-TiCN+过渡层+α—Al2O3+TiCN+TiN
对比例2：专利ZL 201010530080.3工艺制备的CVD+PVD复合涂层（14um）：
TiN + MT-TiCN+ 过渡层 + α—Al2O3+ TiN + PVD-TiN
被加工材料：6系铝合金铸棒
切削速度：675m/min
切深：6—8mm
进给量：5mm/转
对比例1涂层刀具寿命：598平方米
对比例2涂层刀具寿命：630平方米
本发明涂层刀具寿命：995平方米
实施例2：
在WC—Co硬质合金基体上沉积CVD涂层，其结构沿基体从内到外依次为：
TiN + MT-TiCN + 过渡层TiAlCNO + （高温α—Al2O3+TiAlCNO）5 + CVD表层
每层α—Al2O3沉积时间为60min，其余参数与表2相同。
α—Al2O3颗粒尺寸0.5um。
（高温α—Al2O3+TiACNO）5 代表高温α—Al2O3+TiACNO作为一个单元涂5次。
CVD表层为CVD-TiCN + CVD-TiN组成的复合涂层。
对比例为根据专利ZL 201010530080.3的工艺制备的CVD涂层，其结构从内到外依次为：
TiN（0.5μm）+ MT-TiCN（7μm）+ 过渡层TiCNO（0.5um） + α—Al2O3 （4um）+ TiCN（0.5um）+ TiN（1.0μm）。
两种CVD涂层都对其进行同样的后处理：用400目的金刚砂对涂层表面进行湿喷砂处理，喷压2.0Kg/cm2,时间5秒。
喷砂处理后的涂层表面均采用与实施例1同样的多弧离子镀工艺沉积一层PVD-TiN表层，之后再次用400目金刚砂对涂层表面进行湿喷砂处理，喷压4.0 Kg/cm2，时间20秒。
切削参数如下：
刀片型号：WNMG080408
被加工材料：304不锈钢
切削速度：180m/min
切深：2-3mm
进给量：110mm/min
刀具寿命：本发明为20-25件
对比例为10-15件

Claims (17)

1.双结构涂层刀具，刀具基体上沿基体表面向外依次有CVD、PVD或PCVD复合涂层，CVD涂层沿基体向外依次为：TiN+MT-TiCN+过渡层TiAlCNO+细颗粒α-Al2O3+CVD或PCVD表层，与基体接触的最内层TiN可以保证基体与涂层的结合力，MT-TiCN依靠其较高的硬度作为耐磨层，同时对后续的α-Al2O3起到支撑作用，过渡层TiAlCNO保证MT-TiCN和α-Al2O3两种涂层的结合力，α-Al2O3作为隔热层保护基体，细颗粒α-Al2硬度得到了提升，粒降低。
2.根据权利要求1所述的双结构涂层刀具，其特征在于刀具基体包含各种高速钢、不锈钢等钢制刀具基体，WC基硬质合金基体，ZrO2基体，赛隆基体，Si3N4基体，TiCN基体，Al2O3基体，CBN基体，金刚石基体 。
3.根据权利要求1所述的双结构涂层刀具，其特征在于过渡层为TiAlCNO，沉积过程中控制Al含量在质量百分比0.5-2%，通过在传统的TiCO和TiCNO过渡层中添加Al，使MT-TiCN均匀过度到α-Al2O3涂层，通过成分的连续性，使涂层结合力更好，同时更有利于后续细颗粒α-Al2O3的沉积。
4.根据权利要求1所述的双结构涂层刀具，其特征在于，α-Al2O3沉积压力为50-60mbar，打断α-Al2O3的生长，形成α-Al2O3+TiAlCNO的多层叠加结构，使α-Al2O3的颗粒尺寸降低到1.2um以下，同时也使α-Al2O3硬度得到了提升，使α-Al2O3的颗粒尺寸降低，同时也使α-Al2O3硬度得到了提升， 细颗粒α-Al2O3涂层厚度1-20um，颗粒尺寸0.5-1.2um。
5.根据权利要求４所述的双结构涂层刀具，其特征在于，细颗粒α-Al2O3涂层，厚度优选5-10um。
6.根据权利要求1所述的双结构涂层刀具，其特征在于，MT-TiCN厚度1-20um。
7.根据权利要求6所述的双结构涂层刀具，其特征在于，MT-TiCN涂层厚度优选3-10um。
8.根据权利要求1所述的双结构涂层刀具，其特征在于，过渡层TiAlCNO厚度为0.1-1um。
9.根据权利要求8所述的双结构涂层刀具，其特征在于，过渡层厚度优选0.5-1um。
10.根据权利要求1所述的双结构涂层刀具，其特征在于，CVD表层为IVB族金属的碳化物、氮化物、碳氮化物、碳氮氧化物、硼化物、硼氮化物、碳硼氮化物、氮硅化物、碳氮硅化物、氮铝化物、碳氮铝化物、碳氮硅铝化物中的一种或几种的复合涂层，厚度1-10um。
11.根据权利要求10所述的双结构涂层刀具，其特征在于，CVD表层厚度优选1-5um。
12.根据权利要求1所述的双结构涂层刀具，其特征在于，CVD表层涂层后需要对产品进行后处理，处理后CVD表层表面粗糙度小于0.5um。
13.根据权利要求12所述的双结构涂层刀具，其特征在于，CVD表层表面粗糙度优选小于0.2um。
14.根据权利要求1所述的双结构涂层刀具，其特征在于，PVD或PCVD表层是通过PVD或PCVD方法制备的金刚石涂层、类金刚石涂层、PVD-Al2O3、PVD-Zr2O3、PVD-Cr2O3、IVB族和VB族金属的碳化物、氮化物、碳氮化物、碳氮氧化物、硼化物、硼氮化物、硼碳氮化物、氮硅化物、碳氮硅化物、氮铝化物、碳氮铝化物、碳氮硅铝化物中的一种或几种的复合涂层，厚度0.5-10um。
15.根据权利要求14所述的双结构涂层刀具，其特征在于，PVD表层厚度优选0.5-5um。
16.根据权利要求1所述的双结构涂层刀具，其特征在于，根据材料的加工特性选择相应的PVD涂层种类，中低速加工普通易加工钢搭配TiN涂层，中高速加工普通易加工钢搭配TiAlN涂层，加工石墨搭配金刚石或DLC涂层，加工硅含量大于12%的铝合金搭配TiCN涂层，加工铜合金搭配CrN涂层，加工不锈钢搭配TiCrAlSiN涂层，加工镍基合金搭配TiAlN+PVD-Al2O3复合涂层，加工铸铁搭配TiCrAlN、TiAlN涂层，加工钛合金搭配AlCrN或CrN涂层，加工非铁合金搭配TiB2涂层。
17.根据权利要求12所述的双结构涂层刀具，其特征在于，后处理是在不损伤刃口的前提下，通过毛刷或喷砂的方法实现，毛刷法选取由SiC、猪鬃构成的毛刷，根据CVD表层的厚度进行短时间的处理，单一刀具处理时间5-10秒即可，喷砂法是通过选用金刚砂、硅砂、树脂砂，在2-4Bar的压力下，对涂层表面进行短时间喷砂处理，单一刀具处理时间5-10秒即可，通过后处理达到降低涂层表面粗糙度的目的。
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CN111826652A (zh) * 2020-07-14 2020-10-27 山东大学 一种利用预切削法制备低摩擦系数涂层刀具的方法及刀具
CN113512716A (zh) * 2021-03-26 2021-10-19 四川大学 一种修复基体的碳氮化钛/氧化铝复合涂层的制备方法
CN113649575A (zh) * 2021-07-02 2021-11-16 湖北刃锋精工有限公司 一种硬质合金刀片及其制备方法
CN113649575B (zh) * 2021-07-02 2023-08-04 湖北刃锋精工有限公司 一种硬质合金刀片及其制备方法
CN113621965A (zh) * 2021-08-11 2021-11-09 无锡锐威精密刀具有限公司 一种合金刀具表面金刚石梯度膜及其制备方法
CN114293144A (zh) * 2022-01-12 2022-04-08 松山湖材料实验室 一种刀具镀膜工艺及设备

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