CN1927512B - Pvd涂覆切削工具 - Google Patents

Pvd涂覆切削工具 Download PDF

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CN1927512B
CN1927512B CN2006101516732A CN200610151673A CN1927512B CN 1927512 B CN1927512 B CN 1927512B CN 2006101516732 A CN2006101516732 A CN 2006101516732A CN 200610151673 A CN200610151673 A CN 200610151673A CN 1927512 B CN1927512 B CN 1927512B
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法伊特·席尔
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Abstract

本发明描述了一种切削工具，该切削工具针对金属加工具有改进的性能，该切削工具具有硬质合金基底和位于该基底的表面上的硬且耐磨的涂层。涂层通过物理气相沉积(PVD)而被沉积。涂层由金属氮化物与氧化铝(Al2O3)结合组成。涂层由分层的多层结构组成。刀片被进一步处理成分别在前刀面和侧面上具有不同的外层。

Description

PVD涂覆切削工具
技术领域
本发明涉及一种切削工具，该切削工具针对金属加工具有改进的性能，该切削工具具有硬质合金基底和位于该基底的表面上的硬且耐磨的涂层。涂层是通过物理汽相沉积(PVD)沉积的。涂层由金属氮化物与氧化铝(Al2O3)结合组成。涂层由分层的多层结构组成。为了优化性能，刀片被进一步处理成分别在前刀面和侧面上具有不同的外层。
背景技术
用于金属的切屑成形加工的现代高产率工具需要具有优良磨损性能的可靠工具。从20世纪60年代末期开始，就已知可以通过向工具表面涂覆适当的涂层以显著地改进工具寿命。用于磨损应用的最早涂层通过化学气相沉积(CVD)形成并且该涂层技术仍然广泛用于切削工具应用。物理气相沉积(PVD)在20世纪80年代中期提出，并且从那时起从单层稳定金属化合物像TiN或Ti(C，N)进一步发展成包括多组分和多层涂层，它们还包括亚稳定化合物像(Ti，Al)N或非金属化合物像Al2O3。
在Shinzato等人在Thin Sol.Films，97(1982)333-337一文中描述了使用高至900℃的沉积温度在硬质合金切削工具上射频溅射氧化铝。在Knotek等人的Surf.Coat.Techn.，(表面涂覆技术)，59(1993)14-20中描述了使用氧化铝的PVD涂层用于磨损保护，其中氧化铝被沉积为耐磨碳氮化物层上的最外层。氧化铝层据说可以将粘附磨损减小到最低，并且可以充当化学侵蚀的障碍。美国专利号5,879,823中公开了一种工具材料，该工具材料涂覆有PVD氧化铝，作为层叠当中的一层或两层，非氧化层例如包含TiAl。该工具可以具有TiN外层。Al2O3可以为α、κ、θ、γ型或无定形的。在美国专利号6,210,726中公开了氧化铝涂覆的工具，其中氧化物多晶型物为γ型，具有400或440晶体结构。美国专利号5,310,607公开了PVD沉积氧化铝，含有大于5％的Cr。对于Cr含量超过20％的氧化铝，可以发现具有大于20GPa的硬度和α相的晶体结构。如果没有Cr添加物，就会给出具有5GPa硬度的无定形氧化铝。
现今的大多数涂覆工具具有金色的TiN以易于通过肉眼区别出使用过的和未使用的切削刃。TiN并不总是优选的顶层，尤其是在其中切屑可能粘附至TiN层的应用中不是优选的。在EP-A-1193328中公开了涂层的部分喷砂，其目的是在保持底层涂层的有益性能的同时能够磨损检测。前刀面上的磨损在本质上主要是化学上的并且需要化学稳定的化合物，而在侧面上的磨损在本质上主要是机械上的并且需要更硬的并且耐磨的化合物。
发明内容
本发明的一个目的是提供一种具有多层涂层的改进的切削工具组分。
本发明的另一个目的是分别在前刀面和侧面上使用不同外层的概念来进一步提高PVD涂覆切削工具的性能。
优选通过PVD工艺形成的涂层包括紧邻基底的(Ti，Al)N化合物、在(Ti，Al)N层上面的氧化铝层和至少另外两个(Ti，Al)N和氧化铝的交替层以及最外层的ZrN。ZrN层在后处理中从前刀面上除去，且优选通过喷砂或刷除而被除去。通常需要几次重复的刷除或喷砂来完全除去前刀面上的ZrN层。不完全的除去通常会导致ZrN残留物局部焊接到切屑上，这会降低工具寿命。为了降低顶部ZrN层的粘附，在氧化铝层上、ZrN层下方沉积亚化学计量的ZrN1-x的中间层。亚化学计量ZrN1-x具有减小的强度并且便于顶部ZrN层的除去。
依照本发明，现在提供了一种切削工具刀片，它具有顶面(前刀面)、相对面和至少一个与所述顶面和相对面相交的间隙面以界定切削刃，其包括硬质合金基底和硬层系统。硬质合金具有如下组成：重量百分比为86-90％的WC、重量百分比为1-2％的(Ta，Nb)C和重量百分比为8-13％的Co，且优选为重量百分比为88-89％的WC、重量百分比为1.2-1.8％的(Ta，Nb)C和重量百分比为10-11％的Co。硬层系统具有3-30微米的总厚度，并且包括：
-(Ti，Al)N的第一层，具有1-5微米且优选2-4微米的厚度，
-氧化铝层，优选为γ-氧化铝，具有1-4微米且优选1-2微米的厚度，
-((Ti，Al)N+氧化铝)*n的多层，其中n≥2，具有小于0.5微米且优选0.1-0.3微米的厚度，
-优选亚化学计量ZrN1-x，优选x＝0.01-0.1，且优选厚度小于0.1微米的薄层，以及
-ZrN层，具有小于1微米且优选为0.1-0.6微米的厚度，在前刀面和刀口上没有ZrN层，
其中，(Ti，Al)N层优选具有60/40＜Al/Ti＜70/30且最优选为Al/Ti＝67/33的原子组成。
本发明还涉及一种用于制造涂覆切削工具刀片的方法，该刀片具有顶面(前刀面)、相对面和至少一个与所述顶面和相对面相交以界定切削刃的间隙面，包括下列步骤：
-提供一种硬质合金基底，该基底具有如下组成：重量百分比为86-90％的WC、重量百分比为1-2％的(Ta，Nb)C和重量百分比为8-13％的Co，且优选为重量百分比为88-89％的WC、重量百分比为1.2-1.8％的(Ta，Nb)C和重量百分比为10-11％的Co
-使用PVD方法，在硬质合金基底上沉积一个硬层系统，其具有3-30微米的总厚度，并且该硬层系统包括：
-(Ti，Al)N的第一层，具有1-5微米且优选2-4微米的厚度，
-氧化铝层，优选为γ-氧化铝，具有1-4微米且优选为1-2微米的厚度，
-((Ti，Al)N+氧化铝)*n的多层，其中n≥2，具有小于0.5微米且优选0.1-0.3微米的厚度，
-优选亚化学计量ZrN1-x，优选x＝0.01-0.1，且优选小于0.1微米的薄层，以及
-最外侧的ZrN层，具有小于1微米且优选0.1-0.6微米的厚度，其中，(Ti，Al)N层优选具有60/40＜Al/Ti＜70/30且最优选为Al/Ti＝67/33的原子组成，并且
-通过后处理且优选通过刷除或喷砂，除去前刀面和刀口上的所述ZrN层。
实例1
硬质合金刀片ADMT 160608R，其具有如下组成：重量百分比为88％的WC、重量百分比为1.5％的(Ta，Nb)C和重量百分比为10.5％的Co，使用PVD技术依照下列次序在一个工序中涂覆
方案A：
层叠(Ti0.33Al0.67N-Al2O3-Ti0.33Al0.67N-Al2O3-Ti0.33Al0.67N-Al2O3)，
方案B：层叠(Ti0.33Al0.67N-Al2O3)
方案C：Ti0.33Al0.67N层。
刀片在干燥的台肩铣削应用中进行测试。
工件材料：马氏体不锈钢X90CrMoV18(1.4112)。
切削速度：140米/分钟
工具寿命标准：所生成零件的数目
表1在工具寿命中铣边之后生成的零件
  涂层   Ti<sub>0.33</sub>Al<sub>0.67</sub>N   Ti<sub>0.33</sub>Al<sub>0.67</sub>N-Al<sub>2</sub>O<sub>3</sub>   3x(Ti<sub>0.33</sub>Al<sub>0.67</sub>N-Al<sub>2</sub>O<sub>3</sub>)
  在工具寿命中生成的零件   3   4   7
结果显示出提高的层厚度在铣边中对工具寿命的影响。
实例2
硬质合金刀片ADMT 160608R，其具有如下组成：重量百分比为88％的WC、重量百分比为1.5％的(Ta，Nb)C和重量百分比为10.5％的Co，使用PVD技术依照下列次序在一个工序中涂覆：3微米的(Ti，Al)N(Al/Ti 67/33％)、1.5微米纳晶态γ-氧化铝、0.2微米的(Ti，Al)N(Al/Ti67/33％)、0.2微米的纳晶态γ-氧化铝、0.1微米的(Ti，Al)N(Al/Ti67/33％)、0.1微米的纳晶态γ-氧化铝、0.1-0.5微米的ZrN。
顶层的ZrN通过在湿喷砂工艺中使用氧化铝而被清理掉。
喷砂和未喷砂的刀片都用于对Ti合金(刚度为1400N/mm2)进行铣边。
在890毫米的切削距离之后测量最大侧面磨损，得到如下结果。
表2.在铣边之后的磨损(毫米)
  未处理的  从前刀面上移除ZrN
  最大侧面磨损   0.40-0.45   0.15-0.23
  最大半径磨损   0.23-0.3   0.10-0.13
它很清楚地显示出，从顶部前刀面上移除ZrN会导致相当小的磨损。

Claims (21)

1.一种PVD涂覆硬质合金刀片，其具有顶面、相对面和至少一个与所述顶面和相对面相交以界定切削刃的间隙面，其特征在于：
-硬质合金基底，具有如下组成：重量比为86-90％的WC、重量比为1-2％的(Ta，Nb)C和重量比为8-13％的Co，并且涂覆有
-硬层系统，其具有3-30微米的总厚度，包括
-(Ti，Al)N的第一层，具有1-5微米的厚度，
-氧化铝层，具有1-4微米的厚度，
-((Ti，Al)N+氧化铝)*n的多层，其中n≥2，具有小于0.5微米的厚度，以及
-ZrN层，具有小于1微米的厚度，在顶面和刀口上没有ZrN层，
其中所述(Ti，Al)N层具有60/40＜Al/Ti＜70/30的原子组成。
2.如权利要求1所述的PVD涂覆硬质合金刀片，其特征在于，该硬质合金具有重量比为88-89％的WC，重量百分比为1.2-1.8％的(Ta，Nb)C和重量百分比为10-11％的Co，且WC、(Ta，Nb)C和Co的重量百分比之和不大于100％。
3.如权利要求1所述的PVD涂覆硬质合金刀片，其特征在于，所述(Ti，Al)N的第一层具有2-4微米的厚度。
4.如权利要求1所述的PVD涂覆硬质合金刀片，其特征在于，所述氧化铝为γ-氧化铝。
5.如权利要求1所述的PVD涂覆硬质合金刀片，其特征在于，所述氧化铝层具有1-2微米的厚度。
6.如权利要求1所述的PVD涂覆硬质合金刀片，其特征在于，所述((Ti，Al)N+氧化铝)*n的多层具有0.1-0.3微米的厚度。
7.如权利要求1所述的PVD涂覆硬质合金刀片，其特征在于，所述ZrN层具有0.1-0.6微米的厚度。
8.如权利要求1所述的PVD涂覆硬质合金刀片，其特征在于，所述(Ti，Al)N层具有Al/Ti＝67/33的原子组成。
9.如权利要求1所述的PVD涂覆硬质合金刀片，其特征在于，在ZrN顶层下面具有亚化学计量ZrN1-x的薄层，其中x＝0.01-0.1。
10.如权利要求9所述的PVD涂覆硬质合金刀片，其特征在于，所述亚化学计量ZrN1-x薄层的厚度小于0.1微米。
11.一种用于制造涂覆切削工具刀片的方法，该刀片具有顶面、相对面和至少一个与所述顶面和相对面相交以界定切削刃的间隙面，其特征在于，该方法包括下列步骤：
-提供一种硬质合金基底，该基底具有如下组成：重量百分比为86-90％的WC、重量百分比为1-2％的(Ta，Nb)C和重量百分比为8-13％的Co，
-使用PVD方法，在硬质合金基底上沉积一个硬层系统，该硬层系统具有3-30微米的总厚度，并且包括
-(Ti，Al)N的第一层，具有1-5微米的厚度，
-氧化铝层，具有1-4微米的厚度，
-((Ti，Al)N+氧化铝)*n的多层，其中n≥2，具有小于0.5微米的厚度，以及
-最外侧的ZrN层，具有小于1微米的厚度，其中该(Ti，Al)N层具有60/40＜Al/Ti＜70/30的原子组成，
-通过后处理除去顶面和刀口上的所述ZrN层。
12.如权利要求11所述的用于制造涂覆切削工具刀片的方法，其特征在于，该硬质合金具有重量百分比为88-89％的WC，重量百分比为1.2-1.8％的(Ta，Nb)C和重量百分比为10-11％的Co，且WC、(Ta，Nb)C和Co的重量百分比之和不大于100％。
13.如权利要求11所述的用于制造涂覆切削工具刀片的方法，其特征在于，所述(Ti，Al)N的第一层具有2-4微米的厚度。
14.如权利要求11所述的用于制造涂覆切削工具刀片的方法，其特征在于，所述氧化铝为γ-氧化铝。
15.如权利要求11所述的用于制造涂覆切削工具刀片的方法，其特征在于，所述氧化铝层具有1-2微米的厚度。
16.如权利要求11所述的用于制造涂覆切削工具刀片的方法，其特征在于，所述((Ti，Al)N+氧化铝)*n的多层具有0.1-0.3微米的厚度。
17.如权利要求11所述的用于制造涂覆切削工具刀片的方法，其特征在于，所述ZrN层具有0.1-0.6微米的厚度。
18.如权利要求11所述的用于制造涂覆切削工具刀片的方法，其特征在于，所述(Ti，Al)N层具有Al/Ti＝67/33的原子组成。
19.如权利要求11所述的用于制造涂覆切削工具刀片的方法，其特征在于，所述后处理为刷除或喷刷。
20.如权利要求11所述的用于制造涂覆切削工具刀片的方法，其特征在于，在((Ti，Al)N+氧化铝)*n的多层上面沉积亚化学计量ZrN1-x的薄层，其中x＝0.01-0.1。
21.如权利要求20所述的用于制造涂覆切削工具刀片的方法，其特征在于，所述亚化学计量ZrN1-x薄层的厚度小于0.1微米。
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