EP0792390B1 - Coated cemented carbide insert for metal cutting applications - Google Patents

Coated cemented carbide insert for metal cutting applications Download PDF

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Publication number
EP0792390B1
EP0792390B1 EP95942809A EP95942809A EP0792390B1 EP 0792390 B1 EP0792390 B1 EP 0792390B1 EP 95942809 A EP95942809 A EP 95942809A EP 95942809 A EP95942809 A EP 95942809A EP 0792390 B1 EP0792390 B1 EP 0792390B1
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EP
European Patent Office
Prior art keywords
binder phase
cemented carbide
weight
max
phase
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP95942809A
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German (de)
French (fr)
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EP0792390A1 (en
Inventor
Marian Mikus
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Sandvik AB
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Sandvik AB
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Anticipated expiration legal-status Critical
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • C23C30/005—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process on hard metal substrates

Definitions

  • the present invention relates to coated cemented carbide inserts with improved cutting properties being obtained as a result of modifications of the chemical and mechanical properties of the binder phase.
  • Cemented carbide grades for metal cutting applications generally contain WC, ⁇ -phase (a solid solution of generally TiC, NbC, TaC and WC) and binder phase, generally cobalt. Their properties are optimized by varying the WC grain size, volume fraction of the binder phase and/or the ⁇ -phase and by optimising the carbon content.
  • One recent major improvement of the properties of coated cemented carbide is the introduction of binder phase enriched surface zones.
  • cemented carbides with binder phase enriched surface zones are mainly found in ⁇ -phase containing grades whereas straight WC-Co grades have even binder phase distribution without said binder phase enrichment.
  • the binder phase is based on cobalt containing varying amounts of tungsten and carbon in solid solution. In addition to tungsten or carbon, only very low contents of other elements (mainly impurities) are present in the binder phase.
  • binder phase alloys based on Co-Ni-Cr or Ni-Cr are used e.g. such as disclosed in EP-A-28620.
  • the invention relates to a coated cemented carbide for interrupted machining of steel and cast iron metal cutting applications.
  • Said cemented carbide contains 4-14 weight-% binder phase consisting of in solid solution in weight-%: Co 20-80, Mo 1-6, preferably about 2, Cr 3-15, and rest Ni and, optionally W max 30, Mo max 15, Al max 2 and Fe max 70. V may be added up to 5 weight-%.
  • the Co:Ni weight ratio in the binder phase is about 1:1 or about 3:1.
  • the carbon content should be between a lower value corresponding to the ⁇ -phase limit and an upper value corresponding to the stoichiometric carbon content.
  • the carbon content can be below the ⁇ -phase limit and thus the cemented carbide will contain also ⁇ -phase or other substoichiometric phases. 1-20 volume-% has been found suitable.
  • the invention can be applied to inserts with even distribution of binder phase or, preferably, to inserts with a binder phase enriched surface zone up to 50 ⁇ m.
  • the degree of the binder phase enrichment shall be between 1.2 and 2.5 times, preferably between 1.4 and 1.8, higher than the binder phase content of the rest of the insert.
  • Such inserts can be made e.g. using the technique disclosed in US 4,610,931.
  • the cemented carbide is coated with wear resistant layers as known in the art using known CVD, MTCVD or PVD technique.
  • MTCVD is a moderate temperature CVD-process using e.g. CH 3 CN gas and TiCl 4 . If the total nickel content is more than about 1.5 weight-% care has to be taken to avoid the detrimental effects of nickel on the coating quality e.g. by using at least at the beginning of the coating process a rather low temperature, preferably ⁇ 960 °C.
  • Coatings comprising carbides and/or carbonitrides and/or oxicarbides and/or oxinitrides and/or oxicarbonitrides of titanium and/or Al 2 O 3 are particularly useful.
  • at least one 0.3-5 ⁇ m, preferably 0.5-1.5 ⁇ m, interlayer comprising Ti(C,O) or Ti(C,O,N) or Ti(N,O) is deposited within a part of the coating containing titanium about 0.5-3 ⁇ m from the cemented carbide surface such as disclosed in Swedish Patent Application 9400951-1.
  • the coating thickness shall be 3-16 ⁇ m.
  • the total coating thickness should be 3-7 ⁇ m and for turning applications the total coating thickness should be 5-16 ⁇ m.
  • the present invention is particularly useful in machining of steel and cast iron when the cutting inserts are subjected to thermal and mechanical fatigue conditions. This is typical for milling operations but sometimes it also occurs in certain turning operations with intermittent character.
  • the reason for the observed tool life for the coated cemented carbide according to the present invention is still not understood in detail. It is believed that through the cracks already present in the coating, or formed during the cutting within the cemented carbide or the coating, the binder phase is oxidised causing weakening of the areas close to the coating. By use of the more oxidation resistant binder phase compositions this type of drawback is largely decreased.
  • the chromium addition increases the binder phase oxidation resistance.
  • addition of nickel both increases the oxidation resistance of the cobalt binder phase but also decreases the deformation hardening by stabilization of the FCC-structure of the cobalt phase.
  • the invention has been described with reference to cutting tool inserts of cemented carbide. It is obvious that the invention can be applied to coated cutting tool insert for metal cutting applications containing at least one hard constituent of a carbide, nitride and/or carbonitride of the metals Ti, Ta, Hf, Nb, V, Zr and W or solid solutions thereof in a binder phase.
  • Cutting tool inserts according to the invention with the following composition in weight-%: 91.5 WC, 3.9 Co, 3.7 Ni, 0.8 Cr, 0.1 Mo were prepared and coated with a coating consisting of 0.5 ⁇ m TiN, 5 ⁇ m Ti(C,N) and 3 ⁇ m Al 2 O 3 .
  • the TiN layer was the inner layer closest to the cemented carbide and it was deposited at a temperature of 920 °C.
  • the Ti(C,N) layer was deposited using MTCVD technique.
  • Tool life criterion Edge frittering of the work piece.
  • Cutting tool inserts according to the invention with the following composition in weight-%: 94.5 WC, 3.3 Co, 1.1 Ni, 0.6 Cr, 0.1 Mo, 0.2 VC were prepared and coated with a coating consisting of: 1.5 ⁇ m TiC, 0.5 ⁇ m Ti(C,O), 7 ⁇ m Ti(C,N) and 6 ⁇ m Al 2 O 3 .
  • the TiC layer was the innermost layer closest to the cemented carbide and the Al 2 O 3 layer was the outermost layer.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Cutting Tools, Boring Holders, And Turrets (AREA)
  • Ceramic Products (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
  • Carbon And Carbon Compounds (AREA)
  • Chemical Vapour Deposition (AREA)

Abstract

The present invention relates to coated inserts for metal cutting applications containing at least one hard constituent of a carbide, nitride and/or carbonitride of the metals Ti, Ta, Hf, Nb, V, Zr and W or solid solutions thereof, in 3-20 weight-%, preferably 4-14 weight-%, binder phase. By using a binder phase comprising in solid solution: Co max 95 %, Ni max 95 % and Cr 3-25 % improved properties are obtained particularly in machining operations of intermittent character. Coatings comprising carbides and/or carbonitrides and/or oxicarbides and/or oxinitrides and/or oxicarbonitrides of titanium and/or Al2O3 are particularly useful.

Description

The present invention relates to coated cemented carbide inserts with improved cutting properties being obtained as a result of modifications of the chemical and mechanical properties of the binder phase.
Cemented carbide grades for metal cutting applications generally contain WC, γ-phase (a solid solution of generally TiC, NbC, TaC and WC) and binder phase, generally cobalt. Their properties are optimized by varying the WC grain size, volume fraction of the binder phase and/or the γ-phase and by optimising the carbon content. One recent major improvement of the properties of coated cemented carbide is the introduction of binder phase enriched surface zones.
Thus, two major groups of coated cemented carbide inserts for metal cutting are used today: one with even distribution of binder phase within the whole insert and one with binder phase enriched surface zones.
The cemented carbides with binder phase enriched surface zones are mainly found in γ-phase containing grades whereas straight WC-Co grades have even binder phase distribution without said binder phase enrichment.
In both these groups of cemented carbides the binder phase is based on cobalt containing varying amounts of tungsten and carbon in solid solution. In addition to tungsten or carbon, only very low contents of other elements (mainly impurities) are present in the binder phase.
In applications in highly corrosive environments e.g. wear parts in pumps, compressors or cutters in wood working industry ordinary WC-Co based cemented carbides fail due to corrosion attacks from various types of the corrosive media which react with and deteriorate the cobalt binder phase. In such applications binder phase alloys based on Co-Ni-Cr or Ni-Cr are used e.g. such as disclosed in EP-A-28620.
Surprisingly it has now been found that by using a cemented carbide with a corrosion resistant binder phase large improvements in tool life are achieved for coated cemented carbides in certain metal cutting operations.
The invention relates to a coated cemented carbide for interrupted machining of steel and cast iron metal cutting applications. Said cemented carbide contains 4-14 weight-% binder phase consisting of in solid solution in weight-%: Co 20-80, Mo 1-6, preferably about 2, Cr 3-15, and rest Ni and, optionally W max 30, Mo max 15, Al max 2 and Fe max 70. V may be added up to 5 weight-%.
The Co:Ni weight ratio in the binder phase is about 1:1 or about 3:1.
The carbon content should be between a lower value corresponding to the η-phase limit and an upper value corresponding to the stoichiometric carbon content. In certain embodiments the carbon content can be below the η-phase limit and thus the cemented carbide will contain also η-phase or other substoichiometric phases. 1-20 volume-% has been found suitable.
At too high carbon or chromium contents the brittle chromium carbide is formed and, thus, both chromium and carbon contents must be selected so that the formation of chromium carbide is kept at a minimum.
The invention can be applied to inserts with even distribution of binder phase or, preferably, to inserts with a binder phase enriched surface zone up to 50 µm. The degree of the binder phase enrichment shall be between 1.2 and 2.5 times, preferably between 1.4 and 1.8, higher than the binder phase content of the rest of the insert. Such inserts can be made e.g. using the technique disclosed in US 4,610,931.
The cemented carbide is coated with wear resistant layers as known in the art using known CVD, MTCVD or PVD technique. MTCVD is a moderate temperature CVD-process using e.g. CH3CN gas and TiCl4. If the total nickel content is more than about 1.5 weight-% care has to be taken to avoid the detrimental effects of nickel on the coating quality e.g. by using at least at the beginning of the coating process a rather low temperature, preferably <960 °C.
Coatings comprising carbides and/or carbonitrides and/or oxicarbides and/or oxinitrides and/or oxicarbonitrides of titanium and/or Al2O3 are particularly useful. In a preferred embodiment at least one 0.3-5 µm, preferably 0.5-1.5 µm, interlayer comprising Ti(C,O) or Ti(C,O,N) or Ti(N,O) is deposited within a part of the coating containing titanium about 0.5-3 µm from the cemented carbide surface such as disclosed in Swedish Patent Application 9400951-1.
The coating thickness shall be 3-16 µm. For milling applications the total coating thickness should be 3-7 µm and for turning applications the total coating thickness should be 5-16 µm.
The present invention is particularly useful in machining of steel and cast iron when the cutting inserts are subjected to thermal and mechanical fatigue conditions. This is typical for milling operations but sometimes it also occurs in certain turning operations with intermittent character.
The reason for the observed tool life for the coated cemented carbide according to the present invention is still not understood in detail. It is believed that through the cracks already present in the coating, or formed during the cutting within the cemented carbide or the coating, the binder phase is oxidised causing weakening of the areas close to the coating. By use of the more oxidation resistant binder phase compositions this type of drawback is largely decreased. The chromium addition increases the binder phase oxidation resistance. However, addition of nickel both increases the oxidation resistance of the cobalt binder phase but also decreases the deformation hardening by stabilization of the FCC-structure of the cobalt phase.
The invention has been described with reference to cutting tool inserts of cemented carbide. It is obvious that the invention can be applied to coated cutting tool insert for metal cutting applications containing at least one hard constituent of a carbide, nitride and/or carbonitride of the metals Ti, Ta, Hf, Nb, V, Zr and W or solid solutions thereof in a binder phase.
Example 1
Cutting tool inserts according to the invention with the following composition in weight-%: 91.5 WC, 3.9 Co, 3.7 Ni, 0.8 Cr, 0.1 Mo were prepared and coated with a coating consisting of 0.5 µm TiN, 5 µm Ti(C,N) and 3 µm Al2O3. The TiN layer was the inner layer closest to the cemented carbide and it was deposited at a temperature of 920 °C. The Ti(C,N) layer was deposited using MTCVD technique.
As reference, inserts with the composition in weight-%: 91.5 WC and 8.5 Co and provided with the same coating were used.
  • Cutting test:
  • 50 inserts from each group were tested with the following conditions:
  • Operation: Face milling
  • Work piece: Pump house in grey cast iron (SS0125)
  • Cutting speed: 263 m/min
  • Feed rate: 0.14 mm/tooth
  • Depth of cut: 2 mm
  • Cutting fluid: Emulsion
  • Insert type: TNHF 1204AN-65
    • Tool life criterion: Edge frittering of the work piece.
  • Tool life:
  • Inserts according to the invention: 29 minutes Reference inserts: 16 minutes
    • Example 2
    Cutting tool inserts according to the invention with the following composition in weight-%: 94.5 WC, 3.3 Co, 1.1 Ni, 0.6 Cr, 0.1 Mo, 0.2 VC were prepared and coated with a coating consisting of: 1.5 µm TiC, 0.5 µm Ti(C,O), 7 µm Ti(C,N) and 6 µm Al2O3. The TiC layer was the innermost layer closest to the cemented carbide and the Al2O3 layer was the outermost layer.
    As reference, inserts with the composition in weight-%: 94.7 WC and 5.3 Co and provided with the same coating were used.
  • Cutting test.
  • Operation: Facing with interrupted cuts
  • Work material: Ferritic-perlitic nodular cast iron (SS0727)
  • Cutting speed: 150 m/min
  • Feed rate: 0.1 mm/rev
  • Depth of cut: 2.0 mm
  • Cutting fluid: none
  • Insert type: CNMA 120412
  • Tool life criterion: Flank wear ≥ 0.3 mm
  • Tool life:
  • Inserts according to the invention: 75 min
  • Reference inserts: 41 min

    • Claims (4)

    1. Coated insert for interrupted machining of steel and cast iron consisting of a 3-16 µm thick coating comprising at least one carbide or carbonitride or oxicarbide or oxinitrides or oxicarbonitrides of titanium or Al2O3 and a substrate containing at least one hard constituent of a carbide, nitride and/or carbonitride of the metals Ti, Ta, Hf, Nb, V, Zr and W or solid solutions thereof in 4-14 weight-% binder phase wherein the binder phase consists of in solid solution the following elements in weight-%: Co 20-80, Cr 3-15, Mo 1-6 and optionally W max 30, Al max 2, Fe max 70 and V up to 5 and rest Ni whereby the Co:Ni weight ratio is about 1:1 or about 3:1.
    2. Coated insert according to claim 1 characterised in an up to 50 µm thick binder phase enriched surface zone.
    3. Coated insert according to claims 1 or 2 characterised in that said coating contains at least one 0.3-5 µm layer of Ti(C,O), Ti(C,O,N) or Ti(N,O) about 0.5-3 µm from the substrate surface.
    4. Coated insert according to any of the preceding claims characterised in containing 1-20 volume-% η-phase or other substoichiometric phase.
    EP95942809A 1994-12-30 1995-12-15 Coated cemented carbide insert for metal cutting applications Expired - Lifetime EP0792390B1 (en)

    Applications Claiming Priority (3)

    Application Number Priority Date Filing Date Title
    SE9404587A SE513978C2 (en) 1994-12-30 1994-12-30 Coated cemented carbide inserts for cutting metalworking
    SE9404587 1994-12-30
    PCT/SE1995/001516 WO1996021052A1 (en) 1994-12-30 1995-12-15 Coated cemented carbide insert for metal cutting applications

    Publications (2)

    Publication Number Publication Date
    EP0792390A1 EP0792390A1 (en) 1997-09-03
    EP0792390B1 true EP0792390B1 (en) 2000-03-08

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    Family Applications (1)

    Application Number Title Priority Date Filing Date
    EP95942809A Expired - Lifetime EP0792390B1 (en) 1994-12-30 1995-12-15 Coated cemented carbide insert for metal cutting applications

    Country Status (6)

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    EP (1) EP0792390B1 (en)
    AT (1) ATE190363T1 (en)
    DE (1) DE69515503T2 (en)
    IL (1) IL116549A (en)
    SE (1) SE513978C2 (en)
    WO (1) WO1996021052A1 (en)

    Families Citing this family (11)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    US5992546A (en) * 1997-08-27 1999-11-30 Kennametal Inc. Rotary earth strata penetrating tool with a cermet insert having a co-ni-fe-binder
    US6010283A (en) * 1997-08-27 2000-01-04 Kennametal Inc. Cutting insert of a cermet having a Co-Ni-Fe-binder
    US6170917B1 (en) 1997-08-27 2001-01-09 Kennametal Inc. Pick-style tool with a cermet insert having a Co-Ni-Fe-binder
    US6022175A (en) * 1997-08-27 2000-02-08 Kennametal Inc. Elongate rotary tool comprising a cermet having a Co-Ni-Fe binder
    US6024776A (en) * 1997-08-27 2000-02-15 Kennametal Inc. Cermet having a binder with improved plasticity
    DE19836392A1 (en) * 1998-08-12 2000-02-17 Wolfgang Wiesener Low cost wear resistant coating, used as a plasma sprayed coating for tools such as screwdrivers, comprises hard metal grains in a binder metal matrix
    US6575671B1 (en) 2000-08-11 2003-06-10 Kennametal Inc. Chromium-containing cemented tungsten carbide body
    US6612787B1 (en) 2000-08-11 2003-09-02 Kennametal Inc. Chromium-containing cemented tungsten carbide coated cutting insert
    US6554548B1 (en) 2000-08-11 2003-04-29 Kennametal Inc. Chromium-containing cemented carbide body having a surface zone of binder enrichment
    JP2002166307A (en) * 2000-11-30 2002-06-11 Kyocera Corp Cutting tool
    DE10213963A1 (en) * 2002-03-28 2003-10-09 Widia Gmbh Tungsten carbide or cermet cutting material and method for machining Cr-containing metal workpieces

    Citations (1)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    WO1980002569A1 (en) * 1979-05-17 1980-11-27 Sandvik Ab Cemented carbide

    Family Cites Families (3)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    US4610931A (en) * 1981-03-27 1986-09-09 Kennametal Inc. Preferentially binder enriched cemented carbide bodies and method of manufacture
    US4447263A (en) * 1981-12-22 1984-05-08 Mitsubishi Kinzoku Kabushiki Kaisha Blade member of cermet having surface reaction layer and process for producing same
    SE9100227D0 (en) * 1991-01-25 1991-01-25 Sandvik Ab CORROSION RESISTANT CEMENTED CARBIDE

    Patent Citations (1)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    WO1980002569A1 (en) * 1979-05-17 1980-11-27 Sandvik Ab Cemented carbide

    Also Published As

    Publication number Publication date
    IL116549A (en) 1999-12-22
    SE9404587L (en) 1996-07-01
    ATE190363T1 (en) 2000-03-15
    SE513978C2 (en) 2000-12-04
    WO1996021052A1 (en) 1996-07-11
    DE69515503D1 (en) 2000-04-13
    IL116549A0 (en) 1996-03-31
    EP0792390A1 (en) 1997-09-03
    DE69515503T2 (en) 2000-11-23
    SE9404587D0 (en) 1994-12-30

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