EP2961550A1 - Cvi bonded and coated pcbn to wc tool body - Google Patents

Cvi bonded and coated pcbn to wc tool body

Info

Publication number
EP2961550A1
EP2961550A1 EP14731406.6A EP14731406A EP2961550A1 EP 2961550 A1 EP2961550 A1 EP 2961550A1 EP 14731406 A EP14731406 A EP 14731406A EP 2961550 A1 EP2961550 A1 EP 2961550A1
Authority
EP
European Patent Office
Prior art keywords
cutting tool
tool body
coating
brazing material
tip
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.)
Withdrawn
Application number
EP14731406.6A
Other languages
German (de)
French (fr)
Inventor
William Russell
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Diamond Innovations Inc
Original Assignee
Diamond Innovations Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Diamond Innovations Inc filed Critical Diamond Innovations Inc
Publication of EP2961550A1 publication Critical patent/EP2961550A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
    • B24D3/04—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
    • B24D3/14—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic ceramic, i.e. vitrified bondings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
    • B23B27/14—Cutting tools of which the bits or tips or cutting inserts are of special material
    • B23B27/141—Specially shaped plate-like cutting inserts, i.e. length greater or equal to width, width greater than or equal to thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
    • C04B37/02—Joining burned ceramic articles with other burned ceramic articles or other articles by heating with metallic articles
    • C04B37/023—Joining burned ceramic articles with other burned ceramic articles or other articles by heating with metallic articles characterised by the interlayer used
    • C04B37/025—Joining burned ceramic articles with other burned ceramic articles or other articles by heating with metallic articles characterised by the interlayer used consisting of glass or ceramic material
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
    • 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
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/04—Coating on selected surface areas, e.g. using masks
    • C23C16/045—Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2226/00—Materials of tools or workpieces not comprising a metal
    • B23B2226/12—Boron nitride
    • B23B2226/125—Boron nitride cubic [CBN]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2226/00—Materials of tools or workpieces not comprising a metal
    • B23B2226/31—Diamond
    • B23B2226/315—Diamond polycrystalline [PCD]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2228/00—Properties of materials of tools or workpieces, materials of tools or workpieces applied in a specific manner
    • B23B2228/04—Properties of materials of tools or workpieces, materials of tools or workpieces applied in a specific manner applied by chemical vapour deposition [CVD]
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/02—Aspects relating to interlayers, e.g. used to join ceramic articles with other articles by heating
    • C04B2237/04—Ceramic interlayers
    • C04B2237/06—Oxidic interlayers
    • C04B2237/062—Oxidic interlayers based on silica or silicates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/02—Aspects relating to interlayers, e.g. used to join ceramic articles with other articles by heating
    • C04B2237/04—Ceramic interlayers
    • C04B2237/08—Non-oxidic interlayers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/02—Aspects relating to interlayers, e.g. used to join ceramic articles with other articles by heating
    • C04B2237/04—Ceramic interlayers
    • C04B2237/08—Non-oxidic interlayers
    • C04B2237/086—Carbon interlayers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/34—Oxidic
    • C04B2237/343—Alumina or aluminates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/36—Non-oxidic
    • C04B2237/361—Boron nitride
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/36—Non-oxidic
    • C04B2237/363—Carbon
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/40—Metallic
    • C04B2237/401—Cermets
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/72—Forming laminates or joined articles comprising at least two interlayers directly next to each other
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/84—Joining of a first substrate with a second substrate at least partially inside the first substrate, where the bonding area is at the inside of the first substrate, e.g. one tube inside another tube

Definitions

  • the present invention relates to a cutting tool for metal machining, comprising at least one body containing polycrystalline cubic boron nitride (PCBN), with or without cemented carbide backing, and on the surface of said body a hard and wear resistant refractory coating, more specifically, to a method of using chemical vapor infiltration (CVI) or chemical vapor deposition (CVD) with porous or fine granule media to fill gaps between a PCBN tool tip and a WC tool body.
  • CVI chemical vapor infiltration
  • CVD chemical vapor deposition
  • PCBN Polycrystalline cubic boron nitride
  • polycrystalline diamond and polycrystalline diamond composite materials are commonly used to provide a superhard cutting edge for cutting tools such as those used in metal machining.
  • Cutting tools having cutting edges formed of a superhard abrasive such as a cubic boron nitride (CBN) based material are manufactured by powder
  • CBN cutting tools are known, the majority consisting of a PCBN tip that has been brazed onto a cemented carbide insert.
  • a cutting tool may comprise a sintered superabrasive tip having a plurality of superhard particles; a tool body retaining the superabrasive tip; and a non-brazing material filling gaps between the superabrasive tip and the tool body.
  • a method may comprise steps of providing a sintered superabrasive tip; providing a tool body; filling a gap between the
  • the superabrasive tip and the tool body with a non-brazing material; and depositing a first coating to the non-brazing material, wherein the first coating is an infiltrant coating to bond the tip, body and non-brazing materials to each other.
  • a cutting tool may comprise a sintered
  • superabrasive tip having a plurality of superhard particles; a tool body retaining the superabrasive tip; infiltrant bond coating between the superabrasive tip and the tool body; and high temperature coatings attached to the sintered superabrasive tip and the tool body.
  • FIG. 1 is a perspective view of a superabrasive tip affixed to a tool body according to an exemplary embodiment
  • FIG. 2 is an optical image of a cross-sectional view of a superabrasive tip affixed to a tool body according to another exemplary embodiment
  • FIG. 3 is a partially enlarged optical image of the cross-sectional view of a superabrasive tip affixed to a tool body as shown in FIG. 2;
  • FIG. 4 is a flowchart illustrating a method of making a superabrasive tip affixed to the tool body according to an exemplary embodiment.
  • cutting tip refers to a body for grinding or cutting a work piece, which is manufactured by fabrication processes including the step of mixing the super abrasive particles with bond.
  • tool body refers to a rigid body that holds a cutting tip or tips firmly in place so that they can be utilized in a turning, milling, boring, cutting, or drilling application.
  • a cutting tip may be made of superabrasive particles affixed to a suitable tool body, such as, cemented carbide hard metal.
  • a suitable tool body such as, cemented carbide hard metal.
  • the exemplary embodiments use chemical vapor infiltration (CVI) or chemical vapor deposition (CVD) with porous or fine granule media to fill gaps between the superabrasive tool tip and a tool body.
  • CVI chemical vapor infiltration
  • CVD chemical vapor deposition
  • INCORPORATED BY REFERENCE (RULE 20.6) porous or fine granule media to each other and to the cutting tip and the tool body.
  • a high temperature resistant coating or sequence of multilayered coatings, such as Al 2 0 3 may be subsequently coated as a part of the same process to provide an enhanced wear resistance.
  • the porous or fine granule media used may survive the CVI or CVD process.
  • fine granule such as diamond or cubic boron nitride, may be consumed by the process.
  • a high temperature resistant coating or sequence of multilayered coatings may be deposited for providing additional wear resistance to the cutting tool during machining, which may not have effects on the strength of the bonding already established (unlike a metallic braze).
  • a cutting tool 10 may include a sintered superabrasive tip 12 and a tool body 14 that contains an aperture 19.
  • the tool body 14 may be made from a number of materials, including cobalt cemented tungsten carbide.
  • the tool body 14 may be designed to retain the superabrasive tip 12.
  • the sintered superabrasive tip 12 may have a plurality of superhard particles, which may be selected from a group of cubic boron nitride, diamond, diamond composite, and ceramic materials. Between the superabrasive tip and the tool body may exist a seam or a gap, such as a bottom gap 15 and a sidewall gap 16, for example.
  • the superabrasive tip 12 may or may not have a backing support.
  • the backing support may be a hard metal support, such as a tungsten carbide support.
  • the cutting tool 10 may comprise a superabrasive tip 12 having a tungsten carbide support 20.
  • the superabrasive tip 12 may have polycrystalline cubic boron nitride (PcBN) particles.
  • the cutting tool 10 may further include a tool body 14 retaining the superabrasive tip 12.
  • a non-brazing material 24, which may have melting point at least 1000 °C, may be deposited to fill the sidewall gap 16 and the bottom gap 15.
  • the non-brazing material 24 may be at least one of zeolite, ceramic, cubic boron nitride, and diamond, for example.
  • the cutting tool 10 may further comprise coatings, such as infiltrant bond coating 22 on the non-brazing material 24 between the superabrasive tip and the tool body.
  • the infiltrant bond such as infiltrant bond
  • INCORPORATED BY REFERENCE (RULE 20.6) coatings 22 may cover the sintered superabrasive tip 12, the backing support 20, and tool body 14.
  • the infiltrant bond coatings may comprise at least one of Group IVB compounds containing C, N, 0, B, such as TiN, TiC, and TiCN, ZrN, ZrC, ZrCN, HfN, HfC, HfCN, for example.
  • a close-up optical image shown in FIG. 3, illustrates that the coatings 22, such as TiN, may cover all cubic boron nitride crystals 24.
  • the coatings 22 may further provide bonding between the non-brazing material, such as cBN, diamond, or zeolite, superabrasive tip 20, and the tool body 14.
  • a high temperature resistant coating such as Al 2 0 3 (not shown) may be deposited or coated to the sintered superabrasive tip 12, the tool body 14, and non-brazing material disposed between the superabrasive tip 12 and the tool body 24.
  • FIG. 4 shows an exemplary method 400 of a process of fabricating a cutting tool.
  • the process includes steps of providing a superabrasive tip in a step 401 ; providing a tool body in a step 402; filling a gap between the superabrasive tip and the tool body with a non-brazing material in a step 403; and depositing a first coating to the non-brazing material in a step 404.
  • the sintered superabrasive tip may be attached by some method to the tool body.
  • the cutting tool may then be placed in a CVD (chemical vapor deposition) reaction vessel, whereupon air is removed and replaced by gases comprising both inert and reactive species.
  • Metallic deposition may employ gases comprising metal carbonyl or metal- acetal-acetonates, for example, iron pentacarbonyl.
  • Ceramic deposition precursors may refer to N, C, and 0 containing compounds that crack under temperature less than 1000 °C.
  • the ceramic deposition precursors may include TiCI 4 , NH 3 , CH 4 , AICI 3 , (Me) 3 AI, N 2 , CH 3 CN, H 2 , CO, C0 2 or mixtures thereof, for example.
  • the gases penetrate via diffusion into gaps, seams, contact voids, and deposit on heated solid surfaces, external or internally gas- accessible, in the equipment. Upon condensation on the surface, the condensed phases chemically react to form a new solid phase as a first
  • the first coating may be an infiltrant coating to bond the superabrasive tip, the tool body, and non-brazing materials together.
  • TiCI 4 + CH 4 -> TiC solid + gas phase 4HCI This solid phase adhesively bonds to the solid surfaces depending on chemical affinity.
  • the quality of the solid phase depends on temperature and affinity to the solid surface(s) upon which they condense. The process of infiltration, condensation and reaction to form a new solid phase continues as long as temperature is high enough and reactants are present. Once the pores are filled, then straight-forward coating on surfaces of the superabrasive tip and the tool holding material may occur.
  • Gas accessibility is determined by the gas diffusion, which depends on temperature and pressure. Lower pressure allows deeper diffusion of reactive gases into seams and gaps in the tool assembly. Gas deposition, reaction and solidification rates forming a solid must be controlled to prevent premature '"plugging" of narrow gaps and seams, thus reducing the film contact area and joint strength. This typically requires that the temperature be lowered, or gas phase partial pressure of reactants be adjusted. Finally, the quality of the film formed, its crystallinity and crystal orientation, depends on temperature and time. If the film is formed and quenched too quickly, it may be of poor quality and crack either within the film or at the film-tip or film-tool interface.
  • non line-of-sight CVD coating does not require tools to be flipped over and processed multiple times to form a uniform coating.
  • CVD coats all gas-accessible surfaces in one furnace cycle.
  • Gas phase reactions that may also be considered CVD include any gas- solid reactions such as oxidation, hydration, or carburization.
  • the solid constituents include any gas- solid reactions such as oxidation, hydration, or carburization.
  • INCORPORATED BY REFERENCE may adsorb onto surfaces first, then react and crystallize, or may form above the surface and deposit by solid-surface tension forces prior to reaction and crystallization.
  • Post-CVD treatment e.g., annealing may be conducted to improve the quality of the film or film-tip/film-tool adhesion.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Metallurgy (AREA)
  • Manufacturing & Machinery (AREA)
  • General Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Composite Materials (AREA)
  • Structural Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
  • Cutting Tools, Boring Holders, And Turrets (AREA)

Abstract

A cutting tool (10) and a method of making a cutting tool are provided. The cutting tool (10) comprises a sintered superabrasive tip (12) with a plurality of superhard particles of polycrystalline boron nitride, a tool body (14) and a non-brazing material (24). The non- brazing material (24) fills a gap (15, 16) between the superabrasive tip (12) and the tool body (14). The method of making a cutting tool comprises steps of providing a superabrasive tip (12); providing a tool body (14); filling a gap (15, 16) between the superabrasive tip (12) and the tool body (14) with a non-brazing material (24); and depositing a first coating (22) to the non-brazing material (24).

Description

CVI BONDED AND COATED PCBN TO WC TOOL BODY
RELATED APPLICATIONS AND CLAIM OF PRIORITY
[0001] This application claims priority to U.S. provisional Patent Application No. 61/770,419, filed February 28, 2013, titled "CVI BONDED AND COATED PCBN TO WC TOOL BODY".
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY
[0002] The present invention relates to a cutting tool for metal machining, comprising at least one body containing polycrystalline cubic boron nitride (PCBN), with or without cemented carbide backing, and on the surface of said body a hard and wear resistant refractory coating, more specifically, to a method of using chemical vapor infiltration (CVI) or chemical vapor deposition (CVD) with porous or fine granule media to fill gaps between a PCBN tool tip and a WC tool body.
[0003] Polycrystalline cubic boron nitride (PCBN), polycrystalline diamond and polycrystalline diamond composite materials are commonly used to provide a superhard cutting edge for cutting tools such as those used in metal machining.
[0004] Cutting tools having cutting edges formed of a superhard abrasive such as a cubic boron nitride (CBN) based material are manufactured by powder
metallurgical techniques and are mainly used for the machining of cast iron and hardened steel. Several types of CBN cutting tools are known, the majority consisting of a PCBN tip that has been brazed onto a cemented carbide insert.
Others have the PCBN sintered directly to a cemented carbide backing of sufficient
1
INCORPORATED BY REFERENCE (RULE 20.6) thickness to produce an insert while yet others consist of a PCBN-containing body without any cemented carbide backing.
[0005] Subjecting a sintered PCBN body to temperatures over 1000 °C may result in unwanted structural changes in the material. Furthermore, in the case of a brazed insert, the braze joint will be destroyed.
[0006] Therefore, it can be seen that there is a need for a cutting tool having a high temperature bond between the PcBN tool tip and the tool body (WC/Co).
SUMMARY
[0007] In one embodiment, a cutting tool may comprise a sintered superabrasive tip having a plurality of superhard particles; a tool body retaining the superabrasive tip; and a non-brazing material filling gaps between the superabrasive tip and the tool body.
[0008] In another embodiment, a method may comprise steps of providing a sintered superabrasive tip; providing a tool body; filling a gap between the
superabrasive tip and the tool body with a non-brazing material; and depositing a first coating to the non-brazing material, wherein the first coating is an infiltrant coating to bond the tip, body and non-brazing materials to each other.
[0009] In yet another embodiment, a cutting tool may comprise a sintered
superabrasive tip having a plurality of superhard particles; a tool body retaining the superabrasive tip; infiltrant bond coating between the superabrasive tip and the tool body; and high temperature coatings attached to the sintered superabrasive tip and the tool body.
2
INCORPORATED BY REFERENCE (RULE 20.6) BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing summary, as well as the following detailed description of the embodiments, will be better understood when read in conjunction with the appended drawings. It should be understood that the embodiments depicted are not limited to the precise arrangements and instrumentalities shown.
[0011] FIG. 1 is a perspective view of a superabrasive tip affixed to a tool body according to an exemplary embodiment;
[0012] FIG. 2 is an optical image of a cross-sectional view of a superabrasive tip affixed to a tool body according to another exemplary embodiment;
[0013] FIG. 3 is a partially enlarged optical image of the cross-sectional view of a superabrasive tip affixed to a tool body as shown in FIG. 2; and
[0014] FIG. 4 is a flowchart illustrating a method of making a superabrasive tip affixed to the tool body according to an exemplary embodiment.
DETAILED DESCRIPTION
[0015] As used herein, the term "cutting tip" refers to a body for grinding or cutting a work piece, which is manufactured by fabrication processes including the step of mixing the super abrasive particles with bond.
[0016] As used herein, the term "tool body" refers to a rigid body that holds a cutting tip or tips firmly in place so that they can be utilized in a turning, milling, boring, cutting, or drilling application.
[0017] In an exemplary embodiment, a cutting tip may be made of superabrasive particles affixed to a suitable tool body, such as, cemented carbide hard metal. The exemplary embodiments use chemical vapor infiltration (CVI) or chemical vapor deposition (CVD) with porous or fine granule media to fill gaps between the superabrasive tool tip and a tool body. The deposition by CVI or CVD may bond the
3
INCORPORATED BY REFERENCE (RULE 20.6) porous or fine granule media to each other and to the cutting tip and the tool body. A high temperature resistant coating or sequence of multilayered coatings, such as Al203 may be subsequently coated as a part of the same process to provide an enhanced wear resistance.
[0018] More specifically, the porous or fine granule media used may survive the CVI or CVD process. Alternatively, fine granule, such as diamond or cubic boron nitride, may be consumed by the process. A high temperature resistant coating or sequence of multilayered coatings may be deposited for providing additional wear resistance to the cutting tool during machining, which may not have effects on the strength of the bonding already established (unlike a metallic braze).
[0019] As shown in FIG. 1 , a cutting tool 10 may include a sintered superabrasive tip 12 and a tool body 14 that contains an aperture 19. The tool body 14 may be made from a number of materials, including cobalt cemented tungsten carbide. The tool body 14 may be designed to retain the superabrasive tip 12. The sintered superabrasive tip 12 may have a plurality of superhard particles, which may be selected from a group of cubic boron nitride, diamond, diamond composite, and ceramic materials. Between the superabrasive tip and the tool body may exist a seam or a gap, such as a bottom gap 15 and a sidewall gap 16, for example. The superabrasive tip 12 may or may not have a backing support. The backing support may be a hard metal support, such as a tungsten carbide support.
[0020] As shown in FIG. 2, the cutting tool 10 may comprise a superabrasive tip 12 having a tungsten carbide support 20. The superabrasive tip 12 may have polycrystalline cubic boron nitride (PcBN) particles. The cutting tool 10 may further include a tool body 14 retaining the superabrasive tip 12. A non-brazing material 24, which may have melting point at least 1000 °C, may be deposited to fill the sidewall gap 16 and the bottom gap 15. The non-brazing material 24 may be at least one of zeolite, ceramic, cubic boron nitride, and diamond, for example. The cutting tool 10 may further comprise coatings, such as infiltrant bond coating 22 on the non-brazing material 24 between the superabrasive tip and the tool body. The infiltrant bond
4
INCORPORATED BY REFERENCE (RULE 20.6) coatings 22 may cover the sintered superabrasive tip 12, the backing support 20, and tool body 14. The infiltrant bond coatings may comprise at least one of Group IVB compounds containing C, N, 0, B, such as TiN, TiC, and TiCN, ZrN, ZrC, ZrCN, HfN, HfC, HfCN, for example.
[0021] A close-up optical image shown in FIG. 3, illustrates that the coatings 22, such as TiN, may cover all cubic boron nitride crystals 24. The coatings 22 may further provide bonding between the non-brazing material, such as cBN, diamond, or zeolite, superabrasive tip 20, and the tool body 14.
[0022] Since the non-brazing material has melting point at least 1000 °C, a high temperature resistant coating, such as Al203 (not shown) may be deposited or coated to the sintered superabrasive tip 12, the tool body 14, and non-brazing material disposed between the superabrasive tip 12 and the tool body 24.
[0023] FIG. 4 shows an exemplary method 400 of a process of fabricating a cutting tool. The process includes steps of providing a superabrasive tip in a step 401 ; providing a tool body in a step 402; filling a gap between the superabrasive tip and the tool body with a non-brazing material in a step 403; and depositing a first coating to the non-brazing material in a step 404.
[0024] The sintered superabrasive tip may be attached by some method to the tool body. The cutting tool may then be placed in a CVD (chemical vapor deposition) reaction vessel, whereupon air is removed and replaced by gases comprising both inert and reactive species. Metallic deposition may employ gases comprising metal carbonyl or metal- acetal-acetonates, for example, iron pentacarbonyl. Ceramic deposition precursors may refer to N, C, and 0 containing compounds that crack under temperature less than 1000 °C. In some exemplary embodiments, the ceramic deposition precursors may include TiCI4, NH3, CH4, AICI3, (Me)3AI, N2, CH3CN, H2, CO, C02 or mixtures thereof, for example. The gases penetrate via diffusion into gaps, seams, contact voids, and deposit on heated solid surfaces, external or internally gas- accessible, in the equipment. Upon condensation on the surface, the condensed phases chemically react to form a new solid phase as a first
5
INCORPORATED BY REFERENCE (RULE 20.6) coating. The first coating may be an infiltrant coating to bond the superabrasive tip, the tool body, and non-brazing materials together. For example, TiCI4 + CH4 -> TiC solid + gas phase 4HCI. This solid phase adhesively bonds to the solid surfaces depending on chemical affinity. The quality of the solid phase (crystal perfection, density) depends on temperature and affinity to the solid surface(s) upon which they condense. The process of infiltration, condensation and reaction to form a new solid phase continues as long as temperature is high enough and reactants are present. Once the pores are filled, then straight-forward coating on surfaces of the superabrasive tip and the tool holding material may occur.
[0025] Gas accessibility is determined by the gas diffusion, which depends on temperature and pressure. Lower pressure allows deeper diffusion of reactive gases into seams and gaps in the tool assembly. Gas deposition, reaction and solidification rates forming a solid must be controlled to prevent premature '"plugging" of narrow gaps and seams, thus reducing the film contact area and joint strength. This typically requires that the temperature be lowered, or gas phase partial pressure of reactants be adjusted. Finally, the quality of the film formed, its crystallinity and crystal orientation, depends on temperature and time. If the film is formed and quenched too quickly, it may be of poor quality and crack either within the film or at the film-tip or film-tool interface.
[0026] It is important that the gas-phase precursors react with solid surfaces indiscriminately, regardless of orientation in the reactor. So-called "line-of-sight" deposition processes, e.g., physical vapor deposition (PVD), may not be as effective as the gas-phase precursors, and may not penetrate gaps and seams, thus reducing the area of adhesion and adhesion strength considerably.
[0027] Furthermore, non line-of-sight CVD coating does not require tools to be flipped over and processed multiple times to form a uniform coating. CVD coats all gas-accessible surfaces in one furnace cycle.
[0028] Gas phase reactions that may also be considered CVD include any gas- solid reactions such as oxidation, hydration, or carburization. The solid constituents
6
INCORPORATED BY REFERENCE (RULE 20.6) may adsorb onto surfaces first, then react and crystallize, or may form above the surface and deposit by solid-surface tension forces prior to reaction and crystallization.
[0029] Post-CVD treatment, e.g., annealing may be conducted to improve the quality of the film or film-tip/film-tool adhesion.
[0030] One or more steps may be inserted in between or substituted for each of the foregoing steps 401-404 without departing from the scope of this disclosure.
[0031] While reference has been made to specific embodiments, it is apparent that other embodiments and variations can be devised by others skilled in the art without departing from their spirit and scope. The appended claims are intended to be construed to include all such embodiments and equivalent variations.
7
INCORPORATED BY REFERENCE (RULE 20.6)

Claims

CLAIMS We claim:
1 . A cutting tool, comprising:
a sintered superabrasive tip having a plurality of superhard particles;
a tool body retaining the superabrasive tip; and
a non-brazing material filling a gap between the superabrasive tip and the tool body.
2. The cutting tool of the claim 1 , wherein the superhard particles are selected from a group of cubic boron nitride, diamond, diamond composite, and ceramic materials.
3. The cutting tool of the claim 1 , wherein the non-brazing material is at least one of zeolite, cubic boron nitride, diamond, and ceramic.
4. The cutting tool of the claim 1 , further comprises coatings on the non-brazing material.
5. The cutting tool of the claim 1 , wherein the non-brazing material has melting point at least 1000 °C.
6. The cutting tool of the claim 4, wherein the coatings comprise at least one of Group IVB compounds containing C, N, 0, B.
7. The cutting tool of the claim 1 , wherein the tool body is made at least one of tungsten carbide, ceramic, or cermet.
8. The cutting tool of the claim 4, wherein the coatings cover the sintered superabrasive tip and the tool body.
9. A method, comprising:
providing a superabrasive tip;
8
INCORPORATED BY REFERENCE (RULE 20.6) providing a tool body;
filling a gap between the superabrasive tip and the tool body with a non- brazing material; and
depositing a first coating to the non-brazing material.
10. The method of the claim 9, further comprising depositing the first coating is an infiltrant coating to bond the superabrasive tip, the tool body, and non-brazing materials together.
1 1. The method of the claim 10, wherein the first coatings comprise at least one of Group IVB compounds containing C, N, 0, B.
12. The method of the claim 9, further comprising depositing a second coating or sequence of multilayered coatings to the sintered superabrasive tip, the tool body, and the non-brazing material.
13. The method of the claim 12, wherein the second coating or sequence of multilayered coatings comprises at least one layer of high temperature resistant oxide coating.
14. The method of the claim 12, wherein the high temperature resistant oxide coating is aluminum oxide coating.
15. The method of the claim 1 1 , further comprising bonding the non-brazing material, sintered superabrasive tip and the tool body.
16. The method of the claim 9, wherein the deposition of the first coating is via chemical vapor deposition.
17. The method of the claim 9, wherein the deposition of the first coating is via chemical vapor infiltration.
18. A cutting tool, comprising:
9
INCORPORATED BY REFERENCE (RULE 20.6) a sintered superabrasive tip having a plurality of superhard particles;
a tool body retaining the superabrasive tip;
infiltrant bond coating between the superabrasive tip and tool body; and high temperature resistant coatings deposited to the sintered superabrasive tip and the tool body.
19. The cutting tool of the claim 18, further comprising a non-brazing material disposed between the superabrasive tip and the tool body.
20. The cutting tool of the claim 18, wherein high temperature resistant coating is aluminum oxide.
21. The cutting tool of the claim 19, wherein the non-brazing material is bonded to the superabrasive tip and the tool body.
22. The cutting tool of the claim 18, wherein the superabrasive tip has superhard particles wherein the superabrasive particles are selected from a group of cubic boron nitride, diamond, diamond composite, and ceramic materials.
23. The cutting tool of the claim 19, wherein the non-brazing material comprises at least one of zeolite, cubic boron nitride, diamond, and ceramic material.
24. The cutting tool of the claim 23, wherein the non-brazing material is bonded by a high temperature coating or coatings.
25. The cutting tool of the claim 18, wherein the high temperature coating is selected from at least one of Group IVB compounds containing C, N, 0, B.
26. The cutting tool of the claim 18, wherein the sintered superabrasive tip has a backing support.
27. The cutting tool of the claim 26, wherein the backing support is hard metal support.
10
INCORPORATED BY REFERENCE (RULE 20.6)
28. The cutting tool of the claim 27, wherein the hard metal support is tungsten carbide.
1 1
INCORPORATED BY REFERENCE (RULE 20.6)
EP14731406.6A 2013-02-28 2014-02-27 Cvi bonded and coated pcbn to wc tool body Withdrawn EP2961550A1 (en)

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KR20120016255A (en) * 2009-04-28 2012-02-23 다이아몬드 이노베이션즈, 인크. How to attach or improve adhesion
CN116410004B (en) * 2022-03-08 2024-07-30 富耐克超硬材料股份有限公司 Preparation method of polycrystalline cubic boron nitride composite material

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