# Patent

## Title
Surface-coated cutting tool

## Abstract

A surface-coated cutting tool includes a tool substrate made of tungsten carbide-based cemented carbide or titanium carbonitride-based cermet; and a hard coating layer formed by vapor-depositing in order, a lower layer (a), an intermediate layer (b), and an upper layer (c) on the tool substrate. The lower layer (a) is a Ti layer composed of one or more of a titanium carbide layer, a titanium nitride layer, a titanium carbonitride layer, a titanium carboxide layer, and a titanium oxycarbonitride layer, and having a thickness of 3 to 20 μm. The intermediate layer (b) is an aluminum oxide layer having a thickness of 1 to 5 μm, and having an α-type crystal structure in a chemically vapor-deposited state. The upper layer (c) is an aluminum oxide layer having a thickness of 2 to 15 μm, and containing one or more elements of Ti, Y, Zr, Cr, and B.

## Background
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
This application is a U.S. National Phase Application under 35 U.S.C. §371 of International Patent Application No. PCT/JP2010/001973, filed Mar. 18, 2010, and claims the benefit of Japanese Patent Applications No. 2009-065814, filed Mar. 18, 2009, No. 2009-147767, filed Jun. 22, 2009, and No. 2009-149350, filed Jun. 24, 2009, all of which are incorporated by reference herein. The International Application was published in Japanese on Sep. 23, 2010 as International Publication No. WO/2010/106811 under PCT Article 21(2).
TECHNICAL FIELD
The present invention relates to a surface-coated cutting tool (hereinafter referred to as a coated tool) which exhibits excellent cutting performance over the long-term, without the hard coating layer becoming chipped, for example, (1) if cutting work on high-hardness steel, such as quenching materials for alloy tool steel or bearing steel, is performed under high-speed intermittent cutting conditions where intermittent impact loading repeatedly acts on the cutting edge, along with the accompanying high heat generation, or (2) if cutting work on difficult-to-cut materials, such as stainless steel or ductile cast iron, is performed under high-speed heavy cutting conditions where a high load resulting from a high feed rate and a high depth of cut act on the cutting edge, along with the accompanying high heat generation.
This application claims priority on Japanese Patent Application No. 2009-065814 filed on Mar. 18, 2009, Japanese Patent Application No. 2009-147767 filed on Jun. 22, 2009, and Japanese Patent Application No. 2009-149350 filed on Jun. 24, 2009, the contents of which are incorporated herein by reference.
BACKGROUND ART
As shown in PTL 1 (Japanese Unexamined Patent Application Publication No. 2006-198735), conventionally, a coated tool (hereinafter referred to as a conventional coated tool 1) is known which is formed by vapor-depositing, on the surface of a tool substrate (hereinafter generally referred to as a tool substrate) made of tungsten carbide (hereinafter referred to as WC)-based cemented carbide or titanium carbonitride (hereinafter referred to as TiCN)-based cermet, a hard-coating layer including a lower layer (a) and an upper layer (b) satisfying the following conditions.
The lower layer (a) is a Ti compound layer composed of one or more of a titanium carbide (TiC) layer, a titanium nitride (TiN) layer, a titanium carbonitride (TiCN) layer, a titanium carboxide (TiCO) layer and a titanium oxycarbonitride (TiCNO) layer, and having a total mean layer thickness of 3 to 20 μm.
The upper layer (b) is an α-type Al2O3 layer (referred to as a conventional α-type Al2O3 layer) having a mean layer thickness of 1 to 15 μm and having an α-type crystal structure in a chemically vapor-deposited state. As for this upper layer, when the field-emission-type scanning electron microscope is used to individually irradiate crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface with an electron beam, and to measure the tilt angle of the normal lines of the (0001) plane and plane (10-10), which are crystal planes of the crystal grains, to the normal line to the polished surface; the crystal grains have a corundum hexagonal close-packing structure in which the constituent atoms composed of Al and oxygen are present at lattice points; the distribution of lattice points (constituent atom sharing lattice points) where the respective constituent atoms share one constituent atom between the crystal lattices at an interface between mutually adjacent crystal grains is calculated on the basis of the resulting measured tilt angles; and a constituent atom sharing lattice point configuration in which N (here, N is any even number equal to or greater than 2 in a crystal structure of a corundum-type hexagonal close-packing crystal, but when the upper limit of N is 28 from the viewpoint of a distribution frequency, even numbers 4, 8, 14, 24, and 26 do not exist) lattice points which do not share any constituent atoms between the constituent atom sharing lattice points are present is expressed by ΣN+1, this layer shows a constituent atom sharing lattice point distribution graph in which the highest peak is present in Σ3 in the constituent atom sharing lattice point distribution graph showing distribution ratios in which individuals of ΣN+1 are accounted for in a total of ΣN+1, and the distribution ratio of Σ3 accounted for in the total of ΣN+1 is 60 to 80%.
Since the α-type Al2O3 layer has excellent high-temperature strength, it is known that the conventional coated tool 1 exhibits chipping resistance in high-speed intermittent cutting work.
As shown in PTL 2 (Japanese Unexamined Patent Application Publication No. 2006-289556), instead of the upper layer (b) of the conventional coated tool 1, a coated tool (hereinafter referred to as a conventional coated tool 2) in which an Al—Ti compound oxide layer (hereinafter referred to as a conventional AlTiO layer) is formed is also known.
The Al—Ti compound oxide layer has a mean layer thickness of 1 to 15 μm, and an α-type crystal structure in a chemically vapor-deposited state. This layer satisfies the compositional formula, (Al1-XTiX)2O3, where X ranges from 0.003 to 0.05 in atomic ratio. Moreover, as for this layer, when the field-emission-type scanning electron microscope and an electronic backscattering diffraction image apparatus are used to individually irradiate crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface with an electron beam, and to measure the tilt angle of the normal lines of the (0001) plane and plane (10-10), which are crystal planes of the crystal grains, to the normal line to the surface of a base; the crystal grains have a corundum hexagonal close-packing structure in which constituent atoms composed of Al, Ti and oxygen are present at lattice points; the distribution of lattice points (constituent atom sharing lattice points) where the respective constituent atoms share one constituent atom between the crystal lattices at an interface between mutually adjacent crystal grains is calculated on the basis of the resulting measured tilt angles; and a constituent atom sharing lattice point configuration in which N (where N is any even number equal to or greater than 2 in a crystal structure of a corundum-type hexagonal close-packing crystal, but when the upper limit of N is 28 from the viewpoint of a distribution frequency, even numbers 4, 8, 14, 24, and 26 do not exist) lattice points which do not share any constituent atoms between the constituent atom sharing lattice points are present is expressed by ΣN+1, this layer shows a constituent atom sharing lattice point distribution graph in which the highest peak is present in Σ3 in the constituent atom sharing lattice point distribution graph showing distribution ratios in which individuals of ΣN+1 are accounted for in a total of ΣN+1, and the distribution ratio of Σ3 accounted for in the total of ΣN+1 is 60 to 80%.
It is known that this conventional coated tool 2 also exhibits excellent chipping resistance.
As shown in PTL 3 (Japanese Unexamined Patent Application Publication No. 2004-1154), instead of the upper layer (b) of the conventional coated tool 1, a coated tool (hereinafter referred to as a conventional coated tool 3) in which an α-type (Al, Y)2O3 layer (hereinafter referred to as a conventional AlYO layer) containing a small amount of Y (yttrium) is formed is also known. In this conventional coated tool 3, it is known that missing out of the crystal grains of α-type Al2O3 is prevented, and excellent cutting durability is shown in continuous cutting work.
As shown in PTL 4 (Japanese Unexamined Patent Application Publication No. 2006-289557), instead of the upper layer (b) of the conventional coated tool 1, a coated tool (hereinafter referred to as a conventional coated tool 4) in which an Al—Zr compound oxide layer (hereinafter referred to as a conventional AlZrO layer) is formed is also known. The Al—Zr compound oxide layer has an α-type crystal structure, and a mean layer thickness of 1 to 15 μm in a chemically vapor-deposited state, and satisfies the compositional formula, (Al1-XZrX)2O3, where X ranges from 0.003 to 0.05 in atomic ratio. As for the Al—Zr compound oxide layer, when the field-emission-type scanning electron microscope is used to individually irradiate crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface with of a base with an electron beam, and to measure the tilt angle of the normal lines of the (0001) plane and plane (10-10), which are crystal planes of the crystal grains, to the normal line to the surface of the base; the crystal grains have a corundum hexagonal close-packing structure in which constituent atoms composed of Al, Zr and oxygen are present at lattice points; the distribution of lattice points (constituent atom sharing lattice points) where the respective constituent atoms share one constituent atom between the crystal lattices at an interface between mutually adjacent crystal grains is calculated on the basis of the resulting measured tilt angles; and a constituent atom sharing lattice point configuration in which N (here, N is any even number equal to or greater than 2 in a crystal structure of a corundum-type hexagonal close-packing crystal, but when the upper limit of N is 28 from the viewpoint of a distribution frequency, even numbers 4, 8, 14, 24, and 26 do not exist) lattice points which do not share any constituent atoms between the constituent atom sharing lattice points are present is expressed by ΣN+1, this layer shows a constituent atom sharing lattice point distribution graph in which the highest peak is present in Σ3 in the constituent atom sharing lattice point distribution graph showing distribution ratios in which individuals of ΣN+1 are accounted for in a total of ΣN+1, and the distribution ratio of Σ3 accounted for in the total of ΣN+1 is 60 to 80%.
It is known that this conventional coated tool 4 also exhibits excellent chipping resistance.
As shown in PTL 5 (Japanese Unexamined Patent Application Publication No. 2006-289586, a coated tool (hereinafter referred to as a conventional coated tool 5) is known which is formed by vapor-depositing, on the surface of a tool substrate made of tungsten carbide (hereinafter referred to as WC)-based cemented carbide or titanium carbonitride (hereinafter referred to as TiCN)-based cermet, a hard-coating layer including following lower layer (a) and upper layer (b).
The lower layer (a) is a Ti compound layer composed of one or more of a titanium carbide (TiC) layer, a titanium nitride (TiN) layer, a titanium carbonitride (TiCN) layer, a titanium carboxide (TiCO) layer and a titanium oxycarbonitride (TiCNO) layer, all of which are formed by vapor deposition, and having a total mean layer thickness of 3 to 20 μm, and
The upper layer (b) is a Cr-containing aluminum oxide layer having a mean layer thickness of 1 to 15 μm and having an α-type crystal structure in a chemically vapor-deposited state. As for this upper layer, when the field-emission-type scanning electron microscope is used to individually irradiate crystal grains having a hexagonal crystal lattice present within the measurement range of the polished surface of the tool substrate with an electron beam, and to measure the tilt angle of the normal line to the (0001) plane, which is a crystal plane of each crystal grain, to the normal line to the polished surface, the measured tilt angles which are within a range of 0 to 45 degrees among the measured tilt angles are divided at every pitch of 0.25 degrees, and a tilt angle frequency distribution graph obtained by summing the frequencies present within the respective divisions is plotted, this layer shows a tilt angle frequency distribution graph in which the highest peak is present in the tilt angle division within a range of 0 to 10 degrees, and the total sum of the frequencies present within a range of 0 to 10 degrees accounts for the ratio of 45% or more of the total frequency in the tilt angle frequency distribution graph.
Since the Cr-containing aluminum oxide layer has excellent high-temperature strength, it is known that the conventional coated tool 5 exhibits chipping resistance in high-speed intermittent cutting work.
RELATED ART DOCUMENT
Patent Literature


    [PTL 1] Japanese Unexamined Patent Application Publication No. 2006-198735
    [PTL 2] Japanese Unexamined Patent Application Publication No. 2006-289556
    [PTL 3] Japanese Unexamined Patent Application Publication No. 2004-1154
    [PTL 4] Japanese Unexamined Patent Application Publication No. 2006-289557
    [PTL 5] Japanese Unexamined Patent Application Publication No. 2006-289586
    [PTL 6] Japanese Patent No. 1388775
    [PTL 7] Japanese Unexamined Patent Application Publication No. 10-291102


DISCLOSURE OF INVENTION
Technical Problem
In recent years, the performance of the cutting device has been significantly improved. At the same time, there is strong demands for power saving, energy saving, and cost reduction in the cutting work. Because of these trends, the cutting work is performed even faster and more efficiently.
A conventional coated tool performs adequately when it is used high-speed cutting work or high-speed intermittent cutting work of ordinary steel, such as low alloy steel or carbon steel, and normal cast iron, such as gray cast iron. However, when this conventional coated tool is used for high-speed intermittent cutting work of high-hardness steel, such as quenching materials for alloy tool steel or bearing steel, the high-temperature strength and surface properties of the hard coating layer are not adequate. Thus, chipping (fine chipping) occurs easily on the cutting edge. As a result, under such conditions, the coated tool comes to the end of its usable lifespan in a relatively short period of time.
In addition, when the conventional coated tool is used for high-speed heavy cutting work on difficult-to-cut materials, such as stainless steel or ductile cast iron, accompanied by high heat generation, and high load of a high feed rate and a high depth of cut acts on the cutting edge, the high-temperature strength and surface properties of the hard coating layer are not adequate. Thus, chipping (fine chipping) easily occurs at the cutting edge. As a result, under such conditions, the conventional coated tool comes to the end of its usable lifespan in a relatively short period of time.
Solution to Problem
Thus, the present inventors have diligently conducted studies from the above viewpoints in order to develop a coated tool having excellent chipping resistance and abrasion resistance for long-term use, even if it is used for: 1) high-speed intermittent cutting work on high-hardness steel, and intermittent impact loading repeatedly acts on the cutting edge, along with the accompanying high heat generation, or 2) high-speed heavy cutting work in which the high load of a high feed rate and a high depth of cut acts on the cutting edge. Accordingly, the following coated cutting tool is invented.
The surface-coated cutting tool of the present invention is a surface-coated cutting tool formed by vapor-depositing, on the surface of a tool substrate made of tungsten carbide-based cemented carbide or titanium carbonitride-based cermet, a hard coating layer including the following lower layer (a), an intermediate layer (b), and an upper layer (c).
The lower layer (a) is a Ti compound layer composed of one or more of a titanium carbide layer, a titanium nitride layer, a titanium carbonitride layer, a titanium carboxide layer, and a titanium oxycarbonitride layer, all of which are formed by chemical vapor deposition, and having a total mean layer thickness of 3 to 20 μm.
The intermediate layer (b) is an aluminum oxide layer having a mean layer thickness of 1 to 5 μm and having an α-type crystal structure in a chemically vapor-deposited state.
The upper layer (c) is an aluminum oxide layer having a mean layer thickness of 2 to 15 μm and an α-type crystal structure in a chemically vapor-deposited state, the aluminum oxide layer containing one or more kinds of elements selected from a group consisting of Ti, Y, Zr, Cr, and B.
The intermediate layer (b) has properties indicated by a tilt-angle frequency distribution graph in which the highest peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph, the tilt-angle frequency distribution graph being obtained by utilizing a field-emission-type scanning electron microscope, irradiating electron beams to individual crystal grains with a hexagonal crystal lattice existing in a measurement range of a polished surface of the tool substrate, measuring a tilt angle formed by the normal line to the polished surface and the normal line to (0001) plane as a crystal plane of the crystal grains, sectioning the measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25°, and collecting the frequencies existing in each section.
The upper layer (c) is an aluminum oxide layer having a texture made of crystal grains with a flat-plate polygonal shape within a plane perpendicular to a layer thickness direction and have an elongated shape in the layer thickness direction within a plane parallel to the layer thickness direction and containing one or more kinds of elements selected from a group consisting of Ti, Y, Zr, Cr, and B, the texture being observed by a field-emission scanning electron microscope.
The upper layer (c) has properties indicated by a tilt-angle frequency distribution graph in which the highest peak exists in a tilt angle division ranging 0 to 10° and the sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies in the tilt-angle frequency distribution graph, the tilt-angle frequency distribution graph being obtained by utilizing a field-emission-type scanning electron microscope, irradiating electron beams to individual crystal grains with a hexagonal crystal lattice existing in a measurement range of a polished surface of the tool substrate, measuring a tilt angle formed by the normal line to the polished surface and the normal line to (0001) plane as a crystal plane of the crystal grains, sectioning the measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25°, and collecting the frequencies existing in each section.
Moreover, as for the upper layer of the above (c), when electron beams are radiated to the individual crystal grains existing within a measurable range of a polished surface of the tool substrate by utilizing a field-emission-type scanning electron microscope and an electron backscatter diffraction imaging device to measure angles formed by normal lines of crystal lattice faces with hexagonal crystal lattices and the normal line to the polished surface, a crystallographic orientation relationship between the adjacent crystal lattices is calculated from the measurement result, a distribution of lattice points (constituent atom sharing lattice points) in each constituent atom of a crystal lattice interface shares one constituent atom between the crystal lattices is calculated, and when a constituent atom sharing lattice point type in which N lattice points not sharing the constituent atom exist between the constituent atom sharing lattice points (where N is an even number of 2 or more in view of a crystal structure of corundum type hexagonal close packed crystal but does not include even numbers of 4, 8, 14, 24, and 26 when the upper limit of N is set to 28 in view of distribution frequency) is expressed as ΣN+1, the insides of the above mentioned crystal grains, which constitutes the upper layer (c) and occupies 60% or more as an area ratio in the crystal grains of the upper layer, are divided by at least one crystal lattice interface with the constituent atom sharing lattice point type expressed by Σ3.
In the surface-coated cutting tool mentioned above, the upper layer (c) may be an aluminum oxide layer containing Ti only.
In the surface-coated cutting tool mentioned above, the upper layer (c) may be an aluminum oxide layer containing Y only.
In the surface-coated cutting tool mentioned above, the upper layer (c) may be an aluminum oxide layer containing Zr only.
In the surface-coated cutting tool mentioned above, the upper layer (c) may be an aluminum oxide layer containing Cr only.
In the surface-coated cutting tool mentioned above, the upper layer (c) may be an aluminum oxide layer containing B only.
In the surface-coated cutting tool mentioned above, when the texture of the upper layer (c) is observed by the field-emission scanning electron microscope, crystal grains which have a flat hexagonal shape within the plane perpendicular to the layer thickness direction and have an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction may account for 35% or more of the whole as an area ratio within the plane perpendicular to the layer thickness direction.
In the surface-coated cutting tool motioned above, the above upper layer (c) may have a surface roughness (Ra) within a range of 0.05 to 0.3 μm.
Advantageous Effects of Invention
Since the surface-coated cutting tool of the present invention has the configuration described above, the ratio of the (0001) plane orientation is high in the intermediate layer composed of the reformed α-type Al2O3 layer. As a result, the surface-coated cutting tool has excellent high-temperature strength, in addition to excellent high-temperature hardness and heat resistance. In addition, by increasing the ratio of the (0001) plane orientation in the upper layer composed of the reformed layer, the upper layer obtains the texture made of crystal grains having flat-plate polygonal shape (including flat hexagonal) at the top and bottom, and elongated shape at sides with surface flatness. Moreover, in the upper layer, strength within the crystal grains is enhanced by forming the Σ3 coincidence site lattice interface inside the crystal grains. Because of this, the upper layer, which is consisted of crystal grains with a concavo-convex polygonal shape at the top and bottom, and an elongated shape at sides, obtains even more superior surface properties and high-temperature strength as compared to the conventional layer with few Σ3 coincidence site lattice interfaces. As a result, in the surface-coated cutting tool of the present invention, even in high-speed heavy cutting work accompanied by high heat generation, and high load resulting from repetition or the like of intermittent impact acts on the cutting edge, the hard coating layer exhibits excellent chipping resistance, fracture resistance, spalling resistance, and allows a more prolonged usable lifespan.



BRIEF DESCRIPTION OF DRAWINGS
FIG. 1A is a schematic explanatory view showing the measurement range of a tilt angle when the (0001) plane of a crystal grain of an α-type Al2O3 layer which constitutes a hard coating layer is measured.
FIG. 1B is a schematic explanatory view showing the measurement range of a tilt angle when the (0001) plane of a crystal grain of an α-type Al2O3 layer which constitutes a hard coating layer is measured.
FIG. 2 is a tilt angle frequency distribution graph of the (0001) plane of a reformed α-type Al2O3 layer which constitutes an intermediate layer of a hard coating layer of a coated tool 1 of the present invention.
FIG. 3A is a schematic view showing a flat-plate polygonal crystal grain structure obtained by observing an upper layer composed of a reformed AlTiO layer of coated tools A1 to A9 of the present invention, using a field-emission-type scanning electron microscope in a plane perpendicular to a layer thickness direction.
FIG. 3B is a schematic view showing a crystal grain structure having a substantially flat layer surface and having an elongated shape in the layer thickness direction, which is obtained by observation using the field-emission-type scanning electron microscope in a plane parallel to the layer thickness direction.
FIG. 3C is a schematic view showing a flat hexagonal crystal grain structure which is obtained by observing an upper layer composed of a reformed AlTiO layer of coated tools A10 to A15 of the present invention, using the field-emission-type scanning electron microscope in the plane perpendicular to the layer thickness direction.
FIG. 4 is a grain boundary analysis view in the plane perpendicular to the layer thickness direction, which is obtained by measuring the upper layer composed of the reformed AlTiO layer of the coated tools A1 to A9 of the present invention, using the field-emission-type scanning electron microscope and an electronic backscattering diffraction image apparatus, showing a flat-plate polygonal grain boundary observed by the field-emission-type scanning electron microscope in a solid line, and showing a Σ3 coincidence site lattice interface within the crystal grain measured by the electronic backscattering diffraction image apparatus in a broken line.
FIG. 5A is a schematic view showing a polygonal crystal grain structure which is obtained by observing an upper layer composed of a conventional AlTiO layer of the comparative coated tools A1 to A10, using the field-emission-type scanning electron microscope in the plane perpendicular to the layer thickness direction.
FIG. 5B is a schematic view showing a crystal grain structure having pyramidal concaves and convexes on the layer surface and having an elongated shape in the layer thickness direction, which is obtained by observation using the field-emission-type scanning electron microscope in the plane parallel to the layer thickness direction.
FIG. 6 is a tilt angle frequency distribution graph of the (0001) plane of a reformed α-type Al2O3 layer which constitutes an intermediate layer of a hard coating layer of a coated tool of the present invention.
FIG. 7A is a schematic view showing a flat-plate polygonal crystal grain structure obtained by observing an upper layer composed of a reformed AlYO layer of coated tools B1 to B9 of the present invention, using the field-emission-type scanning electron microscope in the plane perpendicular to the layer thickness direction.
FIG. 7B is a schematic view showing a crystal grain structure having a substantially flat layer surface and having an elongated shape in the layer thickness direction, which is obtained by observation using the field-emission-type scanning electron microscope in the plane parallel to the layer thickness direction.
FIG. 7C is a schematic view showing a flat hexagonal crystal grain structure obtained by observing an upper layer composed of a reformed AlYO layer of coated tools B10 to B15 of the present invention, using the field-emission-type scanning electron microscope in the plane perpendicular to the layer thickness direction.
FIG. 8 is a grain boundary analysis view in the plane perpendicular to the layer thickness direction, which is obtained by measuring the upper layer composed of the reformed AlYO layer of the coated tools B1 to B9 of the present invention, using the field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus, showing a flat-plate polygonal grain boundary observed by the field-emission-type scanning electron microscope in a solid line, and showing a Σ3 coincidence site lattice interface within the crystal grain measured by the electronic backscattering diffraction image apparatus in a broken line.
FIG. 9A is a schematic view showing a polygonal crystal grain structure which is obtained by observing an upper layer composed of a conventional AlYO layer of the comparative coated tools B1 to B10, using the field-emission-type scanning electron microscope in the plane perpendicular to the layer thickness direction.
FIG. 9B is a schematic view showing a crystal grain structure having pyramidal concaves and convexes on the layer surface and having an elongated shape in the layer thickness direction, which is obtained by observation using the field-emission-type scanning electron microscope in the plane parallel to the layer thickness direction.
FIG. 10 is a tilt angle frequency distribution graph of the (0001) plane of a reformed α-type Al2O3 layer which constitutes an intermediate layer of the hard coating layer of the coated tool C14 of the present invention.
FIG. 11A is a schematic view showing a flat-plate polygonal crystal grain structure obtained by observing an upper layer composed of a reformed AlZrO layer of the coated tool C1 of the present invention, using the field-emission-type scanning electron microscope in the plane perpendicular to the layer thickness direction.
FIG. 11B is a schematic view showing a crystal grain structure having a substantially flat layer surface and having an elongated shape in the layer thickness direction, which is obtained by observation using the field-emission-type scanning electron microscope in the plane parallel to the layer thickness direction.
FIG. 11C is a schematic view showing a flat hexagonal crystal grain structure obtained by observing an upper layer composed of a reformed AlZrO layer of the coated tool C11 of the present invention, using the field-emission-type scanning electron microscope in the plane perpendicular to the layer thickness direction.
FIG. 12 is a grain boundary analysis view in the plane perpendicular to the layer thickness direction, which is obtained by measuring the upper layer composed of the reformed AlZrO layer of the coated tool C1 of the present invention, using the field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus, showing a flat-plate polygonal grain boundary observed by the field-emission-type scanning electron microscope in a solid line, and showing a Σ3 coincidence site lattice interface within the crystal grain measured by the electronic backscattering diffraction image apparatus in a broken line.
FIG. 13A is a schematic view showing a polygonal crystal grain structure obtained by observing an upper layer composed of a conventional AlZrO layer of the comparative coated tool C1, using the field-emission-type scanning electron microscope in the plane perpendicular to the layer thickness direction.
FIG. 13B is a schematic view showing a crystal grain structure having pyramidal concaves and convexes on the layer surface and having an elongated shape in the layer thickness direction, which is obtained by observation using the field-emission-type scanning electron microscope in the plane parallel to the layer thickness direction.
FIG. 14 is a tilt angle frequency distribution graph of the (0001) plane of a reformed Al2O3 layer which constitutes an intermediate layer of a hard coating layer of the coated tool D6 of the present invention.
FIG. 15A is a schematic view showing a flat-plate polygonal crystal grain structure which is obtained by observing an upper layer composed of a reformed Cr-containing Al2O3 layer of the coated tool D1 of the present invention, using a field emission type scanning electron microscope in a plane perpendicular to a layer thickness direction.
FIG. 15B is a schematic view showing a crystal grain structure having a substantially flat layer surface and having an elongated shape in the layer thickness direction, which is obtained by observation using the field-emission-type scanning electron microscope in the plane parallel to the layer thickness direction.
FIG. 15C is a schematic view showing a flat hexagonal crystal grain structure which is obtained by observing an upper layer composed of a reformed Cr-containing Al2O3 layer of the coated tool D11 of the present invention, using a field emission type scanning electron microscope in a plane perpendicular to a layer thickness direction.
FIG. 16 is a grain boundary analysis view in the plane perpendicular to the layer thickness direction, which is obtained by measuring the upper layer composed of the reformed Cr-containing Al2O3 layer of the coated tool D1 of the present invention, using the field-emission-type scanning electron microscope and an electronic backscattering diffraction image apparatus, showing a flat-plate polygonal grain boundary observed by the field-emission-type scanning electron microscope in a solid line, and showing a Σ3 coincidence site lattice interface within the crystal grain measured by the electronic backscattering diffraction image apparatus in a broken line.
FIG. 17A is a schematic view showing a polygonal crystal grain structure which is obtained by observing an upper layer composed of a conventional Cr-containing Al2O3 layer of the conventional coated tool 1, using a field emission type scanning electron microscope in a plane perpendicular to a layer thickness direction.
FIG. 17B is a schematic view showing a crystal grain structure having pyramidal concaves and convexes on the layer surface and having an elongated shape in the layer thickness direction, which is obtained by observation using the field-emission-type scanning electron microscope in the plane parallel to the layer thickness direction.
FIG. 18 is an enlarged sectional schematic view showing one embodiment of a surface-coated cutting tool of the present invention.



DESCRIPTION OF EMBODIMENTS
FIG. 18 is an enlarged sectional schematic view showing a surface-coated cutting tool 10 which is one embodiment of the present invention. In the drawing, reference numeral 11 is, for example, a body of a cutting insert or the like, and a hard coating layer 12 obtained by forming a lower layer 12A, an intermediate layer 12B, and an upper layer 12C in order, is formed on the overall surface of the tool substrate 11. The configuration of each part will be described below. The shape of the tool substrate 11 is appropriately set in conformity with the shape of a tool to which the invention is to be applied, and is not limited in the invention. Each embodiment will be described below.
First Embodiment
(a) The conventional α-type Al2O3 layer in the conventional coated tool 1 is vapor-deposited, for example, using a normal chemical vapor deposition apparatus under the following conditions.
Composition of reaction gas: in vol. %, 6 to 10% of AlCl3, 10 to 15% of CO2, 3 to 5% of HCl, 0.05 to 0.2% of H2S, and H2 as balance
Reaction atmosphere temperature: 1020 to 1050° C.
Reaction atmosphere pressure: 3 to 5 kPa
On the other hand, the α-type Al2O3 layer in the present invention corresponding to the intermediate layer 12B is formed, using a normal chemical vapor deposition apparatus under the following conditions.
Composition of reaction gas: in vol. %, 3 to 10% of AlCl3, 0.5 to 3% of CO2, 0.01 to 0.3% of C2H4, and H2 as balance
Reaction atmosphere temperature: 750 to 900° C.
Reaction atmosphere pressure: 3 to 13 kPa
An Al2O3 neclear is formed on the surface of a Ti compound layer which is the lower layer 12A under the low-temperature condition described above. In this case, it is desirable that the Al2O3 neclear is an Al2O3 neclear thin film having a mean layer thickness of 20 to 200 nm. Subsequently, the Al2O3 neclear thin film is heat treated in a condition where the reaction atmosphere is substituted to a hydrogen atmosphere of pressure: 3 to 13 kPa, and the reaction atmosphere temperature is increased to 1100 to 1200° C. Then, the α-type Al2O3 layer, which serves as the hard coating layer, is formed under a conventional condition. The resulting α-type Al2O3 layer (hereinafter referred to as a reformed α-type Al2O3 layer), which is vapor-deposited on the heat-treated neclear thin film, is analyzed with a field emission type scanning electron microscope as schematically represented in FIGS. 1A and 1B. In the analysis, individual crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface, are irradiated by an electron beam. Then, a tilt angle, which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. The measured tilt angles belonging to a range of 0 to 45° are sectioned every pitch of 0.25°, and the frequencies existing in each section are collected, being represented by a tilt angle frequency distribution graph. As shown in FIG. 2, as an example, a sharp highest peak appears at a specific section of the tilt angle. Based on trial findings, it was found that the highest peak falls inside a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph, when the atmosphere pressure of the chemical vapor deposition apparatus is kept between 5 and 8 KPa. The fact that the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies, means that ratio of the (0001) plane orientation is high. This reformed α-type Al2O3 layer whose highest peak of the tilt angle division appears within the range of 0 to 10° in the tilt-angle frequency distribution graph has superior high-temperature strength compared to the conventional α-type Al2O3 layer of the conventional coated cutting tool 1. This reformed α-type Al2O3 also has excellent high-temperature hardness and heat resistance, as the conventional α-type Al2O3 layer of the conventional coated cutting tool 1 does.
(b) Forming the hard coating layer is further proceeded on the reformed α-type Al2O3 layer described above, as the intermediate layer 12B. A Ti-containing aluminum oxide layer having an α-type crystal structure in a chemically vapor-deposited state is vapor-deposited on the intermediate layer 12B as the upper layer 12C. In this way, the lower layer 12A composed of the Ti compound layer, the intermediate layer 12B composed of the reformed α-type Al2O3 layer, and the upper layer 12C composed of the Ti-containing aluminum oxide layer are vapor-deposited as a hard coating layer on the surface of the tool substrate 11. Since the coated cutting tool 10 with the configuration described above has even more superior high-temperature strength and surface properties, the coated cutting tool 10 exerts excellent chipping resistance, even under high-speed intermittent cutting conditions where high heat is generated and the cutting edges are subjected to intermittent impact loading repeatedly.
(c) The Ti-containing aluminum oxide layer which is the upper layer 12C can be formed on the reformed α-type Al2O3 layer, which is the intermediate layer 12B, under the following conditions. First, as a first step, first-step vapor deposition is performed for 30 minutes under the following conditions (i) to (iii).
(i) Composition of reaction gas (vol. %):
1 to 5% of AlCl3 
0.01 to 0.05% of TiCl4 
2 to 6% of CO2 
1 to 5% of HCl
0.10 to 0.30% of H2S
H2 as balance
(ii) Reaction atmosphere temperature: 960 to 1010° C.
(iii) Reaction atmosphere pressure: 6 to 10 kPa
Next, as a second step, vapor deposition is performed under the following conditions (i) to (iii).
(i) Composition of reaction gas (vol. %):
6 to 10% of AlCl3 
0.05 to 0.6% of TiCl4 
4 to 8% of CO2 
3 to 5% of HCl
0 to 0.05% of H2S
H2 as balance
(ii) Reaction atmosphere temperature: 920 to 1000° C.
(iii) Reaction atmosphere pressure: 6 to 10 kPa
By following the steps described above, a Ti-containing aluminum oxide layer (hereinafter referred to as a reformed AlTiO layer), which has an α-type crystal structure in a chemically vapor-deposited state, can be formed. The reformed AlTiO layer has a mean layer thickness of 1 to 15 μm, and the content ratio of the Ti component to the total amount of the Al component is 0.002 to 0.01 (as atomic ratio).
(d) When the texture of the reformed AlTiO layer is observed by the emission type scanning electron microscope, a flat-plate polygonal shape of a large-sized grain can be seen within a plane perpendicular to the layer thickness direction as shown in FIG. 3A. When the reformed AlTiO layer is observed in the plane parallel to the layer thickness direction as shown in FIG. 3B, it can be seen that the outer surface of the reformed AlTiO layer is substantially flat, and the reformed AlTiO layer has a texture made of the grains whose shapes are elongated in the layer thickness direction (hereinafter, the shape of the crystal grain described above is referred a flat-plate polygonal vertically elongated shape).
When the vapor deposition of the reformed AlTiO layer is performed under further limited conditions, the texture exemplified in FIG. 3C is formed. In the further limited condition, the volume % of TiCl4 is set 0.05 to 0.6, the volume % of H2S 0 to 0.03, and the reaction atmosphere temperature 960 to 980° C. in the second step vapor deposition, for example. As shown in FIG. 3C, when the reformed AlTiO layer is formed by the further limited condition, and is seen within the plane perpendicular to the layer thickness direction, the large-sized grains with a flat hexagonal shape are observed. When the reformed AlTiO layer is seen within the plane parallel to the layer thickness direction, it can be seen that the outer surface of the reformed AlTiO layer is substantially flat, as shown in FIG. 3B. In addition, the grains that have the elongated shape within the plane parallel to the layer thickness direction, account for 35% or more in area ratio, in the whole surface area perpendicular to the thickness direction of the layer.
(e) As in the reformed α-type Al2O3 layer, the reformed AlTiO layer is analyzed with the field-emission-type scanning electron microscope. In the analysis, individual crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface, are irradiated by an electron beam. Then, a tilt angle, which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. The measured tilt angles belonging to a range of 0 to 45° are sectioned every pitch of 0.25°, and the frequencies existing in each section are collected, being represented by a tilt angle frequency distribution graph. In the tilt-angle frequency distribution graph, a sharp highest peak appears at a specific section of the tilt angle, and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies. This means that the reformed AlTiO layer with high (0001) plane orientation ratio is formed. The (0001) plane orientation ratio of the reformed AlTiO layer is higher than that of the conventional AlTiO layer of the conventional coated cutting tool, resulting even more superior high-temperature strength of the reformed AlTiO layer.
(f) In addition, the reformed AlTiO layer is analyzed by the field-emission-type scanning electron microscope and an electronic backscattering diffraction image apparatus. In the analysis, individual crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface, are irradiated by an electron beam. Then, a tilt angle, which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. Based on the measurement results, a crystallographic orientation relationship between the adjacent crystal lattices is calculated, and a distribution of lattice points (constituent atom sharing lattice points) is calculated. The constituent atom sharing lattice point is a lattice point that has a constituent atom shared by two crystal lattices forming the grain boundary at the grain boundary. A constituent atom sharing lattice point type in which N lattice points not sharing the constituent atom exist between the constituent atom sharing lattice points (where N is an even number of 2 or more in view of a crystal structure of corundum type hexagonal close packed crystal but does not include even numbers of 4, 8, 14, 24, and 26 when the upper limit of N is set to 28 in view of distribution frequency) is expressed as ΣN+1. When the reformed AlTiO layer is observed by the field-emission-type scanning electron microscope, it is seen that the reformed AlTiO layer includes the crystal grains with the flat-plate polygonal vertically elongated shape, as shown in FIG. 4. Among the crystal grains with the flat-plate polygonal vertically elongated shape, 60% or more of them are divided by at least one of crystal lattice interface with the constituent atom sharing lattice point type expressed by Σ3 (hereinafter referred as a Σ3 coincidence site lattice interface) inside.
(h) As described above, the upper layer composed of the reformed AlTiO layer has a high (0001) plane orientation rate, and a crystal plane at the surface thereof has the same orientation as a crystal plane (for example, (0001)) within the plane perpendicular to the layer thickness direction of this layer. Thus, outer surface of the upper layer is formed in the shape of a flat plate which is substantially flat (as seen within the plane parallel to the layer thickness direction), and shows excellent chipping resistance due to the surface properties thereof. Furthermore, the strength within the crystal grains is increased since the Σ3 coincidence site lattice interfaces are present inside the grains with the flat-plate polygonal vertically elongated shape. Therefore, the reformed AlTiO layer has excellent high-temperature hardness and high-temperature strength and shows excellent chipping resistance, compared to the conventional AlTiO layer.
(i) Accordingly, as the hard coating layer, the coated tool of the present invention includes the reformed α-type Al2O3 layer having a high (0001) plane orientation rate and having excellent high-temperature strength as the intermediate layer. Furthermore, the coated tool of the present invention includes the reformed AlTiO layer having excellent high-temperature hardness, high-temperature strength, and surface properties as the upper layer. The coated tool of the present invention has superior high-temperature hardness, heat resistance, and high-temperature strength as compared to the conventional coated tools 1 and 2. As a result, it exhibits excellent chipping resistance for a long-term use, even when the coated tool is used for high-speed intermittent cutting accompanied by high heat generation, and intermittent impact loading acts repeatedly on the cutting edge. The present invention has been made on the basis of the above knowledge, and the surface-coated cutting tool of the present invention includes the following configurations.
(1) Provided is a surface-coated cutting tool formed by vapor-depositing, on the surface of a tool substrate made of tungsten carbide-based cemented carbide or titanium carbonitride-based cermet, a hard coating layer including (a) to (c) below.
(a) The lower layer is a Ti compound layer composed of one or more of a titanium carbide layer, a titanium nitride layer, a titanium carbonitride layer, a titanium carboxide layer, and a titanium oxycarbonitride layer, all of which are formed by chemical vapor deposition, and having a total mean layer thickness of 3 to 20 μm.
(b) The intermediate layer is an aluminum oxide layer having a mean layer thickness of 1 to 5 μm and having an α-type crystal structure in a chemically vapor-deposited state.
(c) The upper layer is a Ti-containing aluminum oxide layer having a mean layer thickness of 2 to 15 μm and having an α-type crystal structure in a chemically vapor-deposited state.
The intermediate layer (b) has properties indicated by a tilt-angle frequency distribution graph in which the highest peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph. The tilt-angle frequency distribution graph is obtained by utilizing a field-emission-type scanning electron microscope. Electron beams are irradiated to individual crystal grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected.
When the texture of the upper layer of the above (c) is observed by the emission type scanning electron microscope, the upper layer is a Ti-containing aluminum oxide layer having a texture composed of crystal grains which have a flat-plate polygonal shape within the plane perpendicular to the layer thickness direction and have an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction.
The upper layer (c) has properties indicated by a tilt-angle frequency distribution graph in which the highest peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies in the tilt-angle frequency distribution graph. The tilt-angle frequency distribution graph is obtained by utilizing a field-emission-type scanning electron microscope. Electron beams are irradiated to individual crystal grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected.
The upper layer (c) is a Ti-containing aluminum oxide layer. Electron beams are irradiated to individual crystal grains within the measurement area on the polished surface with field-emission-type scanning electron microscope and an electron backscatter diffraction imaging device. Then, angles formed by normal lines of crystal lattice faces with hexagonal crystal lattices and the normal line to the polished surface are measured. Then, based on the measurement, a crystallographic orientation relationship between the adjacent crystal lattices is calculated. Then, a distribution of lattice points (constituent atom sharing lattice points) in which constituent atoms of a crystal lattice interface sharing one constituent atom between the crystal lattices is calculated. The constituent atom sharing lattice point type is expressed as ΣN+1, where “N” represents a number of lattice points (N) without a shared constituent atom between the constituent atom sharing lattice points. The constituent atom sharing lattice point type is even numbers more than 2 between crystal grains having a corundum type hexagonal close-packed structure. If the maximum number of N is set to 28 in view of distribution frequency, even numbers 4, 8, 14, 24, and 26 are excluded from the option for crystal grains having hexagonal close-packed structure. The upper layer (c) is a Y-containing aluminum oxide layer consisted of crystal grains, 60% or more of the grains being divided within each grain by at least one or more crystal lattice interfaces with a constituent atom sharing lattice point type expressed by Σ3.
(2) When the texture of the upper layer (c) of the surface-coated cutting tool described above (as (1)) is observed by the emission type scanning electron microscope, crystal grains corresponding to 35% or more of the whole surface area perpendicular to the layer thickness direction, has a flat-plate polygonal shape within the plane perpendicular to the layer thickness direction and an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction.
(3) The surface roughness (Ra) of the upper layer (c) in the cutting tool described above (as (1) and (2)) ranges from 0.05 to 0.3 μm.
The configuration of the hard coating layer of the coated tool of this aspect will be described below in more detail.
(a) Ti Compound Layer (Lower Layer 12A)
The lower layer 12A is a Ti compound layer composed of one more of titanium carbide (hereinafter, referred to as TiC) layer, a titanium nitride (hereinafter, referred to as TiN) layer, a titanium carbonitride (hereinafter, referred to as TiCN) layer, a titanium carboxide (hereinafter, referred to as TiCO) layer, and a titanium oxycarbonitride (hereinafter, referred to as TiCNO) layer. The lower layer 12A is basically present as a lower layer of the reformed α-type Al2O3 layer which is the intermediate layer. It has superior toughness and abrasion resistance, contributing to improve high-temperature strength of the hard coating layer. In addition, the lower layer 12A adheres tightly to both the tool substrate and the reformed α-type Al2O3 layer, contributing an adhesive property of the hard coating layer to the tool substrate. If the total mean layer thickness is less than 3 μm, the improvements described above cannot be sufficiently obtained. On the other hand, if the total mean layer thickness exceeds 20 μm, thermal plastic deformation occurs easily, particularly when the cutting tool is used under high-speed intermittent cutting conditions where high heat is generated and a high load acts. Thermal plastic deformation causes uneven wear of the cutting tool. Accordingly, the total mean layer thickness is set to 3 to 20 μm.
(b) Reformed α-Type Al2O3 Layer (Intermediate Layer 12B)
In order to form the reformed α-type Al2O3 layer, which constitutes the intermediate layer 12B, as already described, an Al2O3 neclear is formed on the surface of the Ti compound layer, which is the lower layer, under the following low-temperature conditions.
A normal chemical vapor deposition apparatus is used. Composition of reaction gas includes 3 to 10% of AlCl3, 0.5 to 3% of CO2, 0.01 to 0.3% of C2H4 in vol. %, and H2 as balance. Reaction atmosphere temperature is set at 750 to 900° C. Reaction atmosphere pressure is set at 3 to 13 kPa.
It is desirable that the Al2O3 neclear is an Al2O3 neclear thin film having a mean layer thickness of 20 to 200 nm. After the formation of the Al2O3 neclear, the reaction atmosphere is substituted with a hydrogen atmosphere with pressure of 3 to 13 kPa. Then, temperature of the reaction atmosphere is increased to 1100 to 1200° C. and the Al2O3 neclear thin film is heat treated. An α-type Al2O3 layer, which serves as the hard coating layer, is formed under normal conditions. By following steps described above, an α-type Al2O3 layer is vapor deposited on the heat-treated Al2O3 neclear thin film, resulting formation of the intermediate layer 12B.
The reformed α-type Al2O3 layer vapor deposited on the lower layer 12A is analyzed by the field-emission-type scanning electron microscope, as shown in FIGS. 1A and 1B. Electron beams are irradiated to the individual grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected and a tilt-angle frequency distribution graph is plotted. In the tilt-angle frequency distribution graph, the sharp highest peak exists in a tilt angle division ranging 0 to 10°, as shown in FIG. 2.
The highest peak position of the measured tilt angles in the tilt angle frequency distribution graph of the reformed α-type Al2O3 layer can be changed by performing heat-treatment after the formation of the Al2O3 neclear (thin film) with a predetermined layer thickness. In addition, the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph (which means the (0001) plane orientation rate is high). Accordingly, whenever the thickness of the Al2O3 neclear (thin film) becomes too thin or too thick, the position of the highest peak of the measured tilt angles moves out of the range of 0 to 10°. In addition, the total sum of frequencies existing in the range of 0 to 10° becomes less than a ratio of 45% of the total frequencies in the tilt-angle frequency distribution graph. As a result, excellent high-temperature strength cannot be obtained.
The reformed α-type Al2O3 layer has superior high-temperature strength in addition to the excellent high-temperature hardness and heat resistance of the α-type Al2O3 layer of the conventional coated tool. Furthermore, by configuring the reformed α-type Al2O3 layer as an intermediate layer with a high (0001) plane orientation rate, the (0001) plane orientation rate of the reformed AlTiO layer vapor-deposited thereon can be increased. As a result, the surface properties of an upper layer composed of the reformed AlTiO layer can be improved, and high-temperature strength can be improved.
If the mean layer thickness of the intermediate layer composed of the reformed α-type Al2O3 layer is less than 1 μm, the hard coating layer cannot be provided with the above characteristics of the reformed α-type Al2O3 layer. On the other hand, if the mean layer thickness exceeds 5 μm, high temperature generated during cutting and high load subjected to the cutting edge leads to a higher rate of occurrence of thermal plastic deformation, which causes uneven wear of the cutting tool. As a result, the cutting tool is abrased faster. Thus, the mean layer thickness is set to 1 to 5 μm.
(c) Reformed AlTiO Layer (Upper Layer 12C)
As for the upper layer 12C composed of the reformed AlTiO layer chemically vapor-deposited on the intermediate layer 12B, an Al component which is a constituent component of the upper layer improves the high-temperature hardness and heat resistance of the layer. An extremely small amount (Ti/(Al+Ti) is 0.002 to 0.01 (as an atomic ratio) in a ratio accounted for in the total amount with Al) of Ti component contained in the upper layer improves the crystal grain boundary strength of the reformed AlTiO layer, and contributes to improving the high-temperature strength of the upper layer. If the content ratio of the Ti component in the upper layer is less than 0.002, the above functions cannot be obtained. On the other hand, if the content ratio of the Ti component exceeds 0.01, the grain boundary strength deteriorates as TiO2 grains precipitate in the layer. Therefore, it is desirable that the content ratio of the Ti component (the value of the ratio of Ti/(Al+Ti)) in the upper layer accounted for in the total amount with the Al component is 0.002 to 0.01 (as an atomic ratio).
The reformed AlTiO layer can be vapor-deposited by adjusting chemical vapor deposition conditions of the composition of a reaction gas during vapor deposition, the reaction atmosphere temperature, and the reaction atmosphere pressure as follows, for example.
First, the first-step vapor deposition is performed for 30 minutes under the following conditions:
(i) Composition of reaction gas (vol. %):
1 to 5% of AlCl3,
0.01 to 0.05% of TiCl4,
2 to 6% of CO2,
1 to 5% of HCl,
0.10 to 0.30% of H2S, and
H2 as balance,
(ii) Reaction atmosphere temperature: 960 to 1010° C., and
(iii) Reaction atmosphere pressure: 6 to 10 kPa,
Second, the second-step vapor deposition is performed under the following conditions.
(i) Composition of reaction gas (vol. %):
6 to 10% of AlCl3,
0.05 to 0.6% of TiCl4,
4 to 8% of CO2,
3 to 5% of HCl,
0 to 0.05% of H2S, and
H2 as balance,
(ii) Reaction atmosphere temperature: 920 to 1000° C., and
(iii) Reaction atmosphere pressure: 6 to 10 kPa.
When a vapor deposition layer with a mean layer thickness of 1 to 15 μm is formed as a film, by performing the first-step and the second-step vapor deposition in the conditions described above, the reformed AlTiO layer whose ratio of Ti/(Al+Ti) is 0.002 to 0.01 in atomic ratio, is formed.
When the reformed AlTiO layer is observed by the emission type scanning electron microscope, the textures shown in FIGS. 3A and 3B are observed. In FIG. 3A, the reformed AlTiO layer is viewed within the plane perpendicular to the layer thickness direction. In FIG. 3A, the texture containing large crystal grains with a flat-plate polygonal shape is formed. In FIG. 3B, the reformed AlTiO layer is viewed within the plane parallel to the layer thickness direction. In FIG. 3B, the outer surface of the reformed AlTiO layer is substantially flat. Also, the texture containing crystal grains with elongated shape is formed (Referred as a flat-plate polygonal elongated shape crystal grain).
As for the reformed AlTiO layer, similarly to the reformed α-type Al2O3 layer, which constitutes the intermediate layer, the tilt angle of the normal line to the (0001) plane to the normal line to a polished surface is measured and a tilt angle frequency graph is plotted. In the tilt angle frequency graph of the reformed AlTiO layer, a peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies in the tilt-angle frequency distribution graph. These results indicate that the (0001) plane orientation rate of the reformed AlTiO layer, which constitutes the upper layer, is high.
That is, as for the reformed AlTiO layer, since the (0001) plane orientation rate of the reformed α-type Al2O3 layer, which is the intermediate layer, is 45% or more, the reformed AlTiO layer is also formed as a layer having a high (0001) plane orientation rate (the (0001) plane orientation rate is 60% or more).
When the upper layer is viewed within the plane parallel to the layer thickness direction, the outer surface of the upper layer is formed in the shape of a substantially flat plate. Thus, the upper layer has a excellent surface property. Consequently, the upper layer shows superior chipping resistance as compared to the conventional AlTiO layer.
When the vapor deposition of the reformed AlTiO layer is performed under further limited conditions (for example, the conditions where volume percentages of TiCl4 and H2S in the reaction gas are 0.05 to 0.2 vol. % and 0 to 0.03, respectively, and the reaction atmosphere temperature is set to 960 to 980° C., in the second-step vapor deposition), the texture shown in FIG. 3C is formed. In the texture, when it is viewed within the plane perpendicular to the layer thickness direction, there are large-sized crystal grains with a flat-plate hexagonal shape. When the texture is viewed within the plane parallel to the layer thickness direction, the outer surface of the upper layer is substantially flat and the crystal grains have an elongated shape stretched in the layer thickness direction, as shown in FIG. 3B. The ratio of the surface area occupied by the crystal grains having the flat-plate hexagonal elongated shape, to the whole surface area of the plane parallel to the layer thickness direction, accounts for 35% or more, in the upper layer formed in the further limited conditions.
The reformed AlTiO layer is analyzed with a field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus. In the analysis, electron beams are irradiated to individual crystal grains within the measurement range of the polished surface. Then, angles between the normal line to each of crystal lattice planes with a hexagonal crystal lattice and the normal line to the polished surface are measured. From the measurement results, the crystal orientation relationship between adjacent crystal lattices is calculated. Then, distribution of lattice points (constituent atom sharing lattice points) is calculated. The constituent atom sharing lattice point is a lattice point that has a constituent atom shared by two crystal lattices forming the grain boundary at the grain boundary. A constituent atom sharing lattice point configuration is expressed by ΣN+1, where the number represented by N is the number of lattice points that have no constituent atom shared at the grain boundary between two constituent atom sharing lattice points with constituent atoms. The constituent atom sharing lattice point type is even numbers more than 2 between crystal grains having a corundum type hexagonal close-packed structure. If the maximum number of N is set to 28 in view of distribution frequency, even numbers 4, 8, 14, 24, and 26 are excluded from the option for crystal grains having hexagonal close-packed structure. As shown in FIG. 4, the crystal grains of the reformed AlTiO layer are divided by at least one of Σ3 coincidence site lattice interface within each crystal grain. The ratio of surface area occupied by the crystal grains that have the flat-plate polygonal elongated shape and divided by at least one of Σ3 coincidence site lattice interface, to the surface area occupied by crystal grains with the flat-plate polygonal elongated shape (including the flat-plate hexagonal elongated shape), is 60% or more.
The strength within the crystal grains of the reformed AlTiO layer is increased due to the presence of the Σ3 coincidence site lattice interface in the crystal grains with the flat-plate polygonal (including hexagonal) elongated shape. As a result, cracking of the reformed AlTiO layer is suppressed during high-speed intermittent cutting work where high load is subjected to the reformed AlTiO layer. Even if the cracking occurred, growth and spreading of the cracking would be prevented. Therefore, chipping resistance, fracture resistance, and spalling resistance are improved in the cutting tool having the reformed AlTiO layer.
Accordingly, the upper layer of the present invention, which has a high (0001) plane orientation rate, has flat surface properties, and is composed of the reformed AlTiO layer in which the Σ3 coincidence site lattice interfaces are present with in the flat-plate polygonal (including flat hexagonal) elongated crystal grains, exhibits excellent chipping resistance and abrasion resistance for a prolonged period of time without causing chipping, fracture, spalling, or the like and also without causing thermal plastic deformation, uneven wear, or the like, even in high-speed intermittent cutting work accompanied by high heat generation and high load subjected on the cutting edge.
If the layer thickness of the upper layer composed of the reformed AlTiO layer is less than 2 μm, the excellent characteristics of the upper layer cannot be sufficiently exhibited. On the other hand, if the layer thickness of the upper layer exceeds 15 μm, thermal plastic deformation, which causes uneven wear, easily occurs. In addition, a rate of occurrence of chipping is also increased. Therefore, the mean layer thickness of the upper layer is set to 2 to 15 μm.
As a comparison, the conventional AlTiO layer (the layer described in the PTL 2 (Japanese Unexamined Patent Application Publication No. 2006-289556)), was analyzed by the field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus. In the analysis, the texture of crystal grains and the constituent atom sharing lattice point configuration of the conventional AlTiO layer were analyzed. The texture of the crystal grains of the conventional AlTiO layer is shown in FIGS. 5A and 5B. As shown in FIGS. 5A and 5B, the texture of the crystal grains of the conventional AlTiO layer is made of pyramidal-shaped crystal grains with a polygonal elongated shape stretched to the layer thickness direction. The outer surface of the conventional AlTiO layer has protuberances and recesses along with the pyramidal shape of the crystal grains. Because of these, the abrasion resistance of the conventional AlTiO layer is inferior compared to that of the reformed AlTiO layer. In terms of the constituent atom sharing lattice point configuration, the ratio of surface area occupied by the pyramidal-shaped crystal grains, which have a polygonal elongated shape stretched to the layer thickness direction and contain a Σ3 coincidence site lattice interface within, to the surface area occupied by crystal grains, which consist the conventional AlTiO layer and have the convexoconcave polygonal elongated shape stretched to the layer thickness direction, is 40% or less. Therefore, the strength within the crystal grains is not improved as in the reformed AlTiO layer.
Accordingly, the conventional coated tool 2 in which the upper layer of the hard coating layer is composed of the conventional AlTiO layer cannot prevent occurrence of chipping, fracture, spalling, or the like and is inferior in tool performance, in high-speed intermittent cutting work accompanied by high heat generation and intermittent impact loading subjected on the cutting edge.
In the coated tool of the present invention, after the reformed AlTiO layer of the upper layer is formed, polishing processing using a grind stone or polishing processing using wet blasting can be performed on the surface of the upper layer, so that the surface roughness of the reformed AlTiO layer can be further adjusted. For example, the occurrence of welding to the surface-coated tool during cutting can be suppressed by adjusting the surface roughness of the reformed AlTiO layer to Ra 0.05 to 0.3 μm.
The surface roughness Ra in the present invention means the value of arithmetic mean roughness Ra defined by JIS B0601 (1994), and the measuring method thereof is not particularly limited.
Second Embodiment
A coated tool of the second embodiment of the present invention has the following configuration.
(a) The conventional α-type Al2O3 layer in the conventional coated tool 1 is vapor-deposited, for example, using a normal chemical vapor deposition apparatus under the following conditions.
Composition of reaction gas: in vol. %, 6 to 10% of AlCl3, 10 to 15% of CO2, 3 to 5% of HCl, 0.05 to 0.2% of H2S, and H2 as balance
Reaction atmosphere temperature: 1020 to 1050° C.
Reaction atmosphere pressure: 3 to 5 kPa
In the second embodiment, an Al2O3 neclear is formed on the surface of a Ti compound layer, which is a lower layer, using a standard chemical vapor deposition apparatus under the following low-temperature conditions: composition of reaction gas, in vol. %, 3 to 10% of AlCl3, 0.5 to 3% of CO2, 0.01 to 0.3% of C2H4, and H2 as balance; reaction atmosphere temperature, 750 to 900° C.; reaction atmosphere pressure, 3 to 13 kPa.
An Al2O3 neclear is formed on the surface of a Ti compound layer which is the lower layer 12A under the low-temperature condition described above. In this case, it is desirable that the Al2O3 neclear is an Al2O3 neclear thin film having a mean layer thickness of 20 to 200 nm. Subsequently, the Al2O3 neclear thin film is heat treated in a condition where the reaction atmosphere is substituted to a hydrogen atmosphere of pressure: 3 to 13 kPa, and the reaction atmosphere temperature is increased to 1100 to 1200° C. Then, the α-type Al2O3 layer, which serves as the hard coating layer, is formed under a conventional condition. The resulting α-type Al2O3 layer (hereinafter referred to as a reformed α-type Al2O3 layer), which is vapor-deposited on the heat-treated neclear thin film, is analyzed with a field emission type scanning electron microscope as schematically represented in FIGS. 1A and 1B. In the analysis, individual crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface, are irradiated by an electron beam. Then, a tilt angle, which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. The measured tilt angles belonging to a range of 0 to 45° are sectioned every pitch of 0.25°, and the frequencies existing in each section are collected, being represented by a tilt angle frequency distribution graph. As shown in FIG. 6, as an example, a sharp highest peak appears at a specific section of the tilt angle. Based on trial findings, it was found that the highest peak falls inside a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph, when the atmosphere pressure of the chemical vapor deposition apparatus is kept between 5 and 8 KPa. The fact that the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies, means that ratio of the (0001) plane orientation is high. This reformed α-type Al2O3 layer whose highest peak of the tilt angle division appears within the range of 0 to 10° in the tilt-angle frequency distribution graph has superior high-temperature strength compared to the conventional α-type Al2O3 layer of the conventional coated cutting tool 1. This reformed α-type Al2O3 also has excellent high-temperature hardness and heat resistance, as the conventional α-type Al2O3 layer of the conventional coated cutting tool 1 does.
(b) A hard coating layer is constructed by forming the reformed α-type Al2O3 layer vapor-deposited under the conditions described in the above (a) as the intermediate layer, and further by vapor-depositing a Y(Yttrium)-containing aluminum oxide layer having an α-type crystal structure in a chemically vapor-deposited state as the upper layer on the intermediate layer. Then, provided is a coated tool in which the lower layer composed of the Ti compound layer, the intermediate layer composed of the reformed α-type Al2O3 layer, and the upper layer composed of the Y-containing aluminum oxide layer are vapor-deposited as a hard coating layer on the surface of the tool substrate. The present inventor has found that this coated tool has superior high-temperature strength and surface properties, thereby exhibiting excellent chipping resistance, even under high-speed intermittent cutting conditions where intermittent impact load is subjected on the cutting edge.
(c) The Y-containing aluminum oxide layer which is the upper layer can be formed on the reformed α-type Al2O3 layer, which is the intermediate layer, under the following conditions. For example, first, as a first step, first-step vapor deposition is performed for 1 hour under the following conditions (i) to (iii).
(i) Composition of reaction gas (vol. %):
1 to 5% of AlCl3,
0.05 to 0.1% of YCl3,
2 to 6% of CO2,
1 to 5% of HCl,
H2S of 0.25 to 0.75%, and
H2 as balance
(ii) Reaction atmosphere temperature: 1020 to 1050° C.
(iii) Reaction atmosphere pressure: 3 to 5 kPa
Next, as a second step, vapor deposition is performed under the following conditions (i) to (iii).
(i) Composition of reaction gas (vol. %):
6 to 10% of AlCl3,
0.4 to 1.0% of YCl3,
4 to 8% of CO2,
3 to 5% of HCl,
H2S of 0.25 to 0.6%, and
H2 as balance
(ii) Reaction atmosphere temperature: 920 to 1000° C.
(iii) Reaction atmosphere pressure: 6 to 10 kPa
By following the steps described above, a Y-containing aluminum oxide layer (hereinafter referred to as a reformed AlYO layer), which has an α-type crystal structure in a chemically vapor-deposited state, can be formed. The reformed AlYO layer has a mean layer thickness of 1 to 15 μm, and the content ratio of the Y component to the total amount of the Al component is 0.0005 to 0.01 (as atomic ratio).
(d) When the texture of the reformed AlYO layer is observed by the emission type scanning electron microscope, a flat-plate polygonal shape of a large-sized grain can be seen within a plane perpendicular to the layer thickness direction as shown in FIG. 7A. When the reformed AlYO layer is observed in the plane parallel to the layer thickness direction as shown in FIG. 7B, it can be seen that the outer surface of the reformed AlYO layer is substantially flat, and the reformed AlYO layer has a texture made of the grains whose shapes are elongated in the layer thickness direction (hereinafter, the shape of the crystal grain described above is referred a flat-plate polygonal vertically elongated shape).
When the vapor deposition of the reformed AlYO layer is performed under further limited conditions, the texture exemplified in FIG. 7C is formed. In the further limited condition, the volume % of YCl3 is set 0.6 to 0.8, the volume % of H2S 0.25 to 0.4, and the reaction atmosphere temperature 960 to 980° C. in the second step vapor deposition, for example. As shown in FIG. 7C, when the reformed AlYO layer is formed by the further limited condition, and is seen within the plane perpendicular to the layer thickness direction, the large-sized grains with a flat hexagonal shape are observed. When the reformed AlYO layer is seen within the plane parallel to the layer thickness direction, it can be seen that the outer surface of the reformed AlYO layer is substantially flat, as shown in FIG. 7B. In addition, the grains that have the elongated shape within the plane parallel to the layer thickness direction, account for 35% or more in area ratio, in the whole surface area perpendicular to the thickness direction of the layer.
(e) As in the reformed α-type Al2O3 layer, the reformed AlYO layer is analyzed with the field-emission-type scanning electron microscope. In the analysis, individual crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface, are irradiated by an electron beam. Then, a tilt angle, which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. The measured tilt angles belonging to a range of 0 to 45° are sectioned every pitch of 0.25°, and the frequencies existing in each section are collected, being represented by a tilt angle frequency distribution graph. In the tilt-angle frequency distribution graph, a sharp highest peak appears at a specific section of the tilt angle, and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies. This means that the reformed AlYO layer with high (0001) plane orientation ratio is formed. The (0001) plane orientation ratio of the reformed AlYO layer is higher than that of the conventional AlYO layer of the conventional coated cutting tool, resulting even more superior high-temperature strength of the reformed AlYO layer.
(f) In addition, the reformed AlYO layer is analyzed by the field-emission-type scanning electron microscope and an electronic backscattering diffraction image apparatus. In the analysis, individual crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface, are irradiated by an electron beam. Then, a tilt angle, which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. Based on the measurement results, a crystallographic orientation relationship between the adjacent crystal lattices is calculated, and a distribution of lattice points (constituent atom sharing lattice points) in which constituent atoms of a crystal lattice interface sharing one constituent atom between the crystal lattices is calculated. A constituent atom sharing lattice point type in which N lattice points not sharing the constituent atom exist between the constituent atom sharing lattice points (where N is an even number of 2 or more in view of a crystal structure of corundum type hexagonal close packed crystal but does not include even numbers of 4, 8, 14, 24, and 26 when the upper limit of N is set to 28 in view of distribution frequency) is expressed as ΣN+1. When the reformed AlYO layer is observed by the field-emission-type scanning electron microscope, it is seen that the reformed AlYO layer includes the crystal grains with the flat-plate polygonal vertically elongated shape, as shown in FIG. 8. Among the crystal grains with the flat-plate polygonal vertically elongated shape, 60% or more of them are divided by at least one of crystal lattice interface with the constituent atom sharing lattice point type expressed by Σ3 (hereinafter referred as a Σ3 coincidence site lattice interface) in the crystal grains.
(h) As described above, the upper layer composed of the reformed AlYO layer has a high (0001) plane orientation rate, and a crystal plane at the surface thereof has the same orientation as a crystal plane (for example, (0001)) within the plane perpendicular to the layer thickness direction of this layer. Thus, outer surface of the upper layer is formed in the shape of a flat plate which is substantially flat (as seen within the plane parallel to the layer thickness direction), and shows excellent chipping resistance due to the surface properties thereof. Furthermore, the strength within the crystal grains is increased since the Σ3 coincidence site lattice interfaces are present inside the grains with the flat-plate polygonal vertically elongated shape. Therefore, the reformed AlYO layer has excellent high-temperature hardness and high-temperature strength and shows excellent chipping resistance, compared to the conventional AlYO layer.
(i) Accordingly, as the hard coating layer, the coated tool of the present invention includes the reformed α-type Al2O3 layer having a high (0001) plane orientation rate and having excellent high-temperature strength as the intermediate layer. Furthermore, the coated tool of the present invention includes the reformed AlYO layer having excellent high-temperature hardness, high-temperature strength, and surface properties as the upper layer. The coated tool of the present invention has superior high-temperature hardness, heat resistance, and high-temperature strength as compared to the conventional coated tools 1 and 2. As a result, it exhibits excellent chipping resistance for a long-term use, even when the coated tool is used for high-speed intermittent cutting accompanied by high heat generation, and intermittent impact loading acts repeatedly on the cutting blade. The second embodiment of the present invention has been made on the basis of the above knowledge, and the surface-coated cutting tool of the present invention includes the following configurations.
(1) Provided is a surface-coated cutting tool formed by vapor-depositing, on the surface of a tool substrate made of tungsten carbide-based cemented carbide or titanium carbonitride-based cermet, a hard coating layer including the above (a) to (c).
(a) The lower layer is a Ti compound layer composed of one or more of a titanium carbide layer, a titanium nitride layer, a titanium carbonitride layer, a titanium carboxide layer, and a titanium oxycarbonitride layer, all of which are formed by chemical vapor deposition, and having a total mean layer thickness of 3 to 20 μm.
(b) The intermediate layer is an aluminum oxide layer having a mean layer thickness of 1 to 5 μm and having an α-type crystal structure in a chemically vapor-deposited state.
(c) The upper layer is a Y-containing aluminum oxide layer having a mean layer thickness of 2 to 15 μm and having an α-type crystal structure in a chemically vapor-deposited state.
The intermediate layer (b) has properties indicated by a tilt-angle frequency distribution graph in which the highest peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph. The tilt-angle frequency distribution graph is obtained by utilizing a field-emission-type scanning electron microscope. Electron beams are irradiated to individual crystal grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected.
When the texture of the upper layer of the above (c) is observed by the emission type scanning electron microscope, the upper layer is a Y-containing aluminum oxide layer having a texture composed of crystal grains which have a flat-plate polygonal shape within the plane perpendicular to the layer thickness direction and have an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction.
The upper layer (c) has properties indicated by a tilt-angle frequency distribution graph in which the highest peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies in the tilt-angle frequency distribution graph. The tilt-angle frequency distribution graph is obtained by utilizing a field-emission-type scanning electron microscope. Electron beams are irradiated to individual crystal grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected.
The upper layer (c) is a Y-containing aluminum oxide layer. Electron beams are irradiated to individual crystal grains within the measurement area on the polished surface with field-emission-type scanning electron microscope and an electron backscatter diffraction imaging device. Then, angles formed by normal lines of crystal lattice faces with hexagonal crystal lattices and the normal line to the polished surface are measured. Then, based on the measurement, a crystallographic orientation relationship between the adjacent crystal lattices is calculated. Then, a distribution of lattice points (constituent atom sharing lattice points) in which constituent atoms of a crystal lattice interface sharing one constituent atom between the crystal lattices is calculated. The constituent atom sharing lattice point type is expressed as ΣN+1, where “N” represents a number of lattice points (N) without a shared constituent atom between the constituent atom sharing lattice points. The constituent atom sharing lattice point type is even numbers more than 2 between crystal grains having a corundum type hexagonal close-packed structure. If the maximum number of N is set to 28 in view of distribution frequency, even numbers 4, 8, 14, 24, and 26 are excluded from the option for crystal grains having hexagonal close-packed structure. The upper layer (c) is a Y-containing aluminum oxide layer consisted of crystal grains, 60% or more of the grains being divided within each grain by at least one or more crystal lattice interfaces with a constituent atom sharing lattice point type expressed by Σ3.
(2) When the texture of the upper layer (c) of the surface-coated cutting tool described above (as (1)) is observed by the emission type scanning electron microscope, crystal grains corresponding to 35% or more of the whole surface area perpendicular to the layer thickness direction, has a flat-plate polygonal shape within the plane perpendicular to the layer thickness direction and an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction.
(3) The surface roughness (Ra) of the upper layer (c) in the cutting tool described above (as (1) and (2)) ranges from 0.05 to 0.3 μm.
The configuration of the hard coating layer of the coated tool of the second embodiment will be described below in more detail.
(a) Ti Compound Layer (Lower Layer 12A)
The lower layer 12A is a Ti compound layer composed of one more of titanium carbide (hereinafter, referred to as TiC) layer, a titanium nitride (hereinafter, referred to as TiN) layer, a titanium carbonitride (hereinafter, referred to as TiCN) layer, a titanium carboxide (hereinafter, referred to as TiCO) layer, and a titanium oxycarbonitride (hereinafter, referred to as TiCNO) layer. The lower layer 12A is basically present as a lower layer of the reformed α-type Al2O3 layer which is the intermediate layer. It has superior toughness and abrasion resistance, contributing to improve high-temperature strength of the hard coating layer. In addition, the lower layer 12A adheres tightly to both the tool substrate and the reformed α-type Al2O3 layer, contributing an adhesive property of the hard coating layer to the tool substrate. If the total mean layer thickness is less than 3 μm, the improvements described above cannot be sufficiently obtained. On the other hand, if the total mean layer thickness exceeds 20 μm, chipping occurs easily, particularly when the cutting tool is used under high-speed intermittent cutting conditions where high heat is generated and an intermittent load is subjected to the cutting tool. The chipping causes abnormal wear of the cutting tool. Accordingly, the total mean layer thickness is set to 3 to 20 μm.
(b) Reformed α-Type Al2O3 Layer (Intermediate Layer 12B)
In order to form the reformed α-type Al2O3 layer, which constitutes the intermediate layer 12B, as already described, an Al2O3 neclear is formed on the surface of the Ti compound layer, which is the lower layer, under the normal chemical vapor deposition apparatus under the following low-temperature conditions.
Composition of reaction gas: in vol. %, 3 to 10% of AlCl3, 0.5 to 3% of CO2, 0.01 to 0.3% of C2H4, and H2 as balance
Reaction atmosphere temperature: 750 to 900° C.
Reaction atmosphere pressure: 3 to 13 kPa
It is desirable that the Al2O3 neclear is an Al2O3 neclear thin film having a mean layer thickness of 20 to 200 nm. After the formation of the Al2O3 neclear, the reaction atmosphere is substituted with a hydrogen atmosphere with pressure of 3 to 13 kPa. Then, temperature of the reaction atmosphere is increased to 1100 to 1200° C. and the Al2O3 neclear thin film is heat treated. An α-type Al2O3 layer, which serves as the hard coating layer, is formed under normal conditions. By following steps described above, an α-type Al2O3 layer is vapor deposited on the heat-treated Al2O3 neclear thin film, resulting formation of the intermediate layer 12B.
The intermediate layer 12 is analyzed by the field-emission-type scanning electron microscope, as shown in FIGS. 1A and 1B. Electron beams are irradiated to the individual grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected and a tilt-angle frequency distribution graph is plotted. In the tilt-angle frequency distribution graph, the sharp highest peak exists in a tilt angle division ranging 0 to 10°, as shown in FIG. 6.
The highest peak position of the measured tilt angles in the tilt angle frequency distribution graph of the reformed α-type Al2O3 layer can be changed by performing heat-treatment after the formation of the Al2O3 neclear (thin film) with a predetermined layer thickness. In addition, the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph (which means the (0001) plane orientation rate is high). Accordingly, whenever the thickness of the Al2O3 neclear (thin film) becomes too thin or too thick, the position of the highest peak of the measured tilt angles moves out of the range of 0 to 10°. In addition, the total sum of frequencies existing in the range of 0 to 10° becomes less than a ratio of 45% of the total frequencies in the tilt-angle frequency distribution graph. As a result, excellent high-temperature strength cannot be obtained.
The reformed α-type Al2O3 layer has superior high-temperature strength in addition to the excellent high-temperature hardness and heat resistance of the α-type Al2O3 layer of the conventional coated tool. Furthermore, by configuring the reformed α-type Al2O3 layer as an intermediate layer with a high (0001) plane orientation rate, the (0001) plane orientation rate of the reformed AlYO layer vapor-deposited thereon can be increased. As a result, the surface properties of an upper layer composed of the reformed AlYO layer can be improved, and high-temperature strength can be improved.
If the mean layer thickness of the intermediate layer composed of the reformed α-type Al2O3 layer is less than 1 μm, the hard coating layer cannot be provided with the above characteristics of the reformed α-type Al2O3 layer. On the other hand, if the mean layer thickness exceeds 5 μm, high temperature generated during cutting and an intermittent load subjected to the cutting edge leads to a higher rate of occurrence of chipping, which causes abnormal wear of the cutting tool. As a result, the cutting tool is abrased faster. Thus, the mean layer thickness is set to 1 to 5 μm.
(c) Reformed AlYO Layer (Upper Layer 12C)
As for the upper layer 12C composed of the reformed AlYO layer chemically vapor-deposited on the intermediate layer 12B, an Al component which is a constituent component of the upper layer improves the high-temperature hardness and heat resistance of the layer. An extremely small amount (Y/(Al+Y) is 0.0005 to 0.01 (as an atomic ratio) in a ratio accounted for in the total amount with Al) of Y component contained in the upper layer improves the crystal grain boundary strength of the reformed AlYO layer, and contributes to improving the high-temperature strength of the upper layer. If the content ratio of the Y component in the upper layer is less than 0.0005, the above functions cannot be obtained. On the other hand, if the content ratio of the Y component exceeds 0.01, the grain boundary strength deteriorates as Y2O3 grains precipitate in the layer. Therefore, it is desirable that the content ratio of the Y component (the value of the ratio of Y/(Al+Y)) in the upper layer accounted for in the total amount with the Al component is 0.0005 to 0.01 (as an atomic ratio).
The reformed AlYO layer can be vapor-deposited by adjusting chemical vapor deposition conditions of the composition of a reaction gas during vapor deposition, the reaction atmosphere temperature, and the reaction atmosphere pressure as follows, for example.
First, the first-step vapor deposition is performed for 1 hour under the following conditions:
(i) Composition of reaction gas (vol. %):
1 to 5% of AlCl3,
0.05 to 0.1% of YCl3,
2 to 6% of CO2,
1 to 5% of HCl,
0.25 to 0.75% of H2S, and
H2 as balance,
(ii) Reaction atmosphere temperature: 1020 to 1050° C., and
(iii) Reaction atmosphere pressure: 3 to 5 kPa,
Second, the second-step vapor deposition is performed under the following conditions.
(i) Composition of reaction gas (vol. %):
6 to 10% of AlCl3,
0.4 to 1.0% of YCl3,
4 to 8% of CO2,
3 to 5% of HCl,
0.25 to 0.6% of H2S, and
H2 as balance,
(ii) Reaction atmosphere temperature: 920 to 1000° C., and
(iii) Reaction atmosphere pressure: 6 to 10 kPa.
When a vapor deposition layer with a mean layer thickness of 1 to 15 μm is formed as a film, by performing the first-step and the second-step vapor deposition in the conditions described above, the reformed AlYO layer whose ratio of Y/(Al+Y) is 0.0005 to 0.01 in atomic ratio, is formed.
When the reformed AlYO layer is observed by the emission type scanning electron microscope, the textures shown in FIGS. 7A and 7B are observed. In FIG. 7A, the reformed AlTiO layer is viewed within the plane perpendicular to the layer thickness direction. In FIG. 7A, the texture containing large crystal grains with a flat-plate polygonal shape is formed. In FIG. 7B, the reformed AlYO layer is viewed within the plane parallel to the layer thickness direction. In FIG. 7B, the outer surface of the reformed AlYO layer is substantially flat. Also, the texture containing crystal grains with elongated shape is formed (Referred as a flat-plate polygonal elongated shape crystal grain).
As for the reformed AlYO layer, similarly to the reformed α-type Al2O3 layer, which constitutes the intermediate layer, the tilt angle of the normal line to the (0001) plane to the normal line to a polished surface is measured and a tilt angle frequency graph is plotted. In the tilt angle frequency graph of the reformed AlYO layer, a peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies in the tilt-angle frequency distribution graph. These results indicate that the (0001) plane orientation rate of the reformed AlYO layer, which constitutes the upper layer, is high.
That is, as for the reformed AlYO layer, since the (0001) plane orientation rate of the reformed α-type Al2O3 layer, which is the intermediate layer, is 45% or more, the reformed AlYO layer is also formed as a layer having a high (0001) plane orientation rate (the (0001) plane orientation rate is 60% or more).
When the upper layer is viewed within the plane parallel to the layer thickness direction, the outer surface of the upper layer is formed in the shape of a substantially flat plate. Thus, the upper layer has a excellent surface property. Consequently, the upper layer shows superior chipping resistance as compared to the conventional AlYO layer.
When the vapor deposition of the reformed AlYO layer is performed under further limited conditions (for example, the conditions where volume percentage of H2S in the reaction gas is 0.5 to 0.75 vol. %, and the reaction atmosphere temperature is set to 1020 to 1030° C., in the first-step vapor deposition, and volume percentages of YCl3 and H2S in the reaction gas are 0.6 to 0.8 vol. % and 0.25 to 0.4 vol %, respectively, and the reaction atmosphere temperature is set to 960 to 980° C., in the second-step vapor deposition), the texture shown in FIG. 7C is formed. In the texture, when it is viewed within the plane perpendicular to the layer thickness direction, there are large-sized crystal grains with a flat-plate hexagonal shape. When the texture is viewed within the plane parallel to the layer thickness direction, the outer surface of the upper layer is substantially flat and the crystal grains have an elongated shape stretched in the layer thickness direction, as shown in FIG. 7B. The ratio of the surface area occupied by the crystal grains having the flat-plate hexagonal elongated shape, to the whole surface area of the plane parallel to the layer thickness direction, accounts for 35% or more, in the upper layer formed in the further limited conditions.
The reformed AlYO layer is analyzed with a field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus. In the analysis, electron beams are irradiated to individual crystal grains within the measurement range of the polished surface. Then, angles between the normal line to each of crystal lattice planes with a hexagonal crystal lattice and the normal line to the polished surface are measured. From the measurement results, the crystal orientation relationship between adjacent crystal lattices is calculated. Then, distribution of lattice points (constituent atom sharing lattice points) is calculated. The constituent atom sharing lattice point is a lattice point that has a constituent atom shared by two crystal lattices forming the grain boundary at the grain boundary. A constituent atom sharing lattice point configuration is expressed by ΣN+1, where the number represented by N is the number of lattice points that have no constituent atom shared at the grain boundary between two constituent atom sharing lattice points with constituent atoms. The constituent atom sharing lattice point type is even numbers more than 2 between crystal grains having a corundum type hexagonal close-packed structure. If the maximum number of N is set to 28 in view of distribution frequency, even numbers 4, 8, 14, 24, and 26 are excluded from the option for crystal grains having hexagonal close-packed structure. As shown in FIG. 8, the crystal grains of the reformed AlYO layer are divided by at least one of Σ3 coincidence site lattice interface within each crystal grain. The ratio of surface area occupied by the crystal grains that have the flat-plate polygonal elongated shape and divided by at least one of Σ3 coincidence site lattice interface, to the surface area occupied by crystal grains with the flat-plate polygonal elongated shape (including the flat-plate hexagonal elongated shape), is 60% or more.
The strength within the crystal grains of the reformed AlYO layer is increased due to the presence of the Σ3 coincidence site lattice interface in the crystal grains with the flat-plate polygonal (including hexagonal) elongated shape. As a result, cracking of the reformed AlYO layer is suppressed during high-speed intermittent cutting work where high load is subjected to the reformed AlYO layer. Even if the cracking occurred, growth and spreading of the cracking would be prevented. Therefore, chipping resistance, fracture resistance, and spalling resistance are improved in the cutting tool having the reformed AlYO layer.
Accordingly, the upper layer of the present invention, which has a high (0001) plane orientation rate, has flat surface properties, and is composed of the reformed AlYO layer in which the Σ3 coincidence site lattice interfaces are present with in the flat-plate polygonal (including flat hexagonal) elongated crystal grains, exhibits excellent chipping resistance and abrasion resistance for a prolonged period of time without causing chipping, fracture, spalling, or the like and also without causing uneven wear, or the like, even in high-speed intermittent cutting work accompanied by high heat generation and intermittent load subjected on the cutting edge.
If the layer thickness of the upper layer composed of the reformed AlYO layer is less than 2 μm, the excellent characteristics of the upper layer cannot be sufficiently exhibited. On the other hand, if the layer thickness of the upper layer exceeds 15 μm, a rate of occurrence of chipping is increased. Therefore, the mean layer thickness of the upper layer is set to 2 to 15 μm.
As a comparison, the conventional AlYO layer (the layer described in the PTL 4), was analyzed by the field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus. In the analysis, the texture of crystal grains and the constituent atom sharing lattice point configuration of the conventional AlYO layer were analyzed. The texture of the crystal grains of the conventional AlYO layer is shown in FIGS. 9A and 9B. As shown in FIGS. 9A and 9B, the texture of the crystal grains of the conventional AlYO layer is made of pyramidal-shaped crystal grains with a polygonal elongated shape stretched to the layer thickness direction. The outer surface of the conventional AlYO layer has protuberances and recesses along with the pyramidal shape of the crystal grains. Because of these, the abrasion resistance of the conventional AlYO layer is inferior compared to that of the reformed AlYO layer. In terms of the constituent atom sharing lattice point configuration, the ratio of surface area occupied by the pyramidal-shaped crystal grains, which have a polygonal elongated shape stretched to the layer thickness direction and contain a Σ3 coincidence site lattice interface within, to the surface area occupied by crystal grains, which consist the conventional AlYO layer and have the convexoconcave polygonal elongated shape stretched to the layer thickness direction, is 40% or less. Therefore, the strength within the crystal grains is not improved as in the reformed AlYO layer.
Accordingly, the conventional coated tool 2 in which the upper layer of the hard coating layer is composed of the conventional AlYO layer cannot prevent occurrence of chipping, fracture, spalling, or the like and is inferior in tool performance, in high-speed intermittent cutting work accompanied by high heat generation and repeated intermittent impact loading subjected on the cutting edge. In addition, uneven wear or the like occurs in the conventional coated tool 2.
In the coated tool of the present invention, after the reformed AlYO layer of the upper layer is formed, polishing processing using a grind stone or polishing processing using wet blasting can be performed on the surface of the upper layer, so that the surface roughness of the reformed AlYO layer can be further adjusted. For example, the occurrence of welding to the surface-coated tool during cutting can be suppressed by adjusting the surface roughness of the reformed AlYO layer to Ra 0.05 to 0.3 μm.
The surface roughness Ra in the present invention means the value of arithmetic mean roughness Ra defined by JIS B0601 (1994), and the measuring method thereof is not particularly limited.
Third Embodiment
A third embodiment of the present invention includes the following aspects.
(a) The conventional α-type Al2O3 layer in the conventional coated tool 1 is vapor-deposited, for example, using a normal chemical vapor deposition apparatus under the following conditions.
Composition of reaction gas: in vol. %, 6 to 10% of AlCl3, 10 to 15% of CO2, 3 to 5% of HCl, 0.05 to 0.2% of H2S, and H2 as balance
Reaction atmosphere temperature: 1020 to 1050° C.
Reaction atmosphere pressure: 3 to 5 kPa
On the other hand, the α-type Al2O3 layer in the present invention corresponding to the intermediate layer is formed, using a normal chemical vapor deposition apparatus under the following low-temperature conditions.
Composition of reaction gas: in vol. %, 3 to 10% of AlCl3, 0.5 to 3% of CO2, 0.01 to 0.3% of C2H4, and H2 as balance
Reaction atmosphere temperature: 750 to 900° C.
Reaction atmosphere pressure: 3 to 13 kPa
In this case, it is desirable that the Al2O3 neclear is an Al2O3 neclear thin film having a mean layer thickness of 20 to 200 nm. Subsequently, the Al2O3 neclear thin film is heat treated in a condition where the reaction atmosphere is substituted to a hydrogen atmosphere of pressure: 3 to 13 kPa, and the reaction atmosphere temperature is increased to 1100 to 1200° C. Then, the α-type Al2O3 layer, which serves as the hard coating layer, is formed under a conventional condition. The resulting reformed α-type Al2O3 layer (hereinafter referred to as a reformed α-type Al2O3 layer), which is vapor-deposited on the heat-treated neclear thin film, is analyzed with a field emission type scanning electron microscope as schematically represented in FIGS. 1A and 1B. In the analysis, individual crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface, are irradiated by an electron beam. Then, a tilt angle, which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. The measured tilt angles belonging to a range of 0 to 45° are sectioned every pitch of 0.25°, and the frequencies existing in each section are collected, being represented by a tilt angle frequency distribution graph. As shown in FIG. 10, as an example, a sharp highest peak appears at a specific section of the tilt angle. Based on trial findings, it was found that the highest peak falls inside a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph, when the atmosphere pressure of the chemical vapor deposition apparatus is kept between 5 and 8 KPa. The fact that the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies, means that ratio of the (0001) plane orientation is high. This reformed α-type Al2O3 layer whose highest peak of the tilt angle division appears within the range of 0 to 10° in the tilt-angle frequency distribution graph has superior high-temperature strength compared to the conventional α-type Al2O3 layer of the conventional coated cutting tool 1. This reformed α-type Al2O3 also has excellent high-temperature hardness and heat resistance, as the conventional α-type Al2O3 layer of the conventional coated cutting tool 1 does.
(b) Forming the hard coating layer is further proceeded on the reformed α-type Al2O3 layer described above, as the intermediate layer. A Zr-containing aluminum oxide layer having an α-type crystal structure in a chemically vapor-deposited state is vapor-deposited on the intermediate layer as the upper layer. In this way, the lower layer composed of the Ti compound layer, the intermediate layer composed of the reformed α-type Al2O3 layer, and the upper layer composed of the Zr-containing aluminum oxide layer are vapor-deposited as a hard coating layer on the surface of the tool substrate. The coated cutting tool with the configuration described above has even more superior high-temperature strength and surface properties. The coated cutting tool exerts excellent chipping resistance and abrasion resistance, even under high-speed intermittent cutting conditions where high heat is generated and the cutting edges are subjected to intermittent impact loading repeatedly.
(c) The Zr-containing aluminum oxide layer can be formed on the reformed α-type Al2O3 layer, under the following conditions. First, as a first step, first-step vapor deposition is performed for 1 hour under the following conditions (i) to (iii).
(i) Composition of reaction gas (vol. %):
1 to 5% of AlCl3 
0.05 to 0.1% of ZrCl4 
2 to 6% of CO2 
1 to 5% of HCl
0.25 to 0.75% of H2S
H2 as balance
(ii) Reaction atmosphere temperature: 1020 to 1050° C.
(iii) Reaction atmosphere pressure: 3 to 5 kPa
Next, as a second step, vapor deposition is performed under the following conditions (i) to (iii).
(i) Composition of reaction gas (vol. %):
6 to 10% of AlCl3 
0.6 to 1.2% of ZrCl4 
4 to 8% of CO2 
3 to 5% of HCl
0.25 to 0.6% of H2S
H2 as balance
(ii) Reaction atmosphere temperature: 920 to 1000° C.
(iii) Reaction atmosphere pressure: 6 to 10 kPa
By following the steps described above, a Zr-containing aluminum oxide layer (hereinafter referred to as a reformed AlZrO layer), which has an α-type crystal structure in a chemically vapor-deposited state, can be formed. The reformed AlZrO layer has a mean layer thickness of 2 to 15 μm, and the content ratio of the Zr component to the total amount of the Al component is 0.002 to 0.01 (as atomic ratio).
(d) When the texture of the reformed AlZrO layer is observed by the emission type scanning electron microscope, a flat-plate polygonal shape of a large-sized grain can be seen within a plane perpendicular to the layer thickness direction as shown in FIG. 11A. When the reformed AlZrO layer is observed in the plane parallel to the layer thickness direction as shown in FIG. 11B, it can be seen that the outer surface of the reformed AlZrO layer is substantially flat, and the reformed AlZrO layer has a texture made of the grains whose shapes are elongated in the layer thickness direction (hereinafter, the shape of the crystal grain described above is referred a flat-plate polygonal vertically elongated shape).
When the vapor deposition of the reformed AlZrO layer is performed under further limited conditions, the texture exemplified in FIG. 11C is formed. In the further limited condition, the volume % of H2S is set 0.50 to 0.75, and the reaction atmosphere temperature 1020 to 1030° C. in the first step vapor deposition, and the volume % of ZrCl4 is set 0.6 to 0.9, the volume % of H2S 0.25 to 0.4, and the reaction atmosphere temperature 960 to 980° C. in the second step vapor deposition, for example. As shown in FIG. 11C, when the reformed AlZrO layer is formed by the further limited condition, and is seen within the plane perpendicular to the layer thickness direction, the large-sized grains with a flat hexagonal shape are observed. When the reformed AlZrO layer is seen within the plane parallel to the layer thickness direction, it can be seen that the outer surface of the reformed AlZrO layer is substantially flat, as shown in FIG. 11B. In addition, the grains that have the elongated shape within the plane parallel to the layer thickness direction, account for 35% or more in area ratio, in the whole surface area perpendicular to the thickness direction of the layer.
(e) As in the reformed α-type Al2O3 layer, the reformed AlZrO layer is analyzed with the field-emission-type scanning electron microscope. In the analysis, individual crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface, are irradiated by an electron beam. Then, a tilt angle, which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. The measured tilt angles belonging to a range of 0 to 45° are sectioned every pitch of 0.25°, and the frequencies existing in each section are collected, being represented by a tilt angle frequency distribution graph. In the tilt-angle frequency distribution graph, a sharp highest peak appears at a specific section of the tilt angle, and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies. This means that the reformed AlZrO layer with high (0001) plane orientation ratio is formed. The (0001) plane orientation ratio of the reformed AlZrO layer is higher than that of the conventional AlZrO layer of the conventional coated cutting tool, resulting even more superior high-temperature strength of the reformed AlZrO layer.
(f) In addition, the reformed AlZrO layer is analyzed by the field-emission-type scanning electron microscope and an electronic backscattering diffraction image apparatus. In the analysis, individual crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface, are irradiated by an electron beam. Then, a tilt angle, which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. Based on the measurement results, a crystallographic orientation relationship between the adjacent crystal lattices is calculated, and a distribution of lattice points (constituent atom sharing lattice points) is calculated. The constituent atom sharing lattice point is a lattice point that has a constituent atom shared by two crystal lattices forming the grain boundary at the grain boundary. A constituent atom sharing lattice point type in which N lattice points not sharing the constituent atom exist between the constituent atom sharing lattice points (where N is an even number of 2 or more in view of a crystal structure of corundum type hexagonal close packed crystal but does not include even numbers of 4, 8, 14, 24, and 26 when the upper limit of N is set to 28 in view of distribution frequency) is expressed as ΣN+1. When the reformed AlZrO layer is observed by the field-emission-type scanning electron microscope, it is seen that the reformed AlZrO layer includes the crystal grains with the flat-plate polygonal vertically elongated shape, as shown in FIG. 12. Among the crystal grains with the flat-plate polygonal vertically elongated shape, 60% or more of them are divided by at least one of crystal lattice interface with the constituent atom sharing lattice point type expressed by Σ3 (hereinafter referred as a Σ3 coincidence site lattice interface) inside.
(h) As described above, the upper layer composed of the reformed AlZrO layer has a high (0001) plane orientation rate, and a crystal plane at the surface thereof has the same orientation as a crystal plane (for example, (0001)) within the plane perpendicular to the layer thickness direction of this layer. Thus, outer surface of the upper layer is formed in the shape of a flat plate which is substantially flat (as seen within the plane parallel to the layer thickness direction), and shows excellent chipping resistance due to the surface properties thereof. Furthermore, the strength within the crystal grains is increased since the Σ3 coincidence site lattice interfaces are present inside the grains with the flat-plate polygonal vertically elongated shape. Therefore, the reformed AlZrO layer has excellent high-temperature hardness and high-temperature strength and shows excellent chipping resistance, compared to the conventional AlZrO layer.
(i) Accordingly, as the hard coating layer, the coated tool of the present invention includes the reformed α-type Al2O3 layer having a high (0001) plane orientation rate and having excellent high-temperature strength as the intermediate layer. Furthermore, the coated tool of the present invention includes the reformed AlZrO layer having excellent high-temperature hardness, high-temperature strength, and surface properties as the upper layer. The coated tool of the present invention has superior high-temperature hardness, heat resistance, and high-temperature strength as compared to the conventional coated tools 1 and 2. As a result, it exhibits excellent chipping resistance and abrasion resistance for a long-term use, even when the coated tool is used for high-speed intermittent cutting accompanied by high heat generation, and intermittent impact loading acts repeatedly on the cutting edge, against a high hardness steel. The present invention has been made on the basis of the above knowledge, and the surface-coated cutting tool of the present invention includes the following configurations.
(1) Provided is a surface-coated cutting tool formed by vapor-depositing, on the surface of a tool substrate made of tungsten carbide-based cemented carbide or titanium carbonitride-based cermet, a hard coating layer including the following (a) to (c).
(a) The lower layer is a Ti compound layer composed of one or more of a titanium carbide layer, a titanium nitride layer, a titanium carbonitride layer, a titanium carboxide layer, and a titanium oxycarbonitride layer, all of which are formed by chemical vapor deposition, and having a total mean layer thickness of 3 to 20 μm.
(b) The intermediate layer is an aluminum oxide layer having a mean layer thickness of 1 to 5 μm and having an α-type crystal structure in a chemically vapor-deposited state.
(c) The upper layer is a Zr-containing aluminum oxide layer having a mean layer thickness of 2 to 15 μm and having an α-type crystal structure in a chemically vapor-deposited state.
The intermediate layer (b) has properties indicated by a tilt-angle frequency distribution graph in which the highest peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph. The tilt-angle frequency distribution graph is obtained by utilizing a field-emission-type scanning electron microscope. Electron beams are irradiated to individual crystal grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected.
When the texture of the upper layer of the above (c) is observed by the emission type scanning electron microscope, the upper layer is a Zr-containing aluminum oxide layer having a texture composed of crystal grains which have a flat-plate polygonal shape within the plane perpendicular to the layer thickness direction and have an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction.
The upper layer (c) has properties indicated by a tilt-angle frequency distribution graph in which the highest peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies in the tilt-angle frequency distribution graph. The tilt-angle frequency distribution graph is obtained by utilizing a field-emission-type scanning electron microscope. Electron beams are irradiated to individual crystal grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected.
Moreover, the upper layer (c) is a Zr-containing aluminum oxide layer consisted of crystal grains, 60% or more of the grains being divided within each grain by at least one or more crystal lattice interfaces with a constituent atom sharing lattice point type expressed by Σ3. The constituent atom sharing lattice point type is expressed as ΣN+1, where “N” represents a number of lattice points (N) without a shared constituent atom between the constituent atom sharing lattice points. The constituent atom sharing lattice point type is even numbers more than 2 between crystal grains having a corundum type hexagonal close-packed structure. If the maximum number of N is set to 28 in view of distribution frequency, even numbers 4, 8, 14, 24, and 26 are excluded from the option for crystal grains having hexagonal close-packed structure. To obtain data related to the constituent atom sharing lattice point type, first, electron beams are irradiated to individual crystal grains within the measurement area on the polished surface with field-emission-type scanning electron microscope and an electron backscatter diffraction imaging device. Then, angles formed by normal lines of crystal lattice faces with hexagonal crystal lattices and the normal line to the polished surface are measured. Then, based on the measurement, a crystallographic orientation relationship between the adjacent crystal lattices is calculated. Then, a distribution of lattice points (constituent atom sharing lattice points) in which constituent atoms of a crystal lattice interface sharing one constituent atom between the crystal lattices is calculated. Then, finally, “N” representing a number of lattice points (N) without a shared constituent atom between the constituent atom sharing lattice points, is obtained.
(2) When the texture of the upper layer (c) of the surface-coated cutting tool described above (as (1)) is observed by the emission type scanning electron microscope, crystal grains corresponding to 35% or more of the whole surface area perpendicular to the layer thickness direction, has a flat-plate polygonal shape within the plane perpendicular to the layer thickness direction and an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction.
(3) The surface roughness (Ra) of the upper layer (c) in the cutting tool described above (as (1) and (2)) ranges from 0.05 to 0.3 μm.
The configuration of the hard coating layer of the coated tool of this embodiment will be described below in more detail.
(a) Ti Compound Layer (Lower Layer 12A)
The lower layer 12A is a Ti compound layer composed of one more of titanium carbide (hereinafter, referred to as TiC) layer, a titanium nitride (hereinafter, referred to as TiN) layer, a titanium carbonitride (hereinafter, referred to as TiCN) layer, a titanium carboxide (hereinafter, referred to as TiCO) layer, and a titanium oxycarbonitride (hereinafter, referred to as TiCNO) layer. The lower layer 12A is basically present as a lower layer of the reformed α-type Al2O3 layer which is the intermediate layer. It has superior toughness and abrasion resistance, contributing to improve high-temperature strength of the hard coating layer. In addition, the lower layer 12A adheres tightly to both the tool substrate and the reformed α-type Al2O3 layer, contributing an adhesive property of the hard coating layer to the tool substrate. If the total mean layer thickness is less than 3 μm, the improvements described above cannot be sufficiently obtained. On the other hand, if the total mean layer thickness exceeds 20 μm, thermal plastic deformation occurs easily, particularly when the cutting tool is used under high-speed intermittent cutting conditions where an intermittent and blasting high loads are subjected on the cutting edge. Thermal plastic deformation causes uneven wear of the cutting tool. Accordingly, the total mean layer thickness is set to 3 to 20 μm.
(b) Reformed α-Type Al2O3 Layer (Intermediate Layer 12B)
In order to form the reformed α-type Al2O3 layer, which constitutes the intermediate layer 12B, as already described, an Al2O3 neclear is formed on the surface of the Ti compound layer, which is the lower layer, under the following low-temperature conditions.
A normal chemical vapor deposition apparatus is used. Composition of reaction gas includes 3 to 10% of AlCl3, 0.5 to 3% of CO2, 0.01 to 0.3% of C2H4 in vol. %, and H2 as balance. Reaction atmosphere temperature is set at 750 to 900° C. Reaction atmosphere pressure is set at 3 to 13 kPa.
It is desirable that the Al2O3 neclear is an Al2O3 neclear thin film having a mean layer thickness of 20 to 200 nm. After the formation of the Al2O3 neclear, the reaction atmosphere is substituted with a hydrogen atmosphere with pressure of 3 to 13 kPa. Then, temperature of the reaction atmosphere is increased to 1100 to 1200° C. and the Al2O3 neclear thin film is heat treated. An α-type Al2O3 layer, which serves as the hard coating layer, is formed under normal conditions. By following steps described above, an α-type Al2O3 layer is vapor deposited on the heat-treated Al2O3 neclear thin film, resulting formation of the intermediate layer.
The reformed α-type Al2O3 layer vapor deposited on the lower layer 12A is analyzed by the field-emission-type scanning electron microscope, as shown in FIGS. 1A and 1B. Electron beams are irradiated to the individual grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected and a tilt-angle frequency distribution graph is plotted. In the tilt-angle frequency distribution graph, the sharp highest peak exists in a tilt angle division ranging 0 to 10°, as shown in FIG. 10.
The highest peak position of the measured tilt angles in the tilt angle frequency distribution graph of the reformed α-type Al2O3 layer can be changed by performing heat-treatment after the formation of the Al2O3 neclear (thin film) with a predetermined layer thickness. In addition, the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies in the tilt-angle frequency distribution graph (which means the (0001) plane orientation rate is high). Accordingly, whenever the thickness of the Al2O3 neclear (thin film) becomes too thin or too thick, the position of the highest peak of the measured tilt angles moves out of the range of 0 to 10°. In addition, the total sum of frequencies existing in the range of 0 to 10° becomes less than a ratio of 60% of the total frequencies in the tilt-angle frequency distribution graph. As a result, excellent high-temperature strength cannot be obtained.
The reformed α-type Al2O3 layer has superior high-temperature strength in addition to the excellent high-temperature hardness and heat resistance of the α-type Al2O3 layer of the conventional coated tool. Furthermore, by configuring the reformed α-type Al2O3 layer as an intermediate layer with a high (0001) plane orientation rate, the (0001) plane orientation rate of the reformed AlZrO layer vapor-deposited thereon can be increased. As a result, the surface properties of an upper layer composed of the reformed AlZrO layer can be improved, and high-temperature strength can be improved.
If the mean layer thickness of the intermediate layer composed of the reformed α-type Al2O3 layer is less than 1 μm, the hard coating layer cannot be provided with the above characteristics of the reformed α-type Al2O3 layer. On the other hand, if the mean layer thickness exceeds 5 μm, high temperature generated during cutting and an intermittent and blasting high load subjected to the cutting edge leads to a higher rate of occurrence of thermal plastic deformation, which causes uneven wear of the cutting tool. As a result, the cutting tool is abrased faster. Thus, the mean layer thickness is set to 1 to 5 μm.
(c) Reformed AlZrO Layer (Upper Layer 12C)
As for the upper layer 12C composed of the reformed AlZrO layer chemically vapor-deposited on the intermediate layer 12B, an Al component which is a constituent component of the upper layer improves the high-temperature hardness and heat resistance of the layer. An extremely small amount (Zr/(Al+Zr) is 0.002 to 0.01 (as an atomic ratio) in a ratio accounted for in the total amount with Al) of Zr component contained in the upper layer improves the crystal grain boundary strength of the reformed AlZrO layer, and contributes to improving the high-temperature strength of the upper layer. If the content ratio of the Zr component in the upper layer is less than 0.002, the above functions cannot be obtained. On the other hand, if the content ratio of the Zr component exceeds 0.01, the grain boundary strength deteriorates as ZrO2 grains precipitate in the layer. Therefore, it is desirable that the content ratio of the Zr component (the value of the ratio of Zr/(Al+Zr)) in the upper layer accounted for in the total amount with the Al component is 0.002 to 0.01 (as an atomic ratio).
The reformed AlZrO layer can be vapor-deposited by adjusting chemical vapor deposition conditions of the composition of a reaction gas during vapor deposition, the reaction atmosphere temperature, and the reaction atmosphere pressure as follows, for example.
First, the first-step vapor deposition is performed for 1 hour under the following conditions:
(i) Composition of reaction gas (vol. %):
1 to 5% of AlCl3,
0.05 to 0.1% of ZrCl4,
2 to 6% of CO2,
1 to 5% of HCl,
0.25 to 0.75% of H2S, and
H2 as balance,
(ii) Reaction atmosphere temperature: 1020 to 1050° C., and
(iii) Reaction atmosphere pressure: 3 to 5 kPa,
Second, the second-step vapor deposition is performed under the following conditions.
(i) Composition of reaction gas (vol. %):
6 to 10% of AlCl3,
0.6 to 1.2% of ZrCl4,
4 to 8% of CO2,
3 to 5% of HCl,
0.25 to 0.6% of H2S, and
H2 as balance,
(ii) Reaction atmosphere temperature: 920 to 1000° C., and
(iii) Reaction atmosphere pressure: 6 to 10 kPa.
When a vapor deposition layer with a mean layer thickness of 1 to 15 μm is formed as a film, by performing the first-step and the second-step vapor deposition in the conditions described above, the reformed AlZrO layer whose ratio of Zr/(Al+Zr) is 0.002 to 0.01 in atomic ratio, is formed.
When the reformed AlZrO layer is observed by the emission type scanning electron microscope, the textures shown in FIGS. 11A and 11B are observed. In FIG. 11A, the reformed AlZrO layer is viewed within the plane perpendicular to the layer thickness direction. In FIG. 11A, the texture containing large crystal grains with a flat-plate polygonal shape is formed. In FIG. 11B, the reformed AlZrO layer is viewed within the plane parallel to the layer thickness direction. In FIG. 11B, the outer surface of the reformed AlZrO layer is substantially flat. Also, the texture containing crystal grains with elongated shape is formed (Referred as a flat-plate polygonal elongated shape crystal grain).
As for the reformed AlZrO layer, similarly to the reformed α-type Al2O3 layer, which constitutes the intermediate layer, the tilt angle of the normal line to the (0001) plane to the normal line to a polished surface is measured and a tilt angle frequency graph is plotted. In the tilt angle frequency graph of the reformed AlZrO layer, a peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies in the tilt-angle frequency distribution graph. These results indicate that the (0001) plane orientation rate of the reformed AlZrO layer, which constitutes the upper layer, is high.
That is, as for the reformed AlZrO layer, since the (0001) plane orientation rate of the reformed α-type Al2O3 layer, which is the intermediate layer, is 45% or more, the reformed AlZrO layer is also formed as a layer having a high (0001) plane orientation rate (the (0001) plane orientation rate is 60% or more).
When the upper layer is viewed within the plane parallel to the layer thickness direction, the outer surface of the upper layer is formed in the shape of a substantially flat plate. Thus, the upper layer has a excellent surface property. Consequently, the upper layer shows superior chipping resistance as compared to the conventional AlZrO layer.
When the vapor deposition of the reformed AlZrO layer is performed under further limited conditions (for example, the conditions where a volume percentage of H2S in the reaction gas are 0.50 to 0.75 and the reaction atmosphere temperature is set to 1020 to 1030° C. in the first-step vapor deposition, and volume percentages of ZrCl4 and H2S in the reaction gas are 0.6 to 0.9 vol. % and 0.25 to 0.4, respectively, and the reaction atmosphere temperature is set to 960 to 980° C., in the second-step vapor deposition), the texture shown in FIG. 11C is formed. In the texture, when it is viewed within the plane perpendicular to the layer thickness direction, there are large-sized crystal grains with a flat-plate hexagonal shape. When the texture is viewed within the plane parallel to the layer thickness direction, the outer surface of the upper layer is substantially flat and the crystal grains have an elongated shape stretched in the layer thickness direction, as shown in FIG. 11B. The ratio of the surface area occupied by the crystal grains having the flat-plate hexagonal elongated shape, to the whole surface area of the plane parallel to the layer thickness direction, accounts for 35% or more, in the upper layer formed in the further limited conditions.
The reformed AlZrO layer is analyzed with a field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus. In the analysis, electron beams are irradiated to individual crystal grains within the measurement range of the polished surface. Then, angles between the normal line to each of crystal lattice planes with a hexagonal crystal lattice and the normal line to the polished surface are measured. From the measurement results, the crystal orientation relationship between adjacent crystal lattices is calculated. Then, distribution of lattice points (constituent atom sharing lattice points) is calculated. The constituent atom sharing lattice point is a lattice point that has a constituent atom shared by two crystal lattices forming the grain boundary at the grain boundary. A constituent atom sharing lattice point configuration is expressed by ΣN+1, where the number represented by N is the number of lattice points that have no constituent atom shared at the grain boundary between two constituent atom sharing lattice points with constituent atoms. The constituent atom sharing lattice point type is even numbers more than 2 between crystal grains having a corundum type hexagonal close-packed structure. If the maximum number of N is set to 28 in view of distribution frequency, even numbers 4, 8, 14, 24, and 26 are excluded from the option for crystal grains having hexagonal close-packed structure. As shown in FIG. 12, the crystal grains of the reformed AlZrO layer are divided by at least one of Σ3 coincidence site lattice interface within each crystal grain. The ratio of surface area occupied by the crystal grains that have the flat-plate polygonal elongated shape and divided by at least one of Σ3 coincidence site lattice interface, to the surface area occupied by crystal grains with the flat-plate polygonal elongated shape (including the flat-plate hexagonal elongated shape), is 60% or more.
The strength within the crystal grains of the reformed AlZrO layer is increased due to the presence of the Σ3 coincidence site lattice interface in the crystal grains with the flat-plate polygonal (including hexagonal) elongated shape. As a result, cracking of the reformed AlZrO layer is suppressed during high-speed intermittent cutting work where high load is subjected to the reformed AlZrO layer, against a high hardness steel. Even if the cracking occurred, growth and spreading of the cracking would be prevented. Therefore, chipping resistance, fracture resistance, and spalling resistance are improved in the cutting tool having the reformed AlZrO layer.
Accordingly, the upper layer of the present invention, which has a high (0001) plane orientation rate, has flat surface properties, and is composed of the reformed AlZrO layer in which the Σ3 coincidence site lattice interfaces are present with in the flat-plate polygonal (including flat hexagonal) elongated crystal grains, exhibits excellent chipping resistance and abrasion resistance for a prolonged period of time without causing chipping, fracture, spalling, or the like and also without causing thermal plastic deformation, uneven wear, or the like, even in high-speed intermittent cutting work against a high hardness steel accompanied by high heat generation and intermittent and blasting high loads subjected on the cutting edge.
If the layer thickness of the upper layer composed of the reformed AlZrO layer is less than 2 μm, the excellent characteristics of the upper layer cannot be sufficiently exhibited. On the other hand, if the layer thickness of the upper layer exceeds 15 μm, thermal plastic deformation, which causes uneven wear, easily occurs. In addition, a rate of occurrence of chipping is also increased. Therefore, the mean layer thickness of the upper layer is set to 2 to 15 μm.
As a comparison, the conventional AlZrO layer (the layer described in the PTL 3), was analyzed by the field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus. In the analysis, the texture of crystal grains and the constituent atom sharing lattice point configuration of the conventional AlZrO layer were analyzed. The texture of the crystal grains of the conventional AlZrO layer is shown in FIGS. 13A and 13B. As shown in FIGS. 13A and 13B, the texture of the crystal grains of the conventional AlZrO layer is made of pyramidal-shaped crystal grains with a polygonal elongated shape stretched to the layer thickness direction. The outer surface of the conventional AlZrO layer has protuberances and recesses along with the pyramidal shape of the crystal grains. Because of these, the abrasion resistance of the conventional AlZrO layer is inferior compared to that of the reformed AlZrO layer. In terms of the constituent atom sharing lattice point configuration, the ratio of surface area occupied by the pyramidal-shaped crystal grains, which have a polygonal elongated shape stretched to the layer thickness direction and contain a Σ3 coincidence site lattice interface within, to the surface area occupied by crystal grains, which consist the conventional AlZrO layer and have the convexoconcave polygonal elongated shape stretched to the layer thickness direction, is 40% or less. Therefore, the strength within the crystal grains is not improved as in the reformed AlZrO layer.
Accordingly, the conventional coated tool in which the upper layer of the hard coating layer is composed of the conventional AlZrO layer cannot prevent occurrence of chipping, fracture, spalling, or the like, in high-speed intermittent cutting work accompanied by high heat generation and intermittent impact loading subjected on the cutting edge. Thus, thermal deformation and uneven wear occur easily in the conventional coated tool with the conventional AlZrO layer. Therefore the conventional cutting tool with the conventional AlZrO layer is inferior compared to the one with reformed AlZrO layer, in tool performance.
In the coated tool of the present invention, after the reformed AlZrO layer of the upper layer is formed, polishing processing using a grind stone or polishing processing using wet blasting can be performed on the surface of the upper layer, so that the surface roughness of the reformed AlZrO layer can be further adjusted. For example, the occurrence of welding to the surface-coated tool during cutting can be suppressed by adjusting the surface roughness of the reformed AlZrO layer to Ra 0.05 to 0.3 μm.
The surface roughness Ra in the present invention means the value of arithmetic mean roughness Ra defined by JIS B0601 (1994), and the measuring method thereof is not particularly limited.
Fourth Embodiment
(a) As for the Cr-containing aluminum oxide layer (hereinafter referred to as a conventional AlTiO layer) in the above conventional coated tool, a Cr-containing Al2O3 neclear is formed on the surface of a Ti compound layer which is a lower layer, for example, using the normal chemical vapor deposition apparatus under the following conditions:
Composition of reaction gas: in vol. %, 0.05 to 0.2% of H2S
2.3 to 4% of AlCl3,
0.04 to 0.26% of CrCl3,
6 to 8% of CO2,
1.5 to 3% of HCl,
0.05 to 0.2% of H2S, and
H2 as balance,
Reaction atmosphere temperature: 750 to 900° C., and
Reaction atmosphere pressure: 6 to 10 kPa.
It is desirable that the Cr-containing Al2O3 neclear is a neclear thin film with a mean layer thickness of 20 to 200 nm (0.02 to 0.2 μm), and the content ratio of Cr accounted for in the total amount with Al (Cr/(Al+Cr)) satisfies 0.01 to 0.1 (as an atomic ratio). Subsequently, the Cr-containing Al2O3 neclear thin film is heat-treated under conditions where the heating atmosphere temperature is increased to 1100 to 1200° C. in a hydrogen atmosphere of pressure: 6 to 10 kPa.
Next, under the following conditions:
Composition of reaction gas: in vol. %,
2.3 to 4% of AlCl3,
0.04 to 0.26% of CrCl3,
6 to 8% of CO2,
1.5 to 3% of HCl,
0.05 to 0.2% of H2S, and
H2 as balance,
Reaction atmosphere temperature: 1020 to 1050° C., and
Reaction atmosphere pressure: 6 to 10 kPa,
the conventional Cr-containing Al2O3 layer is vapor-deposited, similarly, by forming a Cr-containing Al2O3 layer (it is desirable that the content ratio (Cr/(Al+Cr)) of Cr accounted for in the total amount with Al satisfies 0.01 to 0.1 in atomic ratio).
The conventional Cr-containing Al2O3 has a properties indicated by a tilt-angle frequency distribution graph in which the highest peak exist in a tilt angle division ranging 0 to 10° and the sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle distribution graph as shown in FIG. 14 as an example (this sum of the frequencies and the height of the highest peak are in a proportional relation), the tilt angle frequency distribution graph being obtained by utilizing a field-emission-type scanning electron microscope as shown in schematic explanatory views in FIGS. 1A and 1B, irradiating electron beams to individual crystal grains with a hexagonal crystal lattice existing in a measurement range of a polished surface of the tool substrate, measuring a tilt angle formed by the normal line to the polished surface and the normal line to (0001) plane as a crystal plane of the crystal grains, sectioning the measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25°, and collecting the frequencies existing in each section.
The conventional Cr-containing Al2O3 layer has excellent high-temperature hardness, heat resistance, and high-temperature strength and is excellent in mechanical thermal shock resistance. Therefore, when this layer is vapor-deposited as the upper layer of the hard coated layer, the layer exhibits excellent chipping resistance even in high-speed intermittent cutting work accompanied by mechanical thermal shock.
However, as described also in the section “Technical Problem”, when the conventional coated tool in which the conventional Cr-containing Al2O3 is formed as an upper layer of a hard coating layer is used, for example, for high-speed heavy cutting work of difficult-to-cut materials, such as stainless steel or ductile cast iron, that is, high-speed heavy cutting work accompanied by high heat generation, and high load of a high feed rate and a high depth of cut acts on the cutting edge, the high-temperature strength and surface properties of the hard coating layer cannot be satisfied. Therefore, there is a problem in that chipping (fine chipping) easily occurs at the cutting edge.
Thus, by vapor-depositing, as an intermediate layer, an aluminum oxide layer (hereinafter referred to as a reformed Al2O3 layer) having an α-type crystal structure with a high (0001) plane orientation rate in which, in a tilt angle frequency distribution graph, the highest peak appears within a range of 0 to 10 degrees, and the total sum of the frequencies present within a range of 0 to 10 degrees accounts for the ratio of 45% or more of the total frequency in the tilt angle frequency distribution graph, on the lower layer of the conventional coated tool, and by vapor-depositing, as an upper layer, a Cr-containing Al2O3 layer (hereinafter referred to as a reformed Cr-containing Al2O3 layer) with increased crystal grain boundary strength, on this reformed Al2O3 layer, thereby forming the structure of a hard coating layer as the three-layer structure of the lower layer, intermediate layer, and upper layer, the present inventors have found out that a coated tool, capable of forming a hard coating layer having excellent high-temperature strength and surface properties and including a hard coating layer having excellent high-temperature strength and surface properties, exhibits excellent tool characteristics for a long-term use without causing chipping (fine chipping) at the cutting edge even when being used high-speed heavy cutting work of difficult-to-cut materials, such as stainless steel and ductile cast iron.
This invention has been made on the basis of the above knowledge, and provides a surface-coated cutting tool formed by vapor-depositing, (1) on the surface of a tool substrate made of tungsten carbide-based cemented carbide or titanium carbonitride-based cermet, a hard coating layer including the following layers (a) to (c):
(a) A lower layer is a Ti compound layer composed of one or more a titanium carbide layer, a titanium nitride layer, a titanium carbonitride layer, a titanium carboxide layer, and a titanium oxycarbonitride layer, all of which are formed by chemical vapor deposition, and having a total mean layer thickness of 3 to 20 μm,
(b) an intermediate layer is an aluminum oxide layer having a mean layer thickness of 1 to 5 μm, and having an α-type crystal structure in a chemically vapor-deposited state, and
(c) an upper layer is a Cr-containing aluminum oxide layer having a mean layer thickness of 2 to 15 μm, and having an α-type crystal structure in a chemically vapor-deposited state.
(d) As for the intermediate layer of the above (b), when the field-emission-type scanning electron microscope is used to individually irradiate crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface of the tool substrate with an electron beam, and to measure the tilt angle of the normal line to the (0001) plane, which is a crystal plane of each crystal grain, to the normal line to the polished surface, and the measured tilt angles which are within a range of 0 to 45 degrees among the measured tilt angles are divided at every pitch of 0.25 degrees, and are expressed by a tilt angle frequency distribution graph obtained by summing the frequencies present within the respective divisions, the intermediate layer shows a tilt angle frequency distribution graph in which the highest peak is present in the tilt angle division within a range of 0 to 10 degrees, and the total sum of the frequencies present within a range of 0 to 10 degrees accounts for the ratio of 45% or more of the total frequency in the tilt angle frequency distribution graph.
(e) When the texture of the upper layer of the above (c) the upper layer is observed by a field emission type scanning electron microscope, the upper layer is a Cr-containing aluminum layer having a texture composed of crystal grains which have a flat-plate polygonal shape within a plane perpendicular to a layer thickness direction, and an elongated shape in the layer thickness direction within a plane parallel to the layer thickness direction. When the field-emission-type scanning electron microscope is used to individually irradiate crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface of the tool substrate with an electron beam, and to measure the tilt angle which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. The measured tilt angles belonging to a range of 0 to 45° are sectioned every pitch of 0.25°, and the frequencies existing in each section are collected, being represented by a tilt angle frequency distribution graph. In the tilt-angle frequency distribution graph, a sharp highest peak appears at a specific section of the tilt angle, and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies. Moreover, as for the upper layer of the above (c), when the field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus are used to individually irradiate crystal grains present within the measurement range of a polished surface with an electron beam, and to measure an angle at which the normal line to each of crystal lattice planes composed of a hexagonal crystal lattice crosses the normal line to the surface of a base; from these measurement results, the crystal orientation relationship between adjacent crystal lattices is calculated. Then the distribution of lattice points (constituent atom sharing lattice points) where respective constituent atoms which constitute a crystal lattice interface sharing one constituent atom between the crystal lattices is calculated. A constituent atom sharing lattice point type in which N lattice points not sharing the constituent atom exist between the constituent atom sharing lattice points (where N is an even number of 2 or more in view of a crystal structure of corundum type hexagonal close packed crystal but does not include even numbers of 4, 8, 14, 24, and 26 when the upper limit of N is set to 28 in view of distribution frequency) is expressed as ΣN+1. The upper layer is a Cr-containing aluminum oxide layer in which, among the crystal grains with the flat-plate polygonal vertically elongated shape, 60% or more of them are divided by at least one of crystal lattice interface with the constituent atom sharing lattice point type expressed by Σ3 (hereinafter referred as a Σ3 coincidence site lattice interface) inside.
(2) In the surface-coated cutting tool of this embodiment described in the above (1), when the texture of the upper layer of the above (c) is observed by the emission type scanning electron microscope, the crystal grains, which have a flat hexagonal shape within the plane perpendicular to the layer thickness direction and have an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction, may account for the area ratio of 35% or more of the whole within the plane perpendicular to the layer thickness direction.
(3) The surface-coated cutting tool described in either the above (1) or (2) in which the upper layer of the above (c) has a surface roughness (Ra) within a range of 0.05 to 0.3 μm. The constituent layers of the hard coating layer of the coated tool of this invention will be described below in more detail.
(a) Ti Compound Layer (Lower Layer 12A).
The lower layer is a Ti compound layer composed of one more of titanium carbide (hereinafter, referred to as TiC) layer, a titanium nitride (hereinafter, referred to as TiN) layer, a titanium carbonitride (hereinafter, referred to as TiCN) layer, a titanium carboxide (hereinafter, referred to as TiCO) layer, and a titanium oxycarbonitride (hereinafter, referred to as TiCNO) layer. The lower layer is basically present as a lower layer of the reformed Al2O3 layer which is the intermediate layer. It has superior toughness and abrasion resistance, contributing to improve high-temperature strength of the hard coating layer. In addition, the lower layer adheres tightly to both the tool substrate and the reformed Al2O3 layer, contributing an adhesive property of the hard coating layer to the tool substrate. If the total mean layer thickness is less than 3 the improvements described above cannot be sufficiently obtained. On the other hand, if the total mean layer thickness exceeds 20 μm, thermal plastic deformation occurs easily, particularly when the cutting tool is used under high-speed heavy cutting conditions where high heat is generated and a high load is subjected on the cutting edge of the cutting tool. Thermal plastic deformation causes uneven wear of the cutting tool. Accordingly, the total mean layer thickness is set to 3 to 20 μm.
(b) Reformed Al2O3 Layer (Intermediate Layer 12B)
In order to form the reformed Al2O3 layer, which constitutes the intermediate layer, as already described, an Al2O3 neclear is formed on the surface of the Ti compound layer, which is the lower layer, under the following low-temperature conditions.
A normal chemical vapor deposition apparatus is used. Composition of reaction gas includes 3 to 10% of AlCl3, 0.5 to 3% of CO2, 0.01 to 0.3% of C2H4 in vol. %, and H2 as balance. Reaction atmosphere temperature is set at 750 to 900° C. Reaction atmosphere pressure is set at 3 to 13 kPa.
It is desirable that the Al2O3 neclear is an Al2O3 neclear thin film having a mean layer thickness of 20 to 200 nm. The reaction atmosphere is substituted with a hydrogen atmosphere with pressure of 3 to 13 kPa. Then, temperature of the reaction atmosphere is increased to 1100 to 1200° C. and the Al2O3 neclear thin film is heat treated. An α-type Al2O3 layer, which serves as the hard coating layer, is formed under normal conditions. By following steps described above, an α-type Al2O3 layer is vapor deposited on the heat-treated Al2O3 neclear thin film.
The reformed Al2O3 layer vapor deposited on the lower layer is analyzed by the field-emission-type scanning electron microscope, as shown in FIGS. 1A and 1B. Electron beams are irradiated to the individual grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected and a tilt-angle frequency distribution graph is plotted. In the tilt-angle frequency distribution graph, the sharp highest peak exists in a tilt angle division ranging 0 to 10°, and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies. as shown in FIG. 14, demonstrating that the (0001) plane orientation ratio of the reformed Al2O3 layer is high.
The reformed Al2O3 layer has superior high-temperature strength in addition to the excellent high-temperature hardness and heat resistance of the Al2O3 layer of the conventional coated tool. Furthermore, by configuring the reformed Al2O3 layer as an intermediate layer with a high (0001) plane orientation rate, the (0001) plane orientation rate of the reformed Cr-containing Al2O3 layer vapor-deposited thereon can be increased. As a result, the surface properties of an upper layer composed of the reformed Cr-containing Al2O3 layer can be improved, and high-temperature strength can be improved.
If the mean layer thickness of the intermediate layer composed of the reformed Al2O3 layer is less than 1 μm, the hard coating layer cannot be provided with the above characteristics of the reformed Al2O3 layer. On the other hand, if the mean layer thickness exceeds 5 μm, high temperature generated during cutting and high load subjected to the cutting edge leads to a higher rate of occurrence of thermal plastic deformation, which causes uneven wear of the cutting tool. As a result, the cutting tool is abrased faster. Thus, the mean layer thickness is set to 1 to 5 μm.
(c) Reformed Cr-Containing Al2O3 Layer (Upper Layer 12C)
As for the upper layer composed of the reformed Cr-containing Al2O3 layer chemically vapor-deposited on the intermediate layer, an Al component which is a constituent component of the upper layer improves the high-temperature hardness and heat resistance of the layer. An extremely small amount (Cr/(Al+Cr) is 0.01 to 0.1 (as an atomic ratio) in a ratio accounted for in the total amount with Al) of Cr component contained in the upper layer improves the crystal grain boundary strength of the reformed Cr-containing Al2O3 layer, and contributes to improving the high-temperature strength of the upper layer. If the content ratio of the Cr component in the upper layer is less than 0.01, the above functions cannot be obtained. On the other hand, if the content ratio of the Cr component exceeds 0.1, the grain boundary strength deteriorates as Cr oxide grains precipitate in the layer. Therefore, it is desirable that the content ratio of the Cr component (the value of the ratio of Cr/(Al+Cr)) in the upper layer accounted for in the total amount with the Al component is 0.01 to 0.1 (as an atomic ratio).
The reformed Cr-containing Al2O3 layer can be vapor-deposited by adjusting chemical vapor deposition conditions of the composition of a reaction gas during vapor deposition, the reaction atmosphere temperature, and the reaction atmosphere pressure as follows, for example.
First, deposition is performed for about 1 hour under the following conditions (referred as an initial condition hereinafter):
(i) Composition of reaction gas (vol. %):
2.3 to 4% of AlCl3,
0.04 to 0.26% of CrCl3,
6 to 8% of CO2,
1.5 to 3% of HCl,
0.05 to 0.2% of H2S, and
H2 as balance,
(ii) Reaction atmosphere temperature: 930 to 970° C., and
(iii) Reaction atmosphere pressure: 6 to 10 kPa,
Second, vapor deposition is performed under the following conditions (referred as a film formation condition herein after).
(i) Composition of reaction gas (vol. %):
2.3 to 4% of AlCl3,
0.04 to 0.26% of CrCl3,
6 to 8% of CO2,
1.5 to 3% of HCl,
0.05 to 0.2% of H2S, and
H2 as balance,
(ii) Reaction atmosphere temperature: 1020 to 1050° C., and
(iii) Reaction atmosphere pressure: 6 to 10 kPa.
When a vapor deposition layer with a mean layer thickness of 2 to 15 μm is formed as a film, by performing deposition in the initial and the film forming conditions described above, the reformed Cr-containing Al2O3 layer whose ratio of Cr/(Al+Cr) is 0.01 to 0.1 in atomic ratio is formed.
When the reformed Cr-containing Al2O3 layer is observed by the emission type scanning electron microscope, the textures shown in FIGS. 15A and 15B are observed. In FIG. 15A, the reformed Cr-containing Al2O3 layer is viewed within the plane perpendicular to the layer thickness direction. In FIG. 15A, the texture containing large crystal grains with a flat-plate polygonal shape is formed. In FIG. 15B, the reformed Cr-containing Al2O3 layer is viewed within the plane parallel to the layer thickness direction. In FIG. 15B, the outer surface of the reformed Cr-containing Al2O3 layer is substantially flat. Also, the texture containing crystal grains with elongated shape is formed (Referred as a flat-plate polygonal elongated shape crystal grain).
As for the reformed Cr-containing Al2O3 layer, similarly to the reformed α-type Al2O3 layer, which constitutes the intermediate layer, the tilt angle of the normal line to the (0001) plane to the normal line to a polished surface is measured and a tilt angle frequency graph is plotted. In the tilt angle frequency graph of the reformed Cr-containing Al2O3 layer, a peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies in the tilt-angle frequency distribution graph. These results indicate that the (0001) plane orientation rate of the reformed Cr-containing Al2O3 layer, which constitutes the upper layer, is high.
That is, as for the reformed Cr-containing Al2O3 layer, since the (0001) plane orientation rate of the reformed α-type Al2O3 layer, which is the intermediate layer, is 45% or more, the reformed Cr-containing Al2O3 layer is also formed as a layer having a high (0001) plane orientation rate (the (0001) plane orientation rate is 60% or more). When the upper layer is viewed within the plane parallel to the layer thickness direction, the outer surface of the upper layer is formed in the shape of a substantially flat plate. Thus, the upper layer has a excellent surface property. Consequently, the upper layer shows superior chipping resistance as compared to the conventional Cr-containing Al2O3 layer.
When the vapor deposition of the reformed Cr-containing Al2O3 layer is performed under further limited conditions (for example, ratios of HCl gas and H2S gas are set relatively higher, and the pressure of the reaction atmosphere is set relatively loser in the initial and the film formation conditions), the texture shown in FIG. 15C is formed. In the texture, when it is viewed within the plane perpendicular to the layer thickness direction, there are large-sized crystal grains with a flat-plate hexagonal shape. When the texture is viewed within the plane parallel to the layer thickness direction, the outer surface of the upper layer is substantially flat and the crystal grains have an elongated shape stretched in the layer thickness direction, as shown in FIG. 15B. The ratio of the surface area occupied by the crystal grains having the flat-plate hexagonal elongated shape, to the whole surface area of the plane parallel to the layer thickness direction, accounts for 35% or more, in the upper layer formed in the further limited conditions.
The reformed Cr-containing Al2O3 layer is analyzed with a field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus. In the analysis, electron beams are irradiated to individual crystal grains within the measurement range of the polished surface. Then, angles between the normal line to each of crystal lattice planes with a hexagonal crystal lattice and the normal line to the polished surface are measured. From the measurement results, the crystal orientation relationship between adjacent crystal lattices is calculated. Then, distribution of lattice points (constituent atom sharing lattice points) is calculated. The constituent atom sharing lattice point is a lattice point that has a constituent atom shared by two crystal lattices forming the grain boundary at the grain boundary. A constituent atom sharing lattice point configuration is expressed by ΣN+1, where the number represented by N is the number of lattice points that have no constituent atom shared at the grain boundary between two constituent atom sharing lattice points with constituent atoms. The constituent atom sharing lattice point type is even numbers more than 2 between crystal grains having a corundum type hexagonal close-packed structure. If the maximum number of N is set to 28 in view of distribution frequency, even numbers 4, 8, 14, 24, and 26 are excluded from the option for crystal grains having hexagonal close-packed structure. As shown in FIG. 16, the crystal grains of the reformed Cr-containing Al2O3 layer are divided by at least one of Σ3 coincidence site lattice interface within each crystal grain. The ratio of surface area occupied by the crystal grains that have the flat-plate polygonal elongated shape and divided by at least one of Σ3 coincidence site lattice interface, to the surface area occupied by crystal grains with the flat-plate polygonal elongated shape (including the flat-plate hexagonal elongated shape), is 60% or more.
The strength within the crystal grains of the reformed Cr-containing Al2O3 layer is increased due to the presence of the Σ3 coincidence site lattice interface in the crystal grains with the flat-plate polygonal (including hexagonal) elongated shape. As a result, cracking of the reformed Cr-containing Al2O3 layer is suppressed during high-speed intermittent cutting against a work that is difficult to be cut. In the condition, high load is subjected to the cutting edge of the coated cutting tool under a high heat condition. Even if the cracking occurred, growth and spreading of the cracking would be prevented. Therefore, chipping resistance, fracture resistance, and spalling resistance are improved in the cutting tool having the reformed Cr-containing Al2O3 layer.
Accordingly, the upper layer of the present invention, which has a high (0001) plane orientation rate, has flat surface properties, and is composed of the reformed Cr-containing Al2O3 layer in which the Σ3 coincidence site lattice interfaces are present with in the flat-plate polygonal (including flat hexagonal) elongated crystal grains, exhibits excellent chipping resistance and abrasion resistance for a prolonged period of time without causing chipping, fracture, spalling, or the like and also without causing thermal plastic deformation, uneven wear, or the like, even in high-speed heavy cutting against a cutting work that is difficult to be cut, such as one made of stainless steel, ductile cast iron, or the like accompanied by high heat generation and high load subjected on the cutting edge with deep depth cut.
If the layer thickness of the upper layer composed of the reformed Cr-containing Al2O3 layer is less than 2 μm, the excellent characteristics of the upper layer cannot be sufficiently exhibited. On the other hand, if the layer thickness of the upper layer exceeds 15 μm, thermal plastic deformation, which causes uneven wear, easily occurs. In addition, a rate of occurrence of chipping is also increased. Therefore, the mean layer thickness of the upper layer is set to 2 to 15 μm.
As a comparison, the conventional Cr-containing Al2O3 layer (the layer described in the PTL 2 (Japanese Unexamined Patent Application Publication No. 2006-289556)), was analyzed by the field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus. In the analysis, the texture of crystal grains and the constituent atom sharing lattice point configuration of the conventional Cr-containing Al2O3 layer were analyzed. The texture of the crystal grains of the conventional Cr-containing Al2O3 layer is shown in FIGS. 17A and 17B. As shown in FIGS. 17A and 17B, the texture of the crystal grains of the conventional Cr-containing Al2O3 layer is made of pyramidal-shaped crystal grains with a polygonal elongated shape stretched to the layer thickness direction. The outer surface of the conventional Cr-containing Al2O3 layer has protuberances and recesses along with the pyramidal shape of the crystal grains. Because of these, the abrasion resistance of the conventional Cr-containing Al2O3 layer is inferior compared to that of the reformed Cr-containing Al2O3 layer.
In terms of the constituent atom sharing lattice point configuration, the ratio of surface area occupied by the pyramidal-shaped crystal grains, which have a polygonal elongated shape stretched to the layer thickness direction and contain a Σ3 coincidence site lattice interface within, to the surface area occupied by crystal grains, which consist the conventional Cr-containing Al2O3 layer and have the convexoconcave polygonal elongated shape stretched to the layer thickness direction, is 40% or less. Therefore, the strength within the crystal grains is not improved as in the reformed Cr-containing Al2O3 layer.
Accordingly, the conventional coated tool in which the upper layer of the hard coating layer is composed of the conventional Cr-containing Al2O3 layer cannot prevent occurrence of chipping, fracture, spalling, and thermal deformation and uneven wear occur. Thus, the conventional coated tool is inferior in tool performance, in high-speed heavy cutting work accompanied by high heat generation and heavy impact loading subjected on the cutting edge, such as cutting against a cutting work made of stainless steel, ductile cast iron, or the like.
In the coated tool of the present invention, after the reformed Cr-containing Al2O3 layer of the upper layer is formed, polishing processing using a grind stone or polishing processing using wet blasting can be performed on the surface of the upper layer, so that the surface roughness of the reformed Cr-containing Al2O3 layer can be further adjusted. For example, the occurrence of welding to the surface-coated tool during cutting can be suppressed by adjusting the surface roughness of the reformed Cr-containing Al2O3 layer to Ra 0.05 to 0.3 μm.
The surface roughness Ra in the present invention means the value of arithmetic mean roughness Ra defined by JIS B0601 (1994), and the measuring method thereof is not particularly limited.
Fifth Embodiment
The fifth embodiment of the present invention has the following configuration.
(a) The conventional α-type Al2O3 layer in the conventional coated tool 1 is vapor-deposited, for example, using a normal chemical vapor deposition apparatus under the following conditions.
Composition of reaction gas: in vol. %, 6 to 10% of AlCl3, 10 to 15% of CO2, 3 to 5% of HCl, 0.05 to 0.2% of H2S, and H2 as balance
Reaction atmosphere temperature: 1020 to 1050° C.
Reaction atmosphere pressure: 3 to 5 kPa
Similarly, the α-type Al2O3 layer in the present invention corresponding to the intermediate layer is formed, using a normal chemical vapor deposition apparatus under the following conditions.
Composition of reaction gas: in vol. %, 3 to 10% of AlCl3, 0.5 to 3% of CO2, 0.01 to 0.3% of C2H4, and H2 as balance
Reaction atmosphere temperature: 750 to 900° C.
Reaction atmosphere pressure: 3 to 13 kPa
An Al2O3 neclear is formed on the surface of a Ti compound layer which is the lower layer under the low-temperature condition described above. In this case, it is desirable that the Al2O3 neclear is an Al2O3 neclear thin film having a mean layer thickness of 20 to 200 nm. Subsequently, the Al2O3 neclear thin film is heat treated in a condition where the reaction atmosphere is substituted to a hydrogen atmosphere of pressure: 3 to 13 kPa, and the reaction atmosphere temperature is increased to 1100 to 1200° C. Then, the α-type Al2O3 layer, which serves as the hard coating layer, is formed under a conventional condition. The resulting α-type Al2O3 layer (hereinafter referred to as a reformed α-type Al2O3 layer), which is vapor-deposited on the heat-treated neclear thin film, is analyzed with a field emission type scanning electron microscope as schematically represented in FIGS. 1A and 1B. In the analysis, individual crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface, are irradiated by an electron beam. Then, a tilt angle, which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. The measured tilt angles belonging to a range of 0 to 45° are sectioned every pitch of 0.25°, and the frequencies existing in each section are collected, being represented by a tilt angle frequency distribution graph. Based on a test result, it was found that the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph, when the atmosphere pressure of the chemical vapor deposition apparatus is kept between 5 and 8 KPa. The fact that the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies, means that ratio of the (0001) plane orientation is high. This reformed α-type Al2O3 layer has superior high-temperature strength compared to the conventional α-type Al2O3 layer of the conventional coated cutting tool 1. This reformed α-type Al2O3 also has excellent high-temperature hardness and heat resistance, as the conventional α-type Al2O3 layer of the conventional coated cutting tool 1 does.
(b) Forming the hard coating layer is further proceeded on the reformed α-type Al2O3 layer described above, as the intermediate layer. A B-containing aluminum oxide layer having an α-type crystal structure in a chemically vapor-deposited state is vapor-deposited on the intermediate layer as the upper layer. In this way, the lower layer composed of the Ti compound layer, the intermediate layer composed of the reformed α-type Al2O3 layer, and the upper layer composed of the B-containing aluminum oxide layer are vapor-deposited as a hard coating layer on the surface of the tool substrate. The coated cutting tool with the configuration described above has even more superior high-temperature strength and surface properties. The coated cutting tool exerts excellent chipping resistance, even under high-speed intermittent cutting conditions where high heat is generated and the cutting edges are subjected to intermittent impact loading repeatedly.
(c) The B-containing aluminum oxide layer which is the upper layer can be formed on the reformed α-type Al2O3 layer, which is the intermediate layer, under the following conditions. First, as a first step, first-step vapor deposition is performed for 60 minutes under the following conditions (i) to (iii).
(i) Composition of reaction gas (vol. %):
1 to 5% of AlCl3 
0 to 0.01% of BCl3 
2 to 6% of CO2 
1 to 5% of HCl
0.25 to 0.75% of H2S
H2 as balance
(ii) Reaction atmosphere temperature: 960 to 1010° C.
(iii) Reaction atmosphere pressure: 6 to 10 kPa
Next, as a second step, vapor deposition is performed under the following conditions (i) to (iii).
(i) Composition of reaction gas (vol. %):
6 to 10% of AlCl3 
0.02 to 0.2% of BCl3 
4 to 8% of CO2 
3 to 5% of HCl
0.25 to 0.6% of H2S
H2 as balance
(ii) Reaction atmosphere temperature: 960 to 1010° C.
(iii) Reaction atmosphere pressure: 6 to 10 kPa
By following the steps described above, a B-containing aluminum oxide layer (hereinafter referred to as a reformed AlBO layer), which has an α-type crystal structure in a chemically vapor-deposited state, can be formed. The reformed AlBO layer has a mean layer thickness of 1 to 15 μm, and the content ratio of the B component to the total amount of the Al component is 0.002 to 0.01 (as atomic ratio).
(d) When the texture of the reformed AlBO layer is observed by the emission type scanning electron microscope, a flat-plate polygonal shape of a large-sized grain can be seen within a plane perpendicular to the layer thickness direction. When the reformed AlBO layer is observed in the plane parallel to the layer thickness direction, it can be seen that the outer surface of the reformed AlBO layer is substantially flat, and the reformed AlBO layer has a texture made of the grains whose shapes are elongated in the layer thickness direction (hereinafter, the shape of the crystal grain described above is referred a flat-plate polygonal vertically elongated shape).
When the vapor deposition of the reformed AlBO layer is performed under further limited conditions (for example, the volume % of H2S is set 0.50 to 0.75, and the reaction atmosphere temperature 1000 to 1010° C. in the first vapor deposition, and the volume % s of BCl3 and H2S are set 0.05 to 0.15 and 0.25 to 0.4, respectively, and the reaction atmosphere temperature 960 to 980° C. in the second vapor deposition), a texture described below is formed. When the texture is viewed within the plane perpendicular to the layer thickness direction, the large-sized grains with a flat hexagonal shape are observed. When the reformed AlBO layer is seen within the plane parallel to the layer thickness direction, it can be seen that the outer surface of the reformed AlBO layer is substantially flat. In addition, the grains that have the elongated shape within the plane parallel to the layer thickness direction, account for 35% or more in area ratio, in the whole surface area perpendicular to the thickness direction of the layer.
(e) As in the reformed α-type Al2O3 layer, the reformed AlBO layer is analyzed with the field-emission-type scanning electron microscope. In the analysis, individual crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface, are irradiated by an electron beam. Then, a tilt angle, which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. The measured tilt angles belonging to a range of 0 to 45° are sectioned every pitch of 0.25°, and the frequencies existing in each section are collected, being represented by a tilt angle frequency distribution graph. In the tilt-angle frequency distribution graph, a sharp highest peak appears at a specific section of the tilt angle, and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies. This means that the reformed AlBO layer with high (0001) plane orientation ratio is formed. The (0001) plane orientation ratio of the reformed AlBO layer is higher than that of the conventional AlBO layer of the conventional coated cutting tool, resulting even more superior high-temperature strength of the reformed AlBO layer.
(f) In addition, the reformed AlBO layer is analyzed by the field-emission-type scanning electron microscope and an electronic backscattering diffraction image apparatus. In the analysis, individual crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface, are irradiated by an electron beam. Then, a tilt angle, which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. Based on the measurement results, a crystallographic orientation relationship between the adjacent crystal lattices is calculated, and a distribution of lattice points (constituent atom sharing lattice points) is calculated. The constituent atom sharing lattice point is a lattice point that has a constituent atom shared by two crystal lattices forming the grain boundary at the grain boundary. A constituent atom sharing lattice point type in which N lattice points not sharing the constituent atom exist between the constituent atom sharing lattice points (where N is an even number of 2 or more in view of a crystal structure of corundum type hexagonal close packed crystal but does not include even numbers of 4, 8, 14, 24, and 26 when the upper limit of N is set to 28 in view of distribution frequency) is expressed as ΣN+1. When the reformed AlBO layer is observed by the field-emission-type scanning electron microscope, it is seen that the reformed AlBO layer includes the crystal grains with the flat-plate polygonal vertically elongated shape. Among the crystal grains with the flat-plate polygonal vertically elongated shape, 60% or more of them are divided by at least one of crystal lattice interface with the constituent atom sharing lattice point type expressed by Σ3 (hereinafter referred as a Σ3 coincidence site lattice interface) inside.
(h) As described above, the upper layer composed of the reformed AlBO layer has a high (0001) plane orientation rate, and a crystal plane at the surface thereof has the same orientation as a crystal plane (for example, (0001)) within the plane perpendicular to the layer thickness direction of this layer. Thus, outer surface of the upper layer is formed in the shape of a flat plate which is substantially flat (as seen within the plane parallel to the layer thickness direction), and shows excellent chipping resistance due to the surface properties thereof. Furthermore, the strength within the crystal grains is increased since the Σ3 coincidence site lattice interfaces are present inside the grains with the flat-plate polygonal vertically elongated shape. Therefore, the reformed AlBO layer has excellent high-temperature hardness and high-temperature strength and shows excellent chipping resistance, compared to the conventional AlBO layer.
(i) Accordingly, as the hard coating layer of the present embodiment, the coated tool of the present invention includes the reformed α-type Al2O3 layer having a high (0001) plane orientation rate and having excellent high-temperature strength as the intermediate layer. Furthermore, the coated tool of the present invention includes the reformed AlBO layer having excellent high-temperature hardness, high-temperature strength, and surface properties as the upper layer. The coated tool of the present invention has superior high-temperature hardness, heat resistance, and high-temperature strength as compared to the conventional coated tools 1 and 2. As a result, it exhibits excellent chipping resistance for a long-term use, even when the coated tool is used for high-speed intermittent cutting accompanied by high heat generation, and intermittent impact loading acts repeatedly on the cutting edge. The present embodiment has been made on the basis of the above knowledge and includes the following configurations.
(1) Provided is a surface-coated cutting tool formed by vapor-depositing, on the surface of a tool substrate made of tungsten carbide-based cemented carbide or titanium carbonitride-based cermet, a hard coating layer including (a) to (c) below.
(a) The lower layer is a Ti compound layer composed of one or more of a titanium carbide layer, a titanium nitride layer, a titanium carbonitride layer, a titanium carboxide layer, and a titanium oxycarbonitride layer, all of which are formed by chemical vapor deposition, and having a total mean layer thickness of 3 to 20 μm.
(b) The intermediate layer is an aluminum oxide layer having a mean layer thickness of 1 to 5 μm and having an α-type crystal structure in a chemically vapor-deposited state.
(c) The upper layer is a B-containing aluminum oxide layer having a mean layer thickness of 2 to 15 μm and having an α-type crystal structure in a chemically vapor-deposited state.
The intermediate layer (b) has properties indicated by a tilt-angle frequency distribution graph in which the highest peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph. The tilt-angle frequency distribution graph is obtained by utilizing a field-emission-type scanning electron microscope. Electron beams are irradiated to individual crystal grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected.
When the texture of the upper layer of the above (c) is observed by the emission type scanning electron microscope, the upper layer is a B-containing aluminum oxide layer having a texture composed of crystal grains which have a flat-plate polygonal shape within the plane perpendicular to the layer thickness direction and have an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction.
The upper layer (c) has properties indicated by a tilt-angle frequency distribution graph in which the highest peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies in the tilt-angle frequency distribution graph. The tilt-angle frequency distribution graph is obtained by utilizing a field-emission-type scanning electron microscope. Electron beams are irradiated to individual crystal grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected.
Moreover, the upper layer (c) is a B-containing aluminum oxide layer consisted of crystal grains, 60% or more of the grains being divided within each grain by at least one or more crystal lattice interfaces with a constituent atom sharing lattice point type expressed by Σ3. The constituent atom sharing lattice point type is expressed as ΣN+1, where “N” represents a number of lattice points (N) without a shared constituent atom between the constituent atom sharing lattice points. The constituent atom sharing lattice point type is even numbers more than 2 between crystal grains having a corundum type hexagonal close-packed structure. If the maximum number of N is set to 28 in view of distribution frequency, even numbers 4, 8, 14, 24, and 26 are excluded from the option for crystal grains having hexagonal close-packed structure. To obtain data related to the constituent atom sharing lattice point type, first, electron beams are irradiated to individual crystal grains within the measurement area on the polished surface with field-emission-type scanning electron microscope and an electron backscatter diffraction imaging device. Then, angles formed by normal lines of crystal lattice faces with hexagonal crystal lattices and the normal line to the polished surface are measured. Then, based on the measurement, a crystallographic orientation relationship between the adjacent crystal lattices is calculated. Then, a distribution of lattice points (constituent atom sharing lattice points) in which constituent atoms of a crystal lattice interface sharing one constituent atom between the crystal lattices is calculated. Then, finally, “N” representing a number of lattice points (N) without a shared constituent atom between the constituent atom sharing lattice points, is obtained.
(2) When the texture of the upper layer (c) of the surface-coated cutting tool described above (as (1)) is observed by the emission type scanning electron microscope, crystal grains corresponding to 35% or more of the whole surface area perpendicular to the layer thickness direction, has a flat-plate polygonal shape within the plane perpendicular to the layer thickness direction and an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction.
(3) The surface roughness (Ra) of the upper layer (c) in the cutting tool described above (as (1) and (2)) ranges from 0.05 to 0.3 μm.
The configuration of the hard coating layer of the coated tool of this aspect will be described below in more detail.
(a) Ti Compound Layer (Lower Layer 12A)
The lower layer is a Ti compound layer composed of one more of titanium carbide (hereinafter, referred to as TiC) layer, a titanium nitride (hereinafter, referred to as TiN) layer, a titanium carbonitride (hereinafter, referred to as TiCN) layer, a titanium carboxide (hereinafter, referred to as TiCO) layer, and a titanium oxycarbonitride (hereinafter, referred to as TiCNO) layer. The lower layer is basically present as a lower layer of the reformed α-type Al2O3 layer which is the intermediate layer. It has superior toughness and abrasion resistance, contributing to improve high-temperature strength of the hard coating layer. In addition, the lower layer adheres tightly to both the tool substrate and the reformed α-type Al2O3 layer, contributing an adhesive property of the hard coating layer to the tool substrate. If the total mean layer thickness is less than 3 μm, the improvements described above cannot be sufficiently obtained. On the other hand, if the total mean layer thickness exceeds 20 μm, thermal plastic deformation occurs easily, particularly when the cutting tool is used under high-speed intermittent cutting conditions where a high load is subjected on the cutting edge intermittently and explosively. Thermal plastic deformation causes uneven wear of the cutting tool. Accordingly, the total mean layer thickness is set to 3 to 20 μm.
(b) Reformed α-Type Al2O3 Layer (Intermediate Layer 12B)
In order to form the reformed α-type Al2O3 layer, which constitutes the intermediate layer 12B, as already described, an Al2O3 neclear is formed on the surface of the Ti compound layer, which is the lower layer, under the following low-temperature conditions.
A normal chemical vapor deposition apparatus is used. Composition of reaction gas includes 3 to 10% of AlCl3, 0.5 to 3% of CO2, 0.01 to 0.3% of C2H4 in vol. %, and H2 as balance. Reaction atmosphere temperature is set at 750 to 900° C. Reaction atmosphere pressure is set at 3 to 13 kPa.
It is desirable that the Al2O3 neclear is an Al2O3 neclear thin film having a mean layer thickness of 20 to 200 nm. After the formation of the Al2O3 neclear, the reaction atmosphere is substituted with a hydrogen atmosphere with pressure of 3 to 13 kPa. Then, temperature of the reaction atmosphere is increased to 1100 to 1200° C. and the Al2O3 neclear thin film is heat treated. An α-type Al2O3 layer, which serves as the hard coating layer, is formed under normal conditions. By following steps described above, an α-type Al2O3 layer is vapor deposited on the heat-treated Al2O3 neclear thin film, resulting formation of the intermediate layer.
The reformed α-type Al2O3 layer vapor deposited on the lower layer is analyzed by the field-emission-type scanning electron microscope, as shown in FIGS. 1A and 1B. Electron beams are irradiated to the individual grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected and a tilt-angle frequency distribution graph is plotted. In the tilt-angle frequency distribution graph, the sharp highest peak exists in a tilt angle division ranging 0 to 10°, as shown in FIG. 2.
The highest peak position of the measured tilt angles in the tilt angle frequency distribution graph of the reformed α-type Al2O3 layer can be changed by performing heat-treatment after the formation of the Al2O3 neclear (thin film) with a predetermined layer thickness. In addition, the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph (which means the (0001) plane orientation rate is high). Accordingly, whenever the thickness of the Al2O3 neclear (thin film) becomes too thin or too thick, the position of the highest peak of the measured tilt angles moves out of the range of 0 to 10°. In addition, the total sum of frequencies existing in the range of 0 to 10° becomes less than a ratio of 45% of the total frequencies in the tilt-angle frequency distribution graph. As a result, excellent high-temperature strength cannot be obtained.
The reformed α-type Al2O3 layer has superior high-temperature strength in addition to the excellent high-temperature hardness and heat resistance of the α-type Al2O3 layer of the conventional coated tool. Furthermore, by configuring the reformed α-type Al2O3 layer as an intermediate layer with a high (0001) plane orientation rate, the (0001) plane orientation rate of the reformed AlBO layer vapor-deposited thereon can be increased. As a result, the surface properties of an upper layer composed of the reformed AlBO layer can be improved, and high-temperature strength can be improved.
If the mean layer thickness of the intermediate layer composed of the reformed α-type Al2O3 layer is less than 1 the hard coating layer cannot be provided with the above characteristics of the reformed α-type Al2O3 layer. On the other hand, if the mean layer thickness exceeds 5 μm, high temperature generated during cutting and high load subjected to the cutting edge leads to a higher rate of occurrence of thermal plastic deformation, which causes uneven wear of the cutting tool. As a result, the cutting tool is abrased faster. Thus, the mean layer thickness is set to 1 to 5 μm.
(c) Reformed AlBO Layer (Upper Layer 12C)
As for the upper layer 12C composed of the reformed AlBO layer chemically vapor-deposited on the intermediate layer 12B, an Al component which is a constituent component of the upper layer improves the high-temperature hardness and heat resistance of the layer. An extremely small amount (B/(Al+B) is 0.001 to 0.01 (as an atomic ratio) in a ratio accounted for in the total amount with Al) of B component contained in the upper layer improves the crystal grain boundary strength of the reformed AlBO layer, and contributes to improving the high-temperature strength of the upper layer. If the content ratio of the B component in the upper layer is less than 0.001, the above functions cannot be obtained. On the other hand, if the content ratio of the B component exceeds 0.01, the grain boundary strength deteriorates as BO2 grains precipitate in the layer. Therefore, it is desirable that the content ratio of the B component (the value of the ratio of B/(Al+B)) in the upper layer accounted for in the total amount with the Al component is 0.001 to 0.01 (as an atomic ratio).
The reformed AlBO layer can be vapor-deposited by adjusting chemical vapor deposition conditions of the composition of a reaction gas during vapor deposition, the reaction atmosphere temperature, and the reaction atmosphere pressure as follows, for example.
First, the first-step vapor deposition is performed for 60 minutes under the following conditions:
(i) Composition of reaction gas (vol. %):
1 to 5% of AlCl3,
0 to 0.01% of BCl3,
2 to 6% of CO2,
1 to 5% of HCl,
0.25 to 0.75% of H2S, and
H2 as balance,
(ii) Reaction atmosphere temperature: 960 to 1010° C., and
(iii) Reaction atmosphere pressure: 6 to 10 kPa,
Second, the second-step vapor deposition is performed under the following conditions.
(i) Composition of reaction gas (vol. %):
6 to 10% of AlCl3,
0.02 to 0.2% of BCl3,
4 to 8% of CO2,
3 to 5% of HCl,
0.25 to 0.6% of H2S, and
H2 as balance,
(ii) Reaction atmosphere temperature: 920 to 1010° C., and
(iii) Reaction atmosphere pressure: 6 to 10 kPa.
When a vapor deposition layer with a mean layer thickness of 1 to 15 μm is formed as a film, by performing the first-step and the second-step vapor deposition in the conditions described above, the reformed AlBO layer whose ratio of B/(Al+B) is 0.001 to 0.01 in atomic ratio, is formed.
When the reformed AlBO layer is observed by the emission type scanning electron microscope, the textures shown in FIGS. 3A and 3B are observed. The reformed AlBO layer is viewed within the plane perpendicular to the layer thickness direction. The texture containing large crystal grains with a flat-plate polygonal shape is formed. The reformed AlBO layer is viewed within the plane parallel to the layer thickness direction. The outer surface of the reformed AlBO layer is substantially flat. Also, the texture containing crystal grains with elongated shape is formed (Referred as a flat-plate polygonal elongated shape crystal grain).
As for the reformed AlBO layer, similarly to the reformed α-type Al2O3 layer, which constitutes the intermediate layer, the tilt angle of the normal line to the (0001) plane to the normal line to a polished surface is measured and a tilt angle frequency graph is plotted. In the tilt angle frequency graph of the reformed AlBO layer, a peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies in the tilt-angle frequency distribution graph. These results indicate that the (0001) plane orientation rate of the reformed AlBO layer, which constitutes the upper layer, is high.
That is, as for the reformed AlBO layer, since the (0001) plane orientation rate of the reformed α-type Al2O3 layer, which is the intermediate layer, is 45% or more, the reformed AlBO layer is also formed as a layer having a high (0001) plane orientation rate (the (0001) plane orientation rate is 60% or more).
When the upper layer is viewed within the plane parallel to the layer thickness direction, the outer surface of the upper layer is formed in the shape of a substantially flat plate. Thus, the upper layer has a excellent surface property. Consequently, the upper layer shows superior chipping resistance as compared to the conventional AlBO layer.
When the vapor deposition of the reformed AlBO layer is performed under further limited conditions (for example, the conditions where volume percentage of H2S in the reaction gas is 0.05 to 0.75 vol. %, and the reaction atmosphere temperature is set to 1000 to 1010° C. in the first-step vapor deposition, and volume percentages of BCl3 and H2S in the reaction gas are set 0.05 to 0.15 vol. % and 0.25 to 0.4 vol. %, respectively and the reaction atmosphere temperature is set to 960 to 980° C. in the second-step vapor deposition), a texture described below is formed. In the texture, when it is viewed within the plane perpendicular to the layer thickness direction, there are large-sized crystal grains with a flat-plate hexagonal shape. When the texture is viewed within the plane parallel to the layer thickness direction, the outer surface of the upper layer is substantially flat and the crystal grains have an elongated shape stretched in the layer thickness direction. The ratio of the surface area occupied by the crystal grains having the flat-plate hexagonal elongated shape, to the whole surface area of the plane parallel to the layer thickness direction, accounts for 35% or more, in the upper layer formed in the further limited conditions.
The reformed AlBO layer is analyzed with a field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus. In the analysis, electron beams are irradiated to individual crystal grains within the measurement range of the polished surface. Then, angles between the normal line to each of crystal lattice planes with a hexagonal crystal lattice and the normal line to the polished surface are measured. From the measurement results, the crystal orientation relationship between adjacent crystal lattices is calculated. Then, distribution of lattice points (constituent atom sharing lattice points) is calculated. The constituent atom sharing lattice point is a lattice point that has a constituent atom shared by two crystal lattices forming the grain boundary at the grain boundary. A constituent atom sharing lattice point configuration is expressed by ΣN+1, where the number represented by N is the number of lattice points that have no constituent atom shared at the grain boundary between two constituent atom sharing lattice points with constituent atoms. The constituent atom sharing lattice point type is even numbers more than 2 between crystal grains having a corundum type hexagonal close-packed structure. If the maximum number of N is set to 28 in view of distribution frequency, even numbers 4, 8, 14, 24, and 26 are excluded from the option for crystal grains having hexagonal close-packed structure. The crystal grains of the reformed AlBO layer are divided by at least one of Σ3 coincidence site lattice interface within each crystal grain. The ratio of surface area occupied by the crystal grains that have the flat-plate polygonal elongated shape and divided by at least one of Σ3 coincidence site lattice interface, to the surface area occupied by crystal grains with the flat-plate polygonal elongated shape (including the flat-plate hexagonal elongated shape), is 60% or more.
The strength within the crystal grains of the reformed AlBO layer is increased due to the presence of the Σ3 coincidence site lattice interface in the crystal grains with the flat-plate polygonal (including hexagonal) elongated shape. As a result, cracking of the reformed AlBO layer is suppressed during high-speed intermittent cutting work where high load is subjected to the reformed AlBO layer. Even if the cracking occurred, growth and spreading of the cracking would be prevented. Therefore, chipping resistance, fracture resistance, and spalling resistance are improved in the cutting tool having the reformed AlBO layer.
Accordingly, the upper layer of the present invention, which has a high (0001) plane orientation rate, has flat surface properties, and is composed of the reformed AlBO layer in which the Σ3 coincidence site lattice interfaces are present in the flat-plate polygonal (including flat hexagonal) elongated crystal grains, and exhibits excellent chipping resistance and abrasion resistance for a prolonged period of time without causing chipping, fracture, spalling, or the like and also without causing thermal plastic deformation, uneven wear, or the like, even in high-speed intermittent cutting work accompanied by high heat generation and high load subjected on the cutting edge.
If the layer thickness of the upper layer composed of the reformed AlBO layer is less than 2 μm, the excellent characteristics of the upper layer cannot be sufficiently exhibited. On the other hand, if the layer thickness of the upper layer exceeds 15 μm, thermal plastic deformation, which causes uneven wear, easily occurs. In addition, a rate of occurrence of chipping is also increased. Therefore, the mean layer thickness of the upper layer is set to 2 to 15 μm.
As a comparison, the conventional AlBO layer (the layer described in the PTL 6), was analyzed by the field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus. In the analysis, the texture of crystal grains and the constituent atom sharing lattice point configuration of the conventional AlBO layer were analyzed. The texture of the crystal grains of the conventional AlBO layer is made of pyramidal-shaped crystal grains with a polygonal elongated shape stretched to the layer thickness direction. The outer surface of the conventional AlBO layer has protuberances and recesses along with the pyramidal shape of the crystal grains. Because of these, the abrasion resistance of the conventional AlBO layer is inferior compared to that of the reformed AlBO layer.
In terms of the constituent atom sharing lattice point configuration, the ratio of surface area occupied by the convexoconcave polygonal elongated crystal grains, which contain a Σ3 coincidence site lattice interface within, to the surface area occupied by the convexoconcave elongated crystal grains consisting the conventional AlBO layer was 40% or less. Therefore, the strength within the crystal grains is not improved as in the reformed AlBO layer.
Accordingly, the conventional coated tool 6 in which the upper layer of the hard coating layer is composed of the conventional AlBO layer cannot prevent occurrence of chipping, fracture, spalling, or the like and is inferior in tool performance, in high-speed intermittent cutting work accompanied by high heat generation and intermittent impact loading subjected on the cutting edge.
In the coated tool of the present invention, after the reformed AlBO layer of the upper layer is formed, polishing processing using a grind stone or polishing processing using wet blasting can be performed on the surface of the upper layer, so that the surface roughness of the reformed AlBO layer can be further adjusted. For example, the occurrence of welding to the surface-coated tool during cutting can be suppressed by adjusting the surface roughness of the reformed AlBO layer to Ra 0.05 to 0.3 μm.
The surface roughness Ra in the present invention means the value of arithmetic mean roughness Ra defined by JIS B0601 (1994), and the measuring method thereof is not particularly limited.
Sixth Embodiment
(a) The conventional α-type Al2O3 layer in the conventional coated tool 1 is vapor-deposited, for example, using a normal chemical vapor deposition apparatus under the following conditions.
Composition of reaction gas: in vol. %, 6 to 10% of AlCl3, 10 to 15% of CO2, 3 to 5% of HCl, 0.05 to 0.2% of H2S, and H2 as balance
Reaction atmosphere temperature: 1020 to 1050° C.
Reaction atmosphere pressure: 3 to 5 kPa
Similarly, in the sixth embodiment of the present invention, an Al2O3 neclear is formed on the surface of the lower layer made of the Ti compound layer, using a normal chemical vapor deposition apparatus under the following conditions.
Composition of reaction gas: in vol. %, 3 to 10% of AlCl3, 0.5 to 3% of CO2, 0.01 to 0.3% of C2H4, and H2 as balance
Reaction atmosphere temperature: 750 to 900° C.
Reaction atmosphere pressure: 3 to 13 kPa
An Al2O3 neclear is formed on the surface of a Ti compound layer which is the lower layer under the low-temperature condition described above. In this case, it is desirable that the Al2O3 neclear is an Al2O3 neclear thin film having a mean layer thickness of 20 to 200 nm. Subsequently, the Al2O3 neclear thin film is heat treated in a condition where the reaction atmosphere is substituted to a hydrogen atmosphere of pressure: 3 to 13 kPa, and the reaction atmosphere temperature is increased to 1100 to 1200° C. Then, the α-type Al2O3 layer, which serves as the hard coating layer, is formed under a conventional condition. The resulting α-type Al2O3 layer (hereinafter referred to as a reformed α-type Al2O3 layer), which is vapor-deposited on the heat-treated neclear thin film, is analyzed with a field emission type scanning electron microscope as schematically represented in FIGS. 1A and 1B. In the analysis, individual crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface, are irradiated by an electron beam. Then, a tilt angle, which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. The measured tilt angles belonging to a range of 0 to 45° are sectioned every pitch of 0.25°, and the frequencies existing in each section are collected, being represented by a tilt angle frequency distribution graph. Based on a test result, it was found that the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph, when the atmosphere pressure of the chemical vapor deposition apparatus is kept between 5 and 8 KPa. The fact that the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies, means that ratio of the (0001) plane orientation is high. This reformed α-type Al2O3 layer has superior high-temperature strength compared to the conventional α-type Al2O3 layer of the conventional coated cutting tool 1. This reformed α-type Al2O3 also has excellent high-temperature hardness and heat resistance, as the conventional α-type Al2O3 layer of the conventional coated cutting tool 1 does.
(b) Forming the hard coating layer is further proceeded on the reformed α-type Al2O3 layer described above, as the intermediate layer. A Ti- and Zr-containing aluminum oxide layer having an α-type crystal structure in a chemically vapor-deposited state is vapor-deposited on the intermediate layer as the upper layer. In this way, the lower layer composed of the Ti compound layer, the intermediate layer composed of the reformed α-type Al2O3 layer, and the upper layer composed of the Ti- and Zr-containing aluminum oxide layer are vapor-deposited as a hard coating layer on the surface of the tool substrate. The coated cutting tool with the configuration described above has even more superior high-temperature strength and surface properties. The coated cutting tool exerts excellent chipping resistance, even under high-speed intermittent cutting conditions where high heat is generated and the cutting edges are subjected to intermittent impact loading repeatedly.
(c) The Ti- and Zr-containing aluminum oxide layer which is the upper layer can be formed on the reformed α-type Al2O3 layer, which is the intermediate layer, under the following conditions. First, as a first step, first-step vapor deposition is performed for 60 minutes under the following conditions (i) to (iii).
(i) Composition of reaction gas (vol. %):
1 to 5% of AlCl3 
0 to 0.01% of TiCl4 
0.05 to 0.1 of ZrCl4 
2 to 6% of CO2 
1 to 5% of HCl
0.25 to 0.75% of H2S
H2 as balance
(ii) Reaction atmosphere temperature: 960 to 1010° C.
(iii) Reaction atmosphere pressure: 6 to 10 kPa
Next, as a second step, vapor deposition is performed under the following conditions (i) to (iii).
(i) Composition of reaction gas (vol. %):
6 to 10% of AlCl3 
0.05 to 0.6% of TiCl4 
0.6 to 1.2 of ZrCl4 
2 to 10% of CO2 
3 to 5% of HCl
0 to 0.5% of H2S
H2 as balance
(ii) Reaction atmosphere temperature: 940 to 980° C.
(iii) Reaction atmosphere pressure: 6 to 10 kPa
By following the steps described above, a Ti- and Zr-containing aluminum oxide layer (hereinafter referred to as a reformed AlTiZrO layer), which has an α-type crystal structure in a chemically vapor-deposited state, can be formed. The reformed AlTiZrO layer has a mean layer thickness of 1 to 15 μm, and the content ratio of the Ti component to the total amount of the Al component is 0.002 to 0.01 (as atomic ratio), and the content ratio of the Zr component to the total amount of the Al component is 0.002 to 0.01 (as atomic ratio).
(d) When the texture of the reformed AlTiZrO layer is observed by the emission type scanning electron microscope, a flat-plate polygonal shape of a large-sized grain can be seen within a plane perpendicular to the layer thickness direction. When the reformed AlTiZrO layer is observed in the plane parallel to the layer thickness direction, it can be seen that the outer surface of the reformed AlTiZrO layer is substantially flat, and the reformed AlTiZrO layer has a texture made of the grains whose shapes are elongated in the layer thickness direction (hereinafter, the shape of the crystal grain described above is referred a flat-plate polygonal vertically elongated shape).
When the vapor deposition of the reformed AlTiZrO layer is performed under further limited conditions (for example, the volume % of TiCl4, ZrCl4, and H2S are set 0, 0.05 to 0.1, and 0.50 to 0.75 respectively, and the reaction atmosphere temperature 990 to 1010° C. in the first vapor deposition, and the volume % of TiCl4, ZrCl4 and H2S are set 0.05 to 0.2, 0.05 to 0.1 and 0.05 to 0.1, respectively, and the reaction atmosphere temperature 940 to 960° C. in the second vapor deposition), a texture described below is formed. When the texture is viewed within the plane perpendicular to the layer thickness direction, the large-sized grains with a flat hexagonal shape are observed. When the reformed AlTiZrO layer is seen within the plane parallel to the layer thickness direction, it can be seen that the outer surface of the reformed AlTiZrO layer is substantially flat. In addition, the grains that have the elongated shape within the plane parallel to the layer thickness direction, account for 35% or more in area ratio, in the whole surface area perpendicular to the thickness direction of the layer.
(e) As in the reformed α-type Al2O3 layer, the reformed AlTiZrO layer is analyzed with the field-emission-type scanning electron microscope. In the analysis, individual crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface, are irradiated by an electron beam. Then, a tilt angle, which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. The measured tilt angles belonging to a range of 0 to 45° are sectioned every pitch of 0.25°, and the frequencies existing in each section are collected, being represented by a tilt angle frequency distribution graph. In the tilt-angle frequency distribution graph, a sharp highest peak appears at a specific section of the tilt angle, and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies. This means that the reformed AlTiZrO layer with high (0001) plane orientation ratio is formed. The (0001) plane orientation ratio of the reformed AlTiZrO layer is higher than that of the conventional AlTiZrO layer of the conventional coated cutting tool, resulting even more superior high-temperature strength of the reformed AlTiZrO layer.
(f) In addition, the reformed AlTiZrO layer is analyzed by the field-emission-type scanning electron microscope and an electronic backscattering diffraction image apparatus. In the analysis, individual crystal grains having a hexagonal crystal lattice present within the measurement range of a polished surface, are irradiated by an electron beam. Then, a tilt angle, which is the angle formed between the normal line to the (0001) plane of the crystal grain and the normal line to the polished surface of the cutting tool, is measured. Based on the measurement results, a crystallographic orientation relationship between the adjacent crystal lattices is calculated, and a distribution of lattice points (constituent atom sharing lattice points) is calculated. The constituent atom sharing lattice point is a lattice point that has a constituent atom shared by two crystal lattices forming the grain boundary at the grain boundary. A constituent atom sharing lattice point type in which N lattice points not sharing the constituent atom exist between the constituent atom sharing lattice points (where N is an even number of 2 or more in view of a crystal structure of corundum type hexagonal close packed crystal but does not include even numbers of 4, 8, 14, 24, and 26 when the upper limit of N is set to 28 in view of distribution frequency) is expressed as ΣN+1. When the reformed AlTiZrO layer is observed by the field-emission-type scanning electron microscope, it is seen that the reformed AlTiZrO layer includes the crystal grains with the flat-plate polygonal vertically elongated shape. Among the crystal grains with the flat-plate polygonal vertically elongated shape, 60% or more of them are divided by at least one of crystal lattice interface with the constituent atom sharing lattice point type expressed by Σ3 (hereinafter referred as a Σ3 coincidence site lattice interface) inside.
(h) As described above, the upper layer composed of the reformed AlTiZrO layer has a high (0001) plane orientation rate, and a crystal plane at the surface thereof has the same orientation as a crystal plane (for example, (0001)) within the plane perpendicular to the layer thickness direction of this layer. Thus, outer surface of the upper layer is formed in the shape of a flat plate which is substantially flat (as seen within the plane parallel to the layer thickness direction), and shows excellent chipping resistance due to the surface properties thereof. Furthermore, the strength within the crystal grains is increased since the Σ3 coincidence site lattice interfaces are present inside the grains with the flat-plate polygonal vertically elongated shape. Therefore, the reformed AlTiZrO layer has excellent high-temperature hardness and high-temperature strength and shows excellent chipping resistance, compared to the conventional AlTiZrO layer.
(i) Accordingly, as the hard coating layer of the present embodiment, the coated tool of the present invention includes the reformed α-type Al2O3 layer having a high (0001) plane orientation rate and having excellent high-temperature strength as the intermediate layer. Furthermore, the coated tool of the present invention includes the reformed AlTiZrO layer having excellent high-temperature hardness, high-temperature strength, and surface properties as the upper layer. The coated tool of the present invention has superior high-temperature hardness, heat resistance, and high-temperature strength as compared to the conventional coated tools 1 and 2. As a result, it exhibits excellent chipping resistance for a long-term use, even when the coated tool is used for high-speed intermittent cutting accompanied by high heat generation, and intermittent impact loading acts repeatedly on the cutting edge. The present embodiment has been made on the basis of the above knowledge and includes the following configurations.
(1) Provided is a surface-coated cutting tool formed by vapor-depositing, on the surface of a tool substrate made of tungsten carbide-based cemented carbide or titanium carbonitride-based cermet, a hard coating layer including (a) to (c) below.
(a) The lower layer is a Ti compound layer composed of one or more of a titanium carbide layer, a titanium nitride layer, a titanium carbonitride layer, a titanium carboxide layer, and a titanium oxycarbonitride layer, all of which are formed by chemical vapor deposition, and having a total mean layer thickness of 3 to 20 μm.
(b) The intermediate layer is an aluminum oxide layer having a mean layer thickness of 1 to 5 μm and having an α-type crystal structure in a chemically vapor-deposited state.
(c) The upper layer is a Ti- and Zr-containing aluminum oxide layer having a mean layer thickness of 2 to 15 μm and having an α-type crystal structure in a chemically vapor-deposited state, and contains Ti and Zr.
The intermediate layer (b) has properties indicated by a tilt-angle frequency distribution graph in which the highest peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph. The tilt-angle frequency distribution graph is obtained by utilizing a field-emission-type scanning electron microscope. Electron beams are irradiated to individual crystal grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected.
When the texture of the upper layer of the above (c) is observed by the emission type scanning electron microscope, the upper layer is a Ti- and Zr-containing aluminum oxide layer having a texture composed of crystal grains which have a flat-plate polygonal shape within the plane perpendicular to the layer thickness direction and have an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction.
The upper layer (c) has properties indicated by a tilt-angle frequency distribution graph in which the highest peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies in the tilt-angle frequency distribution graph. The tilt-angle frequency distribution graph is obtained by utilizing a field-emission-type scanning electron microscope. Electron beams are irradiated to individual crystal grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected.
Moreover, the upper layer (c) is a Ti- and Zr-containing aluminum oxide layer consisted of crystal grains, 60% or more of the grains being divided within each grain by at least one or more crystal lattice interfaces with a constituent atom sharing lattice point type expressed by Σ3. The constituent atom sharing lattice point type is expressed as ΣN+1, where “N” represents a number of lattice points (N) without a shared constituent atom between the constituent atom sharing lattice points. The constituent atom sharing lattice point type is even numbers more than 2 between crystal grains having a corundum type hexagonal close-packed structure. If the maximum number of N is set to 28 in view of distribution frequency, even numbers 4, 8, 14, 24, and 26 are excluded from the option for crystal grains having hexagonal close-packed structure. To obtain data related to the constituent atom sharing lattice point type, first, electron beams are irradiated to individual crystal grains within the measurement area on the polished surface with field-emission-type scanning electron microscope and an electron backscatter diffraction imaging device. Then, angles formed by normal lines of crystal lattice faces with hexagonal crystal lattices and the normal line to the polished surface are measured. Then, based on the measurement, a crystallographic orientation relationship between the adjacent crystal lattices is calculated. Then, a distribution of lattice points (constituent atom sharing lattice points) in which constituent atoms of a crystal lattice interface sharing one constituent atom between the crystal lattices is calculated. Then, finally, “N” representing a number of lattice points (N) without a shared constituent atom between the constituent atom sharing lattice points, is obtained.
(2) When the texture of the upper layer (c) of the surface-coated cutting tool described above (as (1)) is observed by the emission type scanning electron microscope, crystal grains corresponding to 35% or more of the whole surface area perpendicular to the layer thickness direction, has a flat-plate polygonal shape within the plane perpendicular to the layer thickness direction and an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction.
(3) The surface roughness (Ra) of the upper layer (c) in the cutting tool described above (as (1) and (2)) ranges from 0.05 to 0.3
The configuration of the hard coating layer of the coated tool of this aspect will be described below in more detail.
(a) Ti Compound Layer (Lower Layer 12A)
The lower layer is a Ti compound layer composed of one more of titanium carbide (hereinafter, referred to as TiC) layer, a titanium nitride (hereinafter, referred to as TiN) layer, a titanium carbonitride (hereinafter, referred to as TiCN) layer, a titanium carboxide (hereinafter, referred to as TiCO) layer, and a titanium oxycarbonitride (hereinafter, referred to as TiCNO) layer. The lower layer is basically present as a lower layer of the reformed α-type Al2O3 layer which is the intermediate layer. It has superior toughness and abrasion resistance, contributing to improve high-temperature strength of the hard coating layer. In addition, the lower layer adheres tightly to both the tool substrate and the reformed α-type Al2O3 layer, contributing an adhesive property of the hard coating layer to the tool substrate. If the total mean layer thickness is less than 3 μm, the improvements described above cannot be sufficiently obtained. On the other hand, if the total mean layer thickness exceeds 20 μm, thermal plastic deformation occurs easily, particularly when the cutting tool is used under high-speed intermittent cutting conditions where a high load is subjected on the cutting edge intermittently and explosively. Thermal plastic deformation causes uneven wear of the cutting tool. Accordingly, the total mean layer thickness is set to 3 to 20 μm.
(b) Reformed α-Type Al2O3 Layer (Intermediate Layer 12B)
In order to form the reformed α-type Al2O3 layer, which constitutes the intermediate layer 12B, as already described, an Al2O3 neclear is formed on the surface of the Ti compound layer, which is the lower layer, under the following low-temperature conditions.
A normal chemical vapor deposition apparatus is used. Composition of reaction gas includes 3 to 10% of AlCl3, 0.5 to 3% of CO2, 0.01 to 0.3% of C2H4 in vol. %, and H2 as balance. Reaction atmosphere temperature is set at 750 to 900° C. Reaction atmosphere pressure is set at 3 to 13 kPa.
It is desirable that the Al2O3 neclear is an Al2O3 neclear thin film having a mean layer thickness of 20 to 200 nm. After the formation of the Al2O3 neclear, the reaction atmosphere is substituted with a hydrogen atmosphere with pressure of 3 to 13 kPa. Then, temperature of the reaction atmosphere is increased to 1100 to 1200° C. and the Al2O3 neclear thin film is heat treated. An α-type Al2O3 layer, which serves as the hard coating layer, is formed under normal conditions. By following steps described above, an α-type Al2O3 layer is vapor deposited on the heat-treated Al2O3 neclear thin film, resulting formation of the intermediate layer.
The reformed α-type Al2O3 layer vapor deposited on the lower layer is analyzed by the field-emission-type scanning electron microscope, as shown in FIGS. 1A and 1B. Electron beams are irradiated to the individual grains, which has a hexagonal crystal lattice and exists in a measurement range of a polished plane. A tilt angle formed by the normal line to the polished plane and the normal line to (0001) plane as a crystal plane of the crystal grains is measured. The measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25° are sectioned. The frequencies existing in each section are collected and a tilt-angle frequency distribution graph is plotted. In the tilt-angle frequency distribution graph, the sharp highest peak exists in a tilt angle division ranging 0 to 10°.
The highest peak position of the measured tilt angles in the tilt angle frequency distribution graph of the reformed α-type Al2O3 layer can be changed by performing heat-treatment after the formation of the Al2O3 neclear (thin film) with a predetermined layer thickness. In addition, the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph (which means the (0001) plane orientation rate is high). Accordingly, whenever the thickness of the Al2O3 neclear (thin film) becomes too thin or too thick, the position of the highest peak of the measured tilt angles moves out of the range of 0 to 10°. In addition, the total sum of frequencies existing in the range of 0 to 10° becomes less than a ratio of 45% of the total frequencies in the tilt-angle frequency distribution graph. As a result, excellent high-temperature strength cannot be obtained.
The reformed α-type Al2O3 layer has superior high-temperature strength in addition to the excellent high-temperature hardness and heat resistance of the α-type Al2O3 layer of the conventional coated tool. Furthermore, by configuring the reformed α-type Al2O3 layer as an intermediate layer with a high (0001) plane orientation rate, the (0001) plane orientation rate of the reformed AlTiZrO layer vapor-deposited thereon can be increased. As a result, the surface properties of an upper layer composed of the reformed AlTiZrO layer can be improved, and high-temperature strength can be improved.
If the mean layer thickness of the intermediate layer composed of the reformed α-type Al2O3 layer is less than 1 μm, the hard coating layer cannot be provided with the above characteristics of the reformed α-type Al2O3 layer. On the other hand, if the mean layer thickness exceeds 5 μm, high temperature generated during cutting and high load subjected to the cutting edge leads to a higher rate of occurrence of thermal plastic deformation, which causes uneven wear of the cutting tool. As a result, the cutting tool is abrased faster. Thus, the mean layer thickness is set to 1 to 5 μm.
(c) Reformed AlTiZrO Layer (Upper Layer 12C)
As for the upper layer 12C composed of the reformed AlTiZrO layer chemically vapor-deposited on the intermediate layer 12B, an Al component which is a constituent component of the upper layer improves the high-temperature hardness and heat resistance of the layer. An extremely small amount (Ti/(Al+Ti+Zr) is 0.002 to 0.01 (as an atomic ratio) in a ratio accounted for in the total amount with Al) of Ti component and an extremely small amount (Zr/(Al+Ti+Zr) is 0.002 to 0.1 (as an atomic ratio) in a ratio accounted for in the total amount with Al) of Zr component contained in the upper layer improves the crystal grain boundary strength of the reformed AlTiZrO layer, and contributes to improving the high-temperature strength of the upper layer. If the content ratio of the Ti and Zr components in the upper layer is less than 0.002, the above functions cannot be obtained. On the other hand, if the content ratio of the Ti and Zr components exceeds 0.01, the grain boundary strength deteriorates as Ti oxide and Zr oxide grains precipitate in the layer. Therefore, it is desirable that the content ratio of the Ti component (the value of the ratio of Ti/(Al+Ti+Zr)) and the content ratio of the Zr component (the value of the ratio of Zr/(Al+Ti+Zr)) in the upper layer accounted for in the total amount with the Al component is 0.002 to 0.01 (as an atomic ratio).
The reformed AlTiZrO layer can be vapor-deposited by adjusting chemical vapor deposition conditions of the composition of a reaction gas during vapor deposition, the reaction atmosphere temperature, and the reaction atmosphere pressure as follows, for example.
First, the first-step vapor deposition is performed for 60 minutes under the following conditions:
(i) Composition of reaction gas (vol. %):
1 to 5% of AlCl3,
0 to 0.01% of TiCl4,
0.05 to 0.1% of ZrCl4 
2 to 6% of CO2,
1 to 5% of HCl,
0.25 to 0.75% of H2S, and
H2 as balance,
(ii) Reaction atmosphere temperature: 960 to 1010° C., and
(iii) Reaction atmosphere pressure: 6 to 10 kPa,
Second, the second-step vapor deposition is performed under the following conditions.
(i) Composition of reaction gas (vol. %):
6 to 10% of AlCl3,
0.05 to 0.6% of TiCl4,
0.6 to 1.2% of ZrCl4 
2 to 10% of CO2,
3 to 5% of HCl,
0 to 0.5% of H2S, and
H2 as balance,
(ii) Reaction atmosphere temperature: 940 to 980° C., and
(iii) Reaction atmosphere pressure: 6 to 10 kPa.
When a vapor deposition layer with a mean layer thickness of 2 to 15 μm is formed as a film, by performing the first-step and the second-step vapor deposition in the conditions described above, the reformed AlTiZrO layer whose ratio of Ti to Al component is 0.002 to 0.01 and that of Zr to Al component is 0.002 to 0.01 in atomic ratio, is formed.
When the reformed AlTiZrO layer is observed by the emission type scanning electron microscope, the textures shown in FIGS. 3A and 3B are observed. The reformed AlTiZrO layer is viewed within the plane perpendicular to the layer thickness direction. The texture containing large crystal grains with a flat-plate polygonal shape is formed. The reformed AlTiZrO layer is viewed within the plane parallel to the layer thickness direction. The outer surface of the reformed AlTiZrO layer is substantially flat. Also, the texture containing crystal grains with elongated shape is formed (Referred as a flat-plate polygonal elongated shape crystal grain).
As for the reformed AlTiZrO layer, similarly to the reformed α-type Al2O3 layer, which constitutes the intermediate layer, the tilt angle of the normal line to the (0001) plane to the normal line to a polished surface is measured and a tilt angle frequency graph is plotted. In the tilt angle frequency graph of the reformed AlTiZrO layer, a peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies in the tilt-angle frequency distribution graph. These results indicate that the (0001) plane orientation rate of the reformed AlTiZrO layer, which constitutes the upper layer, is high.
That is, as for the reformed AlTiZrO layer, since the (0001) plane orientation rate of the reformed α-type Al2O3 layer, which is the intermediate layer, is 45% or more, the reformed AlTiZrO layer is also formed as a layer having a high (0001) plane orientation rate (the (0001) plane orientation rate is 60% or more).
When the upper layer is viewed within the plane parallel to the layer thickness direction, the outer surface of the upper layer is formed in the shape of a substantially flat plate. Thus, the upper layer has a excellent surface property. Consequently, the upper layer shows superior chipping resistance as compared to the conventional AlTiZrO layer.
When the vapor deposition of the reformed AlTiZrO layer is performed under further limited conditions (for example, the conditions where volume percentages of TiCl4, ZrCl4, and H2S in the reaction gas are 0, 0.05 to 0.1, and 0.5 to 0.75 vol. %, respectively, and the reaction atmosphere temperature is set to 990 to 1010° C. in the first-step vapor deposition, and volume percentages of TiCl4, ZrCl4, and H2S in the reaction gas are set 0.05 to 0.2 vol. %, 0.05 to 0.1, and 0.05 to 0.1 vol. %, respectively and the reaction atmosphere temperature is set to 940 to 960° C. in the second-step vapor deposition), a texture described below is formed. In the texture, when it is viewed within the plane perpendicular to the layer thickness direction, there are large-sized crystal grains with a flat-plate hexagonal shape. When the texture is viewed within the plane parallel to the layer thickness direction, the outer surface of the upper layer is substantially flat and the crystal grains have an elongated shape stretched in the layer thickness direction. The ratio of the surface area occupied by the crystal grains having the flat-plate hexagonal elongated shape, to the whole surface area of the plane parallel to the layer thickness direction, accounts for 35% or more, in the upper layer formed in the further limited conditions.
The reformed AlTiZrO layer is analyzed with a field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus. In the analysis, electron beams are irradiated to individual crystal grains within the measurement range of the polished surface. Then, angles between the normal line to each of crystal lattice planes with a hexagonal crystal lattice and the normal line to the polished surface are measured. From the measurement results, the crystal orientation relationship between adjacent crystal lattices is calculated. Then, distribution of lattice points (constituent atom sharing lattice points) is calculated. The constituent atom sharing lattice point is a lattice point that has a constituent atom shared by two crystal lattices forming the grain boundary at the grain boundary. A constituent atom sharing lattice point configuration is expressed by ΣN+1, where the number represented by N is the number of lattice points that have no constituent atom shared at the grain boundary between two constituent atom sharing lattice points with constituent atoms. The constituent atom sharing lattice point type is even numbers more than 2 between crystal grains having a corundum type hexagonal close-packed structure. If the maximum number of N is set to 28 in view of distribution frequency, even numbers 4, 8, 14, 24, and 26 are excluded from the option for crystal grains having hexagonal close-packed structure. The crystal grains of the reformed AlTiZrO layer are divided by at least one of Σ3 coincidence site lattice interface within each crystal grain. The ratio of surface area occupied by the crystal grains that have the flat-plate polygonal elongated shape and divided by at least one of Σ3 coincidence site lattice interface, to the surface area occupied by crystal grains with the flat-plate polygonal elongated shape (including the flat-plate hexagonal elongated shape), is 60% or more.
The strength within the crystal grains of the reformed AlTiZrO layer is increased due to the presence of the Σ3 coincidence site lattice interface in the crystal grains with the flat-plate polygonal (including hexagonal) elongated shape. As a result, cracking of the reformed AlTiZrO layer is suppressed during high-speed heavy cutting work where high load is subjected to the reformed AlTiZrO layer. Even if the cracking occurred, growth and spreading of the cracking would be prevented. Therefore, chipping resistance, fracture resistance, and spalling resistance are improved in the cutting tool having the reformed AlTiZrO layer.
Accordingly, the upper layer of the present invention, which has a high (0001) plane orientation rate, has flat surface properties, and is composed of the reformed AlTiZrO layer in which the Σ3 coincidence site lattice interfaces are present with in the flat-plate polygonal (including flat hexagonal) elongated crystal grains, exhibits excellent chipping resistance and abrasion resistance for a prolonged period of time without causing chipping, fracture, spalling, or the like and also without causing thermal plastic deformation, uneven wear, or the like, even in high-speed intermittent cutting work accompanied by high heat generation and high load subjected on the cutting edge.
If the layer thickness of the upper layer composed of the reformed AlTiZrO layer is less than 2 μm, the excellent characteristics of the upper layer cannot be sufficiently exhibited. On the other hand, if the layer thickness of the upper layer exceeds 15 μm, thermal plastic deformation, which causes uneven wear, easily occurs. In addition, a rate of occurrence of chipping is also increased. Therefore, the mean layer thickness of the upper layer is set to 2 to 15 μm.
As a comparison, the conventional AlTiZrO layer (the layer described in the PTL 7), was analyzed by the field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus. In the analysis, the texture of crystal grains and the constituent atom sharing lattice point configuration of the conventional AlTiZrO layer were analyzed. The texture of the crystal grains of the conventional AlTiZrO layer is made of pyramidal-shaped crystal grains with a polygonal elongated shape stretched to the layer thickness direction. The outer surface of the conventional AlTiZrO layer has protuberances and recesses along with the pyramidal shape of the crystal grains. Because of these, the abrasion resistance of the conventional AlTiZrO layer is inferior compared to that of the reformed AlTiZrO layer.
In terms of the constituent atom sharing lattice point configuration, the ratio of surface area occupied by the pyramidal-shaped crystal grains, which have a polygonal elongated shape stretched to the layer thickness direction and contain a Σ3 coincidence site lattice interface within, to the surface area occupied by crystal grains, which consist the conventional AlTiZrO layer and have the convexoconcave polygonal elongated shape stretched to the layer thickness direction, is 12% or less. Therefore, the strength within the crystal grains is not improved as in the reformed AlTiZrO layer.
Accordingly, the conventional coated tool 7 in which the upper layer of the hard coating layer is composed of the conventional AlTiZrO layer cannot prevent occurrence of chipping, fracture, spalling, or the like and is inferior in tool performance, in high-speed intermittent cutting work accompanied by high heat generation and intermittent impact loading subjected on the cutting edge.
In the coated tool of the present invention, after the reformed AlTiZrO layer of the upper layer is formed, polishing processing using a grind stone or polishing processing using wet blasting can be performed on the surface of the upper layer, so that the surface roughness of the reformed AlTiZrO layer can be further adjusted. For example, the occurrence of welding to the surface-coated tool during cutting can be suppressed by adjusting the surface roughness of the reformed AlTiZrO layer to Ra 0.05 to 0.3 μm.
The surface roughness Ra in the present invention means the value of arithmetic mean roughness Ra defined by JIS B0601 (1994), and the measuring method thereof is not particularly limited.
Although the embodiments of the present invention have been described, the invention is limited to these embodiments. The same effects as those of the respective embodiments can be obtained even if two or more kinds of elements selected from a group consisting of Ti, Y, Zr, Cr, and B are appropriately combined and used as added elements to the upper layer.
Next, the coated tool of the present invention will be specifically described by means of examples.
Example 1
The following powders, each having a mean particle size within a range of 2 to 4 μm, were prepared as raw materials for substrates: WC powder, TiC powder, ZrC powder, VC powder, TaC powder, NbC powder, Cr3C2 powder, TiN powder, TaN powder, and Co powder. These raw powders were compounded with each other in the compounding compositions shown in Table 1, mixed with each other in an acetone solution having wax added thereto for 24 hours using a ball mill, and were then dried under reduced pressure. Thereafter, the resultant powder mixture was press-formed into a green compact having a predetermined shape at a pressure of 98 MPa. The green compact was then sintered in a vacuum under the following conditions: a pressure of 5 Pa, a predetermined temperature within a range of 1370° C. to 1470° C., and a holding duration of 1 hour. After sintering, cutting edges were subjected to honing (R: 0.07 mm) to manufacture bodies 1A to 1E made of WC-based cemented carbide and having a throwaway tip shape defined in ISO-CNMG120408.
Additionally, the following powders, each having a mean particle size within a range of 0.5 to 2 μm, were prepared as raw materials: TiCN (TiC/TiN=50/50 in weight ratio) powder, Mo2C power, ZrC power, NbC powder, TaC powder, WC power, Co powder and Ni powder. These raw powders were compounded with each other in the compounding compositions shown in Table 2, were wet-mixed with each other for 24 hours using a ball mill, and were dried. Thereafter, the resulting powder mixture was press-formed into a green compact at a pressure of 98 MPa. The green compact was then sintered in a nitrogen atmosphere under the following conditions: a pressure of 1.3 kPa, a temperature of 1540° C., and a holding duration of 1 hour. After sintering, cutting edges were subjected to honing (R: 0.07 mm) to manufacture bodies 1a to 1e made of TiCN-based cermet and having a tip shape defined in ISO CNMG120418.
Subsequently, these bodies 1A to 1E and the bodies 1a to 1e were loaded into a normal chemical vapor deposition apparatus.
(a) First, Ti compound layers with target layer thicknesses shown in Table 7 were vapor-deposited as lower layers of hard coating layers under the conditions shown in Table 3 (1-TiCN in Table 3 shows the formation conditions of TiCN layers with a longitudinal growth crystalline structure disclosed in Japanese Unexamined Patent Application Publication No. 6-8010, and the others show the formation conditions of a normal granular crystalline structure).
(b) Subsequently, reformed α-type Al2O3 layers with target layer thicknesses shown in Table 8 were vapor-deposited as intermediate layers of the hard coating layers under the conditions shown in Table 4.
(c) Next, coated tools A1 to A15 of the present invention were manufactured, respectively, by vapor-depositing reformed AlTiO layers with target layer thicknesses similarly shown in Table 8 as upper layers of hard coating layers according to the vapor deposition conditions shown in Table 5.
For the purpose of comparison, comparative coated tools A1 to A10 (equivalent to the conventional coated tool 2) provided with hard coating layers composed of Ti compound layers and conventional AlTiO layers with target layer thicknesses shown in Table 9 were manufactured, respectively, by forming lower layers of hard coating layers under the conditions shown in Table 3 and forming upper layers under the conditions (equivalent to the vapor deposition conditions of the conventional AlTiO layers disclosed in PTL 2 Japanese Unexamined Patent Application Publication No. 2006-289556)) shown in Table 6.
The type of the bodies, the type of the lower layers, and the thickness of the lower layers in the comparative coated tools A1 to A10 are the same as those of the coated tools A1 to A10 of the present invention, respectively.
Moreover, for reference, the reference coated tools A11 to A15 (equivalent to the conventional coated tool 1) provided with hard coating layers composed of Ti compound layers and conventional α-type Al2O3 layers with target layer thicknesses shown in Table 9 were manufactured, respectively, by forming lower layers of hard coating layers under the conditions shown in Table 3 and forming α-type Al2O3 layers under the conditions (equivalent to the vapor deposition conditions of the conventional α-type Al2O3 layers disclosed in PTL 1 (Japanese Unexamined Patent Application Publication No. 2006-198735)) shown in Table 6.
The type of the bodies, the type of the lower layers, and the thickness of the lower layers in the reference tools A11 to A15 are the same as those of the coated tools A11 to A15 of the present invention, respectively.
Post-processing composed of wet blasting processing with projection pressure 0.15 MPa and Al2O3 grains of 200 meshes was performed on the surfaces of some reformed AlTiO layers of the coated tools of the present invention, and the surfaces of some conventional AlTiO layers of the comparative coated tools. As the post-processing, polishing processing using an elastic grind stone may be adopted.
Tables 8 and 9 show the values of the surface roughness (Ra (μm)) of the reformed AlTiO layers (those marked by * in Table 8) of the coated tools of the present invention which were subjected to post-processing and the conventional AlTiO layers (those marked by * in Table 9) of the comparative coated tools. (For reference, the values of Ra regarding the coated tools of the present invention and the comparative coated tools which were not subjected to post-processing are also shown in Tables 8 and 9.)
Subsequently, as for the reformed α-type Al2O3 layers which constitute the intermediate layers of the hard coating layers of the coated tools A1 to A15 of the present invention, the reformed AlTiO layers which constitute the upper layers of the hard coating layers, the conventional AlTiO layers of the comparative coated tools A1 to A10, and the α-type Al2O3 layers of the reference coated tools A11 to A15, tilt angle frequency distribution graphs were plotted, respectively, using the field-emission-type scanning electron microscope.
The tilt angle frequency distribution graphs were plotted by setting the respective layers in the coated tools A1 to A15 of the present invention, the comparative coated tools A1 to A10, and the reference coated tools A11 to A15 within a lens barrel of the field-emission-type scanning electron microscope, with the surfaces of the layers as polished surfaces; individually irradiated crystal grains having a hexagonal crystal lattice present within the measurement range of each polished surface with an electron beam having an acceleration voltage of 15 kV with an irradiating current of 1 nA at an angle of incidence of 70 degrees with respect to each polished surface, thereby measuring the tilt angle of the normal line to the (0001) plane, which is a crystal plane of each crystal grain, to the normal line to each polished surface, at intervals of 0.1 μm/step for a region 30×50 μm, using the electronic backscattering diffraction image apparatus; and on the basis of these measurement results, dividing the measured tilt angles which are within a range of 0 to 45 degrees among the measured tilt angles at every pitch of 0.25 degrees, and summing the frequencies present within the respective divisions.
As an example of the tilt angle frequency distribution graphs, FIG. 2 shows a tilt angle frequency distribution graph of the (0001) plane of a reformed α-type Al2O3 layer which constitutes an intermediate layer of a hard coating layer of a coated tool S1 of the present invention.
The “surface” in this invention includes not only a face parallel to the surface of a base, but also a face which inclines to the surface of the base, for example, the cutting face of a layer.
As a result, in the obtained tilt angle frequency distribution graphs of the reformed α-type Al2O3 layers and reformed AlTiO layers of the coated tools of the present invention, the conventional AlTiO layers of the comparative coated tools A1 to A10, and the conventional α-type Al2O3 layers of the reference coated tools A11 to A15, as shown in Tables 8 and 9, respectively, the distributions of the measured tilt angles of the (0001) plane in the reformed α-type Al2O3 layers and reformed AlTiO layers of the coated tools of the present invention show a tilt angle frequency distribution graph in which the highest peak appears in the tilt angle division within a range of 0 to 10 degrees, respectively. On the other hand, the distribution of the measured tilt angles of the (0001) plane in the conventional AlTiO layers of the comparative coated tools A1 to A10 shows a tilt angle frequency distribution graph in which the highest peak does not present in an unbiased manner within a range of 0 to 45 degrees.
Tables 8 and 9 show the ratios of the frequencies present in the tilt angle division within a range of 0 to 10 degrees, which are accounted for in the overall tilt angle frequency distribution graph.
Subsequently, as for the reformed AlTiO layers which constitute the upper layers of the coated tools A1 to A15 of the present invention, and the conventional AlTiO layers of the comparative coated tools A1 to A10, the crystal grain structure and the constituent atom sharing lattice point configuration were inspected using the field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus.
First, when the reformed AlTiO layers of the coated tools A1 to A15 of the present invention and the conventional AlTiO layers of the comparative coated tools A1 to A10 were observed using the field-emission-type scanning electron microscope, the flat-plate polygonal (including flat hexagonal) and elongated crystal grain structure of a large grain size shown typically in FIGS. 3A and 3B were observed in the coated tools A1 to A15 of the present invention (FIG. 3A is a schematic view of the texture of the coated tools A1 to A9 of the present invention as seen within the plane perpendicular to the layer thickness direction, and FIG. 3C is a schematic view of the texture composed of flat hexagonal and elongated crystal grains of a large grain size, of the coated tools A10 to A15 of the present invention as seen within the plane perpendicular to the layer thickness direction).
On the other hand, as shown typically in FIGS. 5A and 5B, a polygonal and elongated crystal grain structure was observed in the comparative coated tools A1 to A10. However, the grain size of each crystal grain was small as compared to that of the present invention, and as being clear from FIG. 5B, pyramidal irregularities were formed in the layer surface (FIGS. 5A and 5B are schematic views of the texture of the comparative coated tools A1 to A10).
Subsequently, as for the reformed AlTiO layers of the coated tools A1 to A15 of the present invention, and the conventional AlTiO layers of the comparative coated tools A1 to A10, the area ratios of crystal grains in which the Σ3 coincidence site lattice interfaces are present inside the crystal grains which constitute each layer were measured.
First, as for the reformed AlTiO layers of the coated tools A1 to A15 of the present invention, when the respective layers are within a lens barrel of the field-emission-type scanning electron microscope, with the surfaces of the layers as polished surfaces; crystal grains having a hexagonal crystal lattice present within the measurement range of each polished surface are individually irradiated with an electron beam having an acceleration voltage of 15 kV with an irradiating current of 1 nA at an angle of incidence of 70 degrees with respect to each polished surface, thereby measuring the angle at which the normal line to each of crystal lattice planes of the crystal grains crosses the normal line to each base surface, at intervals of 0.1 μm/step for a region 30×50 μm, using the electronic backscattering diffraction image apparatus; and from these measurement results, the crystal orientation relationship between adjacent crystal lattices is calculated, and the distribution of lattice points (constituent atom sharing lattice points) where respective constituent atoms which constitute a crystal lattice interface sharing one constituent atom between the crystal lattices is calculated; and a constituent atom sharing lattice point configuration in which N (here, N is any even number equal to or greater than 2 in a crystal structure of a corundum-type hexagonal close-packing crystal, but when the upper limit of N is 28 from the viewpoint of a distribution frequency, even numbers 4, 8, 14, 24, and 26 do not exist) lattice points which do not share any constituent atoms between the constituent atom sharing lattice points are present is expressed by ΣN+1, the area ratios of crystal grain in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains among all the crystal grains present within the measurement range of the reformed AlTiO layers were obtained, and the values of the area ratios were shown in Table 8 as Σ3 coincidence site lattice interface ratio (%).
Next, even as for the conventional AlTiO layers of the comparative coated tools A1 to A10, by the same method as the case of the coated tools of the present inventions, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains among all the crystal grains present within the measurement range of the conventional reformed AlTiO layers were obtained, and the values of the area ratios were shown in Table 9 as a Σ3 coincidence site lattice interface ratio (%).
As shown in Tables 8 and 9, in the reformed AlTiO layers of the coated tools A1 to A15 of the present invention, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are 60% or more. On the other hand, in the conventional AlTiO layers of the comparative coated tools A1 to A10, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are 40% or less. It can be understood from this that the rate at which the Σ3 coincidence site lattice interfaces are present inside crystal grains is very small.
Subsequently, as for the reformed AlTiO layers of the coated tools A1 to A15 of the present invention, and the conventional AlTiO layers of the comparative coated tools A1 to A10, the area ratios of flat hexagonal crystal grains of a large grain size present within the plane perpendicular to the layer thickness direction were obtained using the field-emission-type scanning electron microscope. These values are shown in Tables 8 and 9.
Here, the “flat hexagonal crystal grains of a large grain size” means polygonal crystal grains in which the mean value of ten grains is 3 to 8 μm when the diameter of grains present within the plane perpendicular to the layer thickness direction observed by the field-emission-type scanning electron microscope is measured, and six vertex angles whose angle of vertex is 100 to 140° are provided.
Subsequently, although the thicknesses of the respective constituent layers in the hard coating layers of the coated tools A1 to A15 of the present invention, the comparative coated tools A1 to A10, and the reference coated tools A11 to A15 were measured using the scanning electron microscope (longitudinal-section measurement), substantially the same mean layer thicknesses (mean value of five-point measurements) as the target layer thicknesses were shown in all cases.
Next, all the coated tools A1 to A15 of the present invention, the comparative coated tools A1 to A10, and the reference coated tools A11 to A15 were screw-fixed to a tip portion of a bite made of tool steel by a fixing jig, and in this state, were subjected to a dry high-speed intermittent cutting test (normal cutting speed is 200 m/min) on bearing steel under the following conditions (referred to as cutting condition A):
Workpiece: a round bar of JIS-SUJ2 (HRC62) with four longitudinal grooves equally-spaced in the length direction,
Cutting speed: 250 m/min,
Depth of cut: 1.5 mm,
Feed rate: 0.15 mm/rev, and
Cutting time: 5 minutes,
a dry high-speed intermittent cutting test (normal cutting speed is 200 m/min) on alloy tool steel under the following conditions (referred to as cutting condition B):
Workpiece: a round bar of JIS-SKD11 (HRC58) with four longitudinal grooves equally-spaced in the length direction,
Cutting speed: 300 m/min,
Depth of cut: 1.5 mm,
Feed rate: 0.15 mm/rev, and
Cutting time: 5 minutes, and
a dry high-speed intermittent cutting test (normal cutting speed is 150 m/min) on carbon tool steel under the following conditions (referred to as cutting condition C):
Workpiece: a round bar of JIS-SK3 (HRC61) with four longitudinal grooves equally-spaced in the length direction,
Cutting speed: 250 m/min,
Depth of cut: 1.5 mm,
Feed rate: 0.15 mm/rev, and
Cutting time: 5 minutes, and
the flank wear widths of the cutting edges were measured in all the cutting tests. These test results are shown in Table 10.









TABLE 1









Compounding composition (Mass %)

















Type
Co
TiC
ZrC
VC
TaC
NbC
Cr3C2
TiN
TaN
WC





















Tool
1A
7
—
—
—
—
—
—
—
—
Balance


substrate
1B
5.7
—
—
—
1.5
0.5
—
1.2
—
Balance



1C
5.7
2.3
—
—
—
—
1 
—
—
Balance



1D
8.5
—
0.5
—
—
—
0.5
—
—
Balance



1E
12.5
2 
—
—
—
—
—
1 
2
Balance


















TABLE 2









Compounding composition (Mass %)















Type
Co
Ni
ZrC
TaC
NbC
Mo2C
WC
TiCN



















Tool
1a
12
6
—
10
—
10
16
Balance


substrate
1b
7
7
—
 5
—
  7.5
—
Balance



1c
5
—
—
—
1
 6
10
Balance



1d
9
6
—
11
2
—
—
Balance



1e
8
5
1
 8
—
10
10
Balance

















TABLE 3







Hard coating layer (Lower layer)
Formation conditions (Reaction atmosphere pressure given in kPa and 










Composition
temperature given in ° C.)











(Numbers indicate

Reaction atmosphere











Type
atomic ratio)
Composition of reaction gas (Vol. %)
Pressure
Temperature














TiC layer
TiC
TiCl4: 4.2%, CH4: 8.5%, H2: Balance
7
1020


TiN layer (First
TiN
TiCl4: 4.2%, N2: 30%, H2: Balance
30
900


layer)






TiN layer (Other
TiN
TiCl4: 4.2%, N2: 35%, H2: Balance
50
1040


layer)






I—TiC0.5N0.5 layer
TiC0.5N0.5
TiCl4: 4.2%, N2: 20%, CH3 CN: 0.6%, H2: Balance
7
900


TiCN layer
TiC0.5N0.5
TiCl4: 4.2%, N2: 20%, CH4: 4%, H2: Balance
12
1020


TiCO layer
TiC0.5O0.5
TiCl4: 4.2%, CO: 4%, H2: Balance
7
1020


TiCNO layer
TiC0.3N0.3O0.4
TiCl4: 4.2%, CO: 3%, CH4: 3%, N2: 20%, H2: Balance
20
1020


α-Type Al2O3 layer
α-Al2O3
AlCl3: 2.2%, CO2: 5.5%, HCI: 2.2%, H2S: 0.2%, H2: Balance
7
1000



















TABLE 4









Neclear thin film formation conditions
Heat treatment










Reaction atmosphere
Reaction atmosphere














Formation

Pressure/
Temper-
Pressure/
Temper-


Type
symbol
Composition of reaction gas (Vol. %)
kPa
ature/° C.
kPa
ature/° C.
















Neclear thin
1A
AlCl3: 3%, CO2: 0.5%, C2H4:
3
800
3
1100


film (1A)

0.01%, H2: Balance


Neclear thin
1B
AlCl3: 6%, CO2: 1.5%, C2H4:
7
750
7
1200


film (1B)

0.12%, H2: Balance


Neclear thin
1C
AlCl3: 10%, CO2: 3%, C2H4:
13
900
13
1000


film (1C)

0.3%, H2: Balance





*Formation conditions of normal α-type Al2O3 layer after formation of various kinds of neclear thin films are described in Table 3














TABLE 5








Formation conditions (Reaction atmosphere


Reformed
pressure given in kPa, and temperature given in ° C.)









AlTiO layer

Reaction atmosphere










Formation symbol
Composition of reaction gas (Vol. %)
Pressure
Temperature














1A
First step
AlCl3: 1%, TiCl4: 0.03%, HCl: 3%, CO2: 2%, H2S: 0.25%, H2: Balance
7
1010



Second step
AlCl3: 6%, TiCl4: 0.6%, HCl: 3%, CO2: 5%, H2S: 0.%, H2: Balance
7
950


1B
First step
AlCl3: 2%, TiCl4: 0.04%, HCl: 1%, CO2: 3%, H2S: 0.30%, H2: Balance
8
1000



Second step
AlCl3: 7%, TiCl4: 0.45%, HCl: 4%, CO2: 6%, H2S: 0.05%, H2: Balance
10
970


1C
First step
AlCl3: 3%, TiCl4: 0.01%, HCl: 4%, CO2: 4%, H2S: 0.15%, H2: Balance
8
960



Second step
AlCl3: 8%, TiCl4: 0.20%, HCl: 4%, CO2: 6%, H2S: 0.04%, H2: Balance
9
920


1D
First step
AlCl3: 4%, TiCl4: 0.05%, HCl: 5%, CO2: 5%, H2S: 0.2%, H2: Balance
9
980



Second step
AlCl3: 10%, TiCl4: 0.06%, HCl: 3%, CO2: 8%, H2S: 0.04%, H2: Balance
9
1000


1E
First step
AlCl3: 5%, TiCl4: 0.02%, HCl: 5%, CO2: 6%, H2S: 0.1%, H2: Balance
8
1000



Second step
AlCl3: 9%, TiCl4: 0.05%, HCl: 5%, CO2: 5%, H2S: 0.02%, H2: Balance
8
960


1F
First step
AlCl3: 3%, TiCl4: 0.01%, HCl: 2%, CO2: 4%, H2S: 0.1%, H2: Balance
6
970



Second step
AlCl3: 8%, TiCl4: 0.05%, HCl: 3%, CO2: 4%, H2S: 0.01%, H2: Balance
6
970

















TABLE 6








Formation conditions (Reaction atmosphere


Conventional AlTiO layer
pressure given in kPa and temperature given in ° C.)










Composition (Numbers
Reaction atmosphere











Type
indicate atomic ratio)
Composition of reaction gas (Vol. %)
Pressure
Temperature














Neclear
(Al0.995Ti0.005)2O3
AlCl3: 4%, TiCl4: 0.02%, CO2: 2%, HCl: 1.5%, H2S: 0.05%, H2: Balance
7
870


thin film






(1a)






Neclear
(Al0.99Ti0.01)2O3
AlCl3: 3.8%, TiCl4: 0.04%, CO2: 2%, HCl: 1.5%, H2S: 0.05%, H2:
7
870


thin film

Balance




(1b)






Neclear
(Al0.98Ti0.02)2O3
AlCl3: 3.5%, TiCl4: 0.05%, CO2: 2%, HCl: 1.5%, H2S: 0.05%, H2:
7
870


thin film

Balance




(1c)






Neclear
(Al0.97Ti0.03)2O3
AlCl3: 3.2%, TiCl4: 0.06%, CO2: 2%, HCl: 1.5%, H2S: 0.05%, H2:
7
870


thin film

Balance




(1d)






Neclear
(Al0.96Ti0.04)2O3
AlCl3: 3%, TiCl4: 0.08%, CO2: 2%, HCl: 1.5%, H2S: 0.05%, H2: Balance
7
870


thin film






(1e)






Neclear
(Al0.955Ti0.045)2O3
AlCl3: 2.6%, TiCl4: 0.1%, CO2: 2%, HCl: 1.5%, H2S: 0.05%, H2: Balance
7
870


thin film






(1f)






Neclear
(Al0.95Ti0.05)2O3
AlCl3: 2.3%, TiCl4: 0.13%, CO2: 2%, HCl: 1.5%, H2S: 0.05%, H2:
7
870


thin film

Balance




(1g)






Reformed
(Al0.995Ti0.005)2O3
AlCl3: 4%, TiCl4: 0.02%, CO2: 4%, HCl: 2.5%, H2S: 0.2%, H2: Balance
7
1020


layer






(1A)






Reformed
(Al0.99Ti0.01)2O3
AlCl3: 3.8%, TiCl4: 0.04%, CO2: 4%, HCl: 2.5%, H2S: 0.2%, H2: Balance
7
1020


layer






(1B)






Reformed
(Al0.98Ti0.02)2O3
AlCl3: 3.5%, TiCl4: 0.05%, CO2: 4%, HCl: 2.5%, H2S: 0.2%, H2: Balance
7
1020


layer






(1C)






Reformed
(Al0.97Ti0.03)2O3
AlCl3: 3.2%, TiCl4: 0.06%, CO2: 4%, HCl: 2.5% H2S: 0.2%, H2: Balance
7
1020


layer






(1D)






Reformed
(Al0.96Ti0.04)2O3
AlCl3: 3%, TiCl4: 0.08%, CO2: 4%, HCl: 2.5% H2S: 0.2%, H2: Balance
7
1020


layer






(1E)






Reformed
(Al0.955Ti0.045)2O3
AlCl3: 2.6%, TiCl4: 0.1%, CO2: 4%, HCl: 2.5% H2S: 0.2%, H2: Balance
7
1020


layer (1F)






Reformed
(Al0.95Ti0.05)2O3
AlCl3: 2.3%, TiCl4: 0.13%, CO2: 4%, HCl: 2.5% H2S: 0.2%, H2: Balance
7
1020


layer






(1G)



















TABLE 7









Tool
Lower layer of hard coating layer [Ti compound layer]













substrate
First layer
Second layer
Third layer
Fourth layer












Type
symbol
(μm)
(μm)
(μm)
(μm)
















Coated tool
A1
1a
TiN
1-TiCN
TiN
TiCNO


of the


(1)
 (17.5)
(1) 
(0.5)


present
A2
1A
TiCN
1-TiCN
TiCO
—


invention


(1)
 (8.5)
(0.5)



A3
1b
TiN
1-TiCN
TiC
TiCNO





(1)
(4)
(4) 
(1) 



A4
1B
TiC
1-TiCN
—
—





(1)
(9)



A5
1c
TiN
1-TiCN
TiCNO
—





(1)
 (4.5)
(0.5)



A6
1C
TiN
1-TiCN
TiC
TiCNO





 (0.5)
 (1.5)
(0.5)
(0.5)



A7
1d
TiN
1-TiCN
TiC
TiCNO





 (0.5)
(10) 
(2) 
(0.3)



A8
1D
TiN
TiCN
—
—





(1)
(19) 



A9
1e
TiC
1-TiCN
TiCO
—





 (0.5)
(9)
(0.5)



A10
1E
TiN
TiC
TiCN
TiCO





(1)
(1)
(7) 
(1) 



A11
1A
TiN
1-TiCN
TiCNO
TiCO





 (0.3)
(5)
(0.7)
(0.1)



A12
1a
TiN
1-TiCN
TiCO
—





(1)
(10) 
(0.5)



A13
1B
TiN
1-TiCN
TiN
TiCNO





 (0.5)
(12) 
(0.5)
(0.2)



A14
1b
TiN
1-TiCN
TiCNO
—





 (0.6)
(7)
(0.3)



A15
1C
TiN
1-TiCN
TiCN
TiCO





 (0.4)
(3)
(0.5)
(0.1)





(Numbers in the parentheses of lower layer column indicate target layer thickness)















TABLE 8









Hard coating layer



Intermediate layer [Reformed α-type Al2O3 layer]

















Frequency ratio






Tilt angle division
of tilt angle



Tool

Target
where (0001) plane
division of 0



substrate
Formation symbol of
layer thickness
shows highest peak
to 10 degrees












Type
symbol
intermediate layer
(μm)
(Degree)
(%)
















Coated
A1
1a
1A
1
1.50-1.75
60


tool of
A2
1A
1B
1
2.75-3.00
52


the
A3
1b
1C
2
2.00-2.25
65


present
A4
1B
1A
2
5.25-5.50
70


invention
A5
1c
1B
3
2.25-2.50
83



A6
1C
1B
3
3.50-3.75
97



A7
1d
1C
4
4.25-4.50
84



A8
1D
1C
4
3.25-3.50
86



A9
1e
1A
5
2.00-2.25
89



A10
1E
1B
5
5.25-5.50
82



A11
1A
1B
2
2.25-2.50
72



A12
1a
1C
2
1.75-2.00
83



A13
1B
1A
3
0.50-0.75
92



A14
1b
1B
2
0.25-0.50
88



A15
1C
1C
3
1.25-1.50
85












Hard coating layer



Upper layer [Reformed AlTiO layer]















Tilt angle division




Content ratio of
Target
where (0001) plane



Formation symbol of
Ti [Ti/(Al + Ti)]
layer thickness
shows highest peak











Type
upper layer
(atomic ratio
(μm)
(Degree)















Coated
A1
1A
0.015
5
1.50-1.75


tool of
A2
1B
0.0075
2
3.25-3.50


the
A3
1C
0.005
4
2.00-2.25


present
A4
1D
0.004
15
5.00-5.25


invention
A5
1C
0.005
13
2.25-2.50



A6
1A
0.01
10
3.50-3.75



A7
1B
0.0075
7
4.00-4.25



A8
1C
0.005
6
3.00-3.25



A9
1D
0.004
14
2.25-2.50



A10
1E
0.003
3
1.75-2.00



A11
1F
0.002
4
1.50-1.75



A12
1E
0.003
5
0.25-0.50



A13
1F
0.002
6
0.25-0.50



A14
1E
0.003
3
0.50-0.75



A15
1E
0.003
4
0.25-0.50












Hard coating layer



Upper layer [Reformed AlTiO layer]












Frequency ratio
Crystal grain ratio





of tilt angle
having Σ3 coinci-
Surface ratio of
Surface



division of 0
dence site lattice in-
flat hexagonal
roughness



to 10 degrees
terface therein
crystal grain
Ra













Type
(%)
(Area %)
(Area %)
(μm)


















Coated
A1
71
65
11
 0.3*



tool of
A2
67
60
5
0.4



the
A3
71
73
22
0.5



present
A4
72
61
11
0.5



invention
A5
74
72
14
0.6




A6
98
84
19
0.8




A7
87
77
26
0.7




A8
89
78
18
 0.05*




A9
71
82
15
0.7




A10
85
75
35
0.8




A11
74
83
78
 0.1*




A12
86
84
67
 0.2*




A13
95
77
84
0.5




A14
90
86
72
 0.3*




A15
87
79
77
0.6



















TABLE 9









Hard coating layer



Intermediate layer [Conventional α-type Al2O3layer]















Frequency ratio





Tilt angle division
of tilt angle




Target
where (0001) plane
division of 0



Formation symbol of
layer thickness
shows highest peak
to 10 degrees











Type
intermediate layer
(μm)
(Degree)
(%)















Comparative
A1
—
—
—
—


coated tool
A2
—
—
—
—



A3
—
—
—
—



A4
—
—
—
—



A5
—
—
—
—



A6
—
—
—
—



A7
—
—
—
—



A8
—
—
—
—



A9
—
—
—
—



A10
—
—
—
—


Reference
A11
1A
2
1.50-1.75
55


coated tool
A12
1B
7
2.00-2.25
63



A13
1C
10 
3.00-3.25
48



A14
1A
8
1.25-1.50
65



A15
1B
5
1.75-2.00
71












Hard coating layer



Upper layer [Conventional AlTiO layer]












Formation symbol of
Content ratio of

Tilt angle division



upper layer
Ti [Ti/
Target
where (0001) plane













Neclear
Reformed
(Al + Ti)]
layer thickness
shows highest peak












Type
thin film
layer
(atomic ratio
(μm)
(Degree)
















Comparative
A1
1a
1B
0.01
3
15.25-15.50


coated tool
A2
1b
1A
0.005
5
20.00-20.25



A3
1c
1C
0.015
10
35.25-35.50



A4
1e
1D
0.02
14
27.75-30.00



A5
1d
1E
0.025
17
17.25-17.50



A6
1f
1F
0.04
15
22.25-22.50



A7
1g
1A
0.005
7
23.50-23.75



A8
1b
1G
0.05
9
32.50-32.75



A9
1a
1B
0.01
8
34.00-34.25



A10
1c
1C
0.015
6
35.25-35.50


Reference
A11
—
—
—
—
—


coated tool
A12
—
—
—
—
—



A13
—
—
—
—
—



A14
—
—
—
—
—



A15
—
—
—
—
—












Hard coating layer



Upper layer [Conventional AlTiO layer]












Frequency ratio
Crystal grain ratio





of tilt angle
having Σ3 coinci-
Surface ratio of
Surface



division of 0
dence site lattice in-
flat hexagonal
roughness



to 10 degrees
terface therein
crystal grain
Ra











Type
(%)
(Area %)
(Area %)
(μm)















Comparative
A1
15
11
0
0.5


coated tool
A2
11
6
0
 0.3 *



A3
7
4
0
0.6



A4
18
12
0
0.8



A5
5
17
0
0.9



A6
14
11
0
0.8



A7
7
15
0
 0.1 *



A8
6
11
0
0.6



A9
5
2
0
  0.05 *



A10
11
0
0
0.6


Reference
A11
—
—
—
—


coated tool
A12
—
—
—
—



A13
—
—
—
—



A14
—
—
—
—



A15
—
—
—
—





(Note)


The mark * in the column “Surface roughness” indicates that wet blasting processing was performed.

















TABLE 10









Flank wear width (mm)

Cutting test result (min)
















Cutting
Cutting
Cutting


Cutting
Cutting
Cutting



condition
condition
condition


condition
condition
condition














Type
(A)
(B)
(C)
Type
(A)
(B)
(C)



















Coated tool
A1
0.23
0.21
0.19
Comparative
A1
 1.3 *
1.5
 1.4 *


of the
A2
0.35
0.33
0.31
coated tool
A2
 2.7 *
2.5
2.3


present
A3
0.28
0.26
0.25

A3
3.8
3.6
3.5


invention
A4
0.36
0.34
0.32

A4
 1.5 *
 1.4 *
1.3



A5
0.37
0.35
0.34

A5
 1.5 *
 1.4 *
 1.2 *



A6
0.38
0.34
0.33

A6
 1.3 *
 1.2 *
 1.0 *



A7
0.30
0.28
0.26

A7
3.6
3.5
3.4



A8
0.31
0.28
0.27

A8
3.4
 3.3 *
3.2



A9
0.37
0.35
0.34

A9
3.5
3.2
3.0



A10
0.16
0.14
0.14

A10
2.9
2.7
2.5



A11
0.17
0.15
0.13
Reference
A11
 1.6 *
 1.4 *
 1.3 *



A12
0.18
0.16
0.14
coated tool
A12
3.8
 3.6 *
3.7



A13
0.15
0.12
0.13

A13
3.9
3.7
3.6



A14
0.17
0.15
0.14

A14
3.9
3.8
3.8



A15
0.17
0.16
0.15

A15
 2.7 *
2.6
2.4





Cutting test results of comparative coated tools and reference coated tools show cutting times (min) until the tools come to the end of their usable lifespan due to chipping or flank wear (usable lifespan determination criterion: Flank wear width of 0.5 mm).


In addition, the mark * in columns indicates a case where tools come to the end of their usable lifespan due to chipping.






From the results shown in Tables 8 to 10, as for the coated tools A1 to A15 of the present invention, the (0001) plane orientation rate of the reformed α-type Al2O3 layers which are the intermediate layers of the hard coating layers show a high ratio of 45% or more, and have excellent high-temperature strength. In addition, the reformed AlTiO layers which constitute the upper layers have the texture of the flat-plate polygonal (flat hexagonal) elongated crystal grains, and the (0001) plane orientation rate show a high ratio of 60% or more. As the area ratio of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains is as high as 60% or more, or as post-processing is performed on the reformed AlTiO layers and the surface smoothness thereof is further improved, the reformed AlTiO layers have superior high-temperature strength, and strength within the crystal grains, and have superior surface flatness. As a result, in high-speed intermittent cutting work accompanied by high heat generation, and intermittent impact loading acts on the cutting edge, the hard coating layers exhibit superior chipping resistance, show excellent cutting performance for a long-term use, and allows a more prolonged usable lifespan.
On the other hand, it is clear that the comparative coated tools A1 to A10 in which the hard coating layers are composed of the Ti compound layers and the conventional AlTiO layers and the reference coated tools A11 to A15 in which the hard coating layers are composed of the Ti compound layers and the conventional α-type Al2O3 layers, come to the end of their usable lifespan in a relatively short time due to occurrence of chipping, promotion of abrasion, or the like.
Example 2
The following powders, each having a mean particle size within a range of 2 to 4 μm, were prepared as raw materials: WC powder, TiC powder, ZrC powder, VC powder, TaC powder, NbC powder, Cr3C2 powder, TiN powder, TaN powder, and Co powder. These raw powders were compounded with each other in the compounding compositions shown in Table 11, mixed with each other in an acetone solution having wax added thereto for 24 hours using a ball mill, and were then dried under reduced pressure. Thereafter, the resultant powder mixture was press-formed into a green compact having a predetermined shape at a pressure of 98 MPa. The green compact was then sintered in a vacuum under the following conditions: a pressure of 5 Pa, a predetermined temperature within a range of 1370° C. to 1470° C., and a holding duration of 1 hour. After sintering, cutting edges were subjected to honing (R: 0.07 mm) to manufacture bodies 2A to 2E made of WC-based cemented carbide and having a throwaway tip shape defined in ISO CNMG120408MA.
Additionally, the following powders, each having a mean particle size within a range of 0.5 to 2 μm, were prepared as raw materials for substrates: TiCN (TiC/TiN=50/50 in weight ratio) powder, Mo2C power, ZrC power, NbC powder, TaC powder, WC power, Co powder and Ni powder. These raw powders were compounded with each other in the compounding compositions shown in Table 12, were wet-mixed with each other for 24 hours using a ball mill, and were dried. Thereafter, the resulting powder mixture was press-formed into a green compact at a pressure of 98 MPa. The green compact was then sintered in a nitrogen atmosphere under the following conditions: a pressure of 1.3 kPa, a temperature of 1540° C., and a holding duration of 1 hour. After sintering, cutting edges were subjected to honing (R: 0.07 mm) to manufacture bodies 2a to 2e made of TiCN-based cermet and having a tip shape defined in ISO Standard CNMG120408MA.
Subsequently, these bodies 2A to 2E and the bodies 2a to 2e were loaded into a normal chemical vapor deposition apparatus.
(a) First, Ti compound layers with target layer thicknesses shown in Table 17 were vapor-deposited as lower layers of hard coating layers under the conditions shown in Table 13 (1-TiCN in Table 13 shows the formation conditions of TiCN layers with a longitudinal growth crystalline structure disclosed in Japanese Unexamined Patent Application Publication No. 6-8010, and the others show the formation conditions of a normal granular crystalline structure).
(b) Subsequently, reformed α-type Al2O3 layers with target layer thicknesses shown in Table 18 were vapor-deposited as intermediate layers of the hard coating layers under the conditions shown in Table 14.
(c) Next, coated tools B1 to B15 of the present invention were manufactured, respectively, by vapor-depositing reformed AlYO layers with target layer thicknesses similarly shown in Table 18 as upper layers of hard coating layers according to the vapor deposition conditions shown in Table 15.
For the purpose of comparison, comparative coated tools B1 to B10 (equivalent to the conventional coated tool 2) provided with hard coating layers composed of Ti compound layers and conventional AlYO layers with target layer thicknesses shown in Table 19 were manufactured, respectively, by forming lower layers of hard coating layers under the conditions shown in Table 13 and forming upper layers under the conditions (equivalent to the vapor deposition conditions of the conventional AlYO layers disclosed in PTL 4)) shown in Table 16.
The type of the bodies, the type of the lower layers, and the thickness of the lower layers in the comparative coated tools B1 to B10 are the same as those of the coated tools B1 to B10 of the present invention, respectively.
Moreover, for reference, reference coated tools B11 to B15 (equivalent to the conventional coated tool 1) provided with hard coating layers composed of Ti compound layers and conventional α-type Al2O3 layers with target layer thicknesses shown in Table 19 were manufactured, respectively, by forming lower layers of hard coating layers under the conditions shown in Table 13 and forming α-type Al2O3 layers under the conditions (equivalent to the vapor deposition conditions of the conventional α-type Al2O3 layers disclosed in PTL 1) shown in Table 16.
The type of the bodies, the type of the lower layers, and the thickness of the lower layers in the reference coated tools B11 to B15 are the same as those of the coated tools B11 to B15 of the present invention, respectively.
Post-processing composed of wet blasting processing with projection pressure 0.15 MPa and Al2O3 grains of 200 meshes was performed on the surfaces of some reformed AlYO layers of the coated tools of the present invention, and the surfaces of some conventional AlYO layers of the comparative coated tools. As the post-processing, polishing processing using an elastic grind stone may be adopted.
Tables 18 and 19 show the values of the surface roughness (Ra (μm)) of the reformed AlYO layers (those marked by * in Table 18) of the coated tools of the present invention which were subjected to post-processing and the conventional AlYO layers (those marked by in Table 19) of the comparative coated tools. (For reference, the values of Ra regarding the coated tools of the present invention and the comparative coated tools which were not subjected to post-processing are also shown in Tables 18 and 19.).
Subsequently, as for the reformed α-type Al2O3 layers which constitute the intermediate layers of the hard coating layers of the coated tools B1 to B15 of the present invention, the reformed AlYO layers which constitute the upper layers of the hard coating layers, the conventional AlYO layers of the comparative coated tools B1 to B10, and the α-type Al2O3 layers of the reference coated tools B11 to B15, tilt angle frequency distribution graphs were plotted, respectively, using the field-emission-type scanning electron microscope.
The tilt angle frequency distribution graphs were plotted by setting the respective layers in the coated tools B1 to B15 of the present invention, the comparative coated tools B1 to B10, and the reference coated tools B11 to B15 within a lens barrel of the field-emission-type scanning electron microscope, with the surfaces of the layers as polished surfaces; individually irradiated crystal grains having a hexagonal crystal lattice present within the measurement range of each polished surface with an electron beam having an acceleration voltage of 15 kV with an irradiating current of 1 nA at an angle of incidence of 70 degrees with respect to each polished surface, thereby measuring the tilt angle of the normal line to the (0001) plane, which is a crystal plane of each crystal grain, to the normal line to each polished surface, at intervals of 0.1 μm/step for a region 30×50 μm, using the electronic backscattering diffraction image apparatus; and on the basis of these measurement results, dividing the measured tilt angles which are within a range of 0 to 45 degrees among the measured tilt angles at every pitch of 0.25 degrees, and summing the frequencies present within the respective divisions.
As an example of the tilt angle frequency distribution graphs, FIG. 6 shows a tilt angle frequency distribution graph of the (0001) plane of a reformed α-type Al2O3 layer which constitutes an intermediate layer of a hard coating layer of a coated tool 1 of the present invention.
The “surface” in this invention includes not only a face parallel to the surface of a base, but also a face which inclines to the surface of the base, for example, the cutting face of a layer.
As a result, in the obtained tilt angle frequency distribution graphs of the reformed α-type Al2O3 layers and reformed AlYO layers of the coated tools of the present invention, the conventional AlYO layers of the comparative coated tools B1 to B10, and the conventional α-type Al2O3 layers of the reference coated tools B11 to B15, as shown in Tables 18 and 19, respectively, the distributions of the measured tilt angles of the (0001) plane in the reformed α-type Al2O3 layers and reformed AlYO layers of the coated tools of the present invention show a tilt angle frequency distribution graph in which the highest peak appears in the tilt angle division within a range of 0 to 10 degrees, respectively. On the other hand, the distribution of the measured tilt angles of the (0001) plane in the conventional AlYO layers of the comparative coated tools B1 to B10 shows a tilt angle frequency distribution graph in which the highest peak does not present in an unbiased manner within a range of 0 to 45 degrees.
Tables 18 and 19 show the ratios of the frequencies present in the tilt angle division within a range of 0 to 10 degrees, which are accounted for in the overall tilt angle frequency distribution graph.
Subsequently, as for the reformed AlYO layers which constitute the upper layers of the coated tools B1 to B15 of the present invention, and the conventional AlYO layers of the comparative coated tools B1 to B10, the crystal grain structure and the constituent atom sharing lattice point configuration were inspected using the field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus.
First, when the reformed AlYO layers of the coated tools B1 to B15 of the present invention and the conventional AlYO layers of the comparative coated tools B1 to B10 were observed using the field-emission-type scanning electron microscope, the flat-plate polygonal (including flat hexagonal) and elongated crystal grain structure of a large grain size shown typically in FIGS. 7A and 7B were observed in the coated tools B1 to B15 of the present invention (FIG. 7A is a schematic view of the texture of the coated tools B1 to B9 of the present invention as seen within the plane perpendicular to the layer thickness direction, and FIG. 7C is a schematic view of the texture composed of flat hexagonal and elongated crystal grains of a large grain size, of the coated tools B10 to B15 of the present invention as seen within the plane perpendicular to the layer thickness direction).
On the other hand, as shown typically in FIGS. 9A and 9B, a polygonal and elongated crystal grain structure was observed in the comparative coated tools B1 to B10. However, the grain size of each crystal grain was small as compared to that of the present invention, and as being clear from FIG. 9B, pyramidal irregularities were formed in the layer surface (FIGS. 9A and 9B are schematic views of the texture of the comparative coated tools B1 to B10).
Subsequently, as for the reformed AlYO layers of the coated tools B1 to B15 of the present invention, and the conventional AlYO layers of the comparative coated tools B1 to B10, the area ratios of crystal grains in which the Σ3 coincidence site lattice interfaces are present inside the crystal grains which constitute each layer were measured.
First, as for the reformed AlYO layers of the coated tools B1 to B15 of the present invention, when the respective layers are within a lens barrel of the field-emission-type scanning electron microscope, with the surfaces of the layers as polished surfaces; crystal grains having a hexagonal crystal lattice present within the measurement range of each polished surface are individually irradiated with an electron beam having an acceleration voltage of 15 kV with an irradiating current of 1 nA at an angle of incidence of 70 degrees with respect to each polished surface, thereby measuring the angle at which the normal line to each of crystal lattice planes of the crystal grains crosses the normal line to each base surface, at intervals of 0.1 μm/step for a region 30×50 using the electronic backscattering diffraction image apparatus; and from these measurement results, the crystal orientation relationship between adjacent crystal lattices is calculated, and the distribution of lattice points (constituent atom sharing lattice points) where respective constituent atoms which constitute a crystal lattice interface sharing one constituent atom between the crystal lattices is calculated; and a constituent atom sharing lattice point configuration in which N (here, N is any even number equal to or greater than 2 in a crystal structure of a corundum-type hexagonal close-packing crystal, but when the upper limit of N is 28 from the viewpoint of a distribution frequency, even numbers 4, 8, 14, 24, and 26 do not exist) lattice points which do not share any constituent atoms between the constituent atom sharing lattice points are present is expressed by ΣN+1, the area ratios of crystal grain in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains among all the crystal grains present within the measurement range of the reformed AlYO layers were obtained, and the values of the area ratios were shown in Table 18 as a Σ3 coincidence site lattice interface ratio (%).
Next, even as for the conventional AlYO layers of the comparative coated tools B1 to B10, by the same method as the case of the coated tools of the present inventions, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains among all the crystal grains present within the measurement range of the conventional reformed AlYO layers were obtained, and the values of the area ratios were shown in Table 19 as Σ3 coincidence site lattice interface ratio (%).
As shown in Tables 18 and 19, in the reformed AlYO layers of the coated tools B1 to B15 of the present invention, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are 60% or more. On the other hand, in the conventional AlYO layers of the comparative coated tools B1 to B10, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are 40% or less. It can be understood from this that the rate at which the Σ3 coincidence site lattice interfaces are present inside crystal grains is very small.
Subsequently, as for the reformed AlYO layers of the coated tools B1 to B15 of the present invention, and the conventional AlYO layers of the comparative coated tools B1 to B10, the area ratios of flat hexagonal crystal grains of a large grain size present within the plane perpendicular to the layer thickness direction were obtained using the field-emission-type scanning electron microscope. These values are shown in Tables 18 and 19.
Here, the “flat hexagonal crystal grains of a large grain size” means polygonal crystal grains in which the mean value of ten grains is 3 to 8 μm when the diameter of grains present within the plane perpendicular to the layer thickness direction observed by the field-emission-type scanning electron microscope is measured, and six vertex angles whose angle of vertex is 100 to 140° are provided.
Subsequently, although the thicknesses of the respective constituent layers in the hard coating layers of the coated tools B1 to B15 of the present invention, the comparative coated tools B1 to B10, and the reference coated tools B11 to B15 were measured using the scanning electron microscope (longitudinal-section measurement), substantially the same mean layer thicknesses (mean value of five-point measurements) as the target layer thicknesses were shown in all cases.
Next, all the coated tools B1 to B15 of the present invention, the comparative coated tools B1 to B10, and the reference coated tools B11 to B15 were screw-fixed to a tip portion of a bite made of tool steel by a fixing jig, and in this state, were subjected to a dry high-speed intermittent cutting test (normal cutting speed is 200 m/min) on bearing steel under the following conditions (referred to as cutting condition A):
Workpiece: a round bar of JIS-SUJ2 (HRC62) with four longitudinal grooves equally-spaced in the length direction,
Cutting speed: 250 m/min,
Depth of cut: 1.5 mm,
Feed rate: 0.15 mm/rev, and
Cutting time: 5 minutes,
a dry high-speed intermittent cutting test (normal cutting speed is 200 m/min) on alloy tool steel under the following conditions (referred to as cutting condition B):
Workpiece: a round bar of JIS-SKD11 (HRC58) with four longitudinal grooves equally-spaced in the length direction,
Cutting speed: 300 m/min,
Depth of cut: 1.5 mm,
Feed rate: 0.15 mm/rev, and
Cutting time: 5 minutes, and
a dry high-speed intermittent cutting test (normal cutting speed is 150 m/min) on carbon tool steel under the following conditions (referred to as cutting condition C):
Workpiece: a round bar of JIS-SK3 (HRC61) with four longitudinal grooves equally-spaced in the length direction,
Cutting speed: 250 m/min,
Depth of cut: 1.5 mm,
Feed rate: 0.15 mm/rev, and
Cutting time: 5 minutes, and
the flank wear width of the cutting edges were measured in all the cutting tests. These test results are shown in Table 12.









TABLE 11









Compounding composition (Mass %)

















Type
Co
TiC
ZrC
VC
TaC
NbC
Cr3C2
TiN
TaN
WC





















Tool
2A
7
—
—
—
—
—
—
—
—
Balance


substrate
2B
5.7
—
—
—
1.5
0.5
—
1.2
—
Balance



2C
5.7
2.3
—
—
—
—
1 
—
—
Balance



2D
8.5
—
0.5
—
—
—
0.5
—
—
Balance



2E
12.5
2 
—
—
—
—
—
1 
2
Balance


















TABLE 12









Compounding composition (Mass %)















Type
Co
Ni
ZrC
TaC
NbC
Mo2C
WC
TiCN



















Tool
2a
12
6
—
10
—
10
16
Balance


substrate
2b
7
7
—
 5
—
  7.5
—
Balance



2c
5
—
—
—
1
 6
10
Balance



2d
9
6
—
11
2
—
—
Balance



2e
8
5
1
 8
—
10
10
Balance

















TABLE 13







Hard coating layer (Lower layer)











Composition
Formation conditions (Reaction atmosphere



(Numbers
pressure given in kPa and temperature given in ° C.)










Indicate
Reaction atmosphere











Type
atomic ratio)
Composition of reaction gas (Vol. %)
Pressure
Temperature














TiC layer
TiC
TiCl4: 4.2%, CH4: 8.5%, H2: Balance
7
1020


TiN layer (First
TiN
TiCl4: 4.2%, N2: 30%, H2: Balance
30
900


layer)






TiN layer (Other
TiN
TiCl4: 4.2%, N2: 35%, H2: Balance
50
1040


layer)






I—TiC0.5N0.5 layer
TiC0.5N0.5
TiCl4: 4.2%, N2: 20%, CH3CN: 0.6%, H2: Balance
7
900


TiCN layer
TiC0.5N0.5
TiCl4: 4.2%, N2: 20%, CH4: 4%, H2: Balance
12
1020


TiCO layer
TiC0.5O0.5
TiCl4: 4.2%, CO: 4%, H2: Balance
7
1020


TiCNO layer
TiC0.3N0.3O0.4
TiCl4: 4.2%, CO: 3%, CH4: 3%, N2: 20%, H2: Balance
20
1020


α-Type Al2O3 layer
α-Al2O3
AlCl3: 2.2%, CO2: 5.5%, HCI: 2.2%, H2S: 0.2%, H2: Balance
7
1000



















TABLE 14









Neclear thin film formation conditions
Heat treatment










Reaction atmosphere
Reaction atmosphere














Formation

Pressure/
Temper-
Pressure/
Temper-


Type
symbol
Composition of reaction gas (Vol. %)
kPa
ature/° C.
kPa
ature/° C.
















Neclear thin
2A
AlCl3: 3%, CO2: 0.5%, C2H4:
3
800
3
1100


film (2A)

0.01%, H2: Balance


Neclear thin
2B
AlCl3: 6%, CO2: 1.5%, C2H4:
7
750
7
1200


film (2B)

0.12%, H2: Balance


Neclear thin
2C
AlCl3: 10%, CO2: 3%, C2H4:
13
900
13
1000


film (2C)

0.3%, H2: Balance





*Formation conditions of normal α-type Al2O3 layer after formation of various kinds of neclear thin films are described in Table 13














TABLE 15








Formation conditions (Reaction atmosphere


Reformed
pressure given in kPa and temperature given in ° C.)









AlYO layer

Reaction atmosphere










Formation symbol
Composition of reaction gas (Vol. %)
Pressure
Temperature














2A
First step
AlCl3: 1%, YCl3: 0.1%, HCl; 3%, CO2: 2%, H2S: 0.25%, H2: Balance
3
1020



Second step
AlCl3: 6%, YCl3: 1%, HCl; 3%, CO2: 5%, H2S: 0.4%, H2: Balance
6
1000


2B
First step
AlCl3: 2%, YCl3: 0.08%, HCl; 1%, CO2: 3%, H2S: 0.30%, H2: Balance
4
1020



Second step
AlCl3: 7%, YCl3: 0.9%, HCl; 4%, CO2: 6%, H2S: 0.3%, H2: Balance
8
980


2C
First step
AlCl3: 3%, YCl3: 0.06%, HCl; 4%, CO2: 4%, H2S: 0.45%, H2: Balance
5
1040



Second step
AlCl3: 8%, YCl3: 0.6%, HCl; 4%, CO2: 6%, H2S: 0.25%, H2: Balance
10
950


2D
First step
AlCl3: 4%, YCl3: 0.08%, HCl; 5%, CO2: 5%, H2S: 0.35%, H2: Balance
5
1050



Second step
AlCl3: 10%, YCl3: 0.4%, HCl; 3%, CO2: 8%, H2S: 0.6%, H2: Balance
8
920


2E
First step
AlCl3: 5%, YCl3: 0.05%, HCl; 5%, CO2: 6%, H2S: 0.50%, H2: Balance
5
1020



Second step
AlCl3: 9%, YCl3: 0.6%, HCl; 5%, CO2: 5%, H2S: 0.4%, H2: Balance
6
960


2F
First step
AlCl3: 3%, YCl3: 0.05%, HCl; 2%, CO2: 4%, H2S: 0.75%, H2: Balance
5
1020



Second step
AlCl3: 8%, YCl3: 0.7%, HCl; 3%, CO2: 4%, H2S: 0.3%, H2: Balance
7
970

















TABLE 16







Conventional
Formation conditions (Reaction atmosphere Pressure


AlYO layer
given in KPa and temperature given in ° C.)









Formation
Composition
Reaction atmosphere










symbol
of reaction gas (Vol. %)
Pressure
Temperature













(2a)
AlCl3: 6%, YCl3: 1%, CO2: 4%,
10
1000



H2: Balance




(2b)
AlCl3: 7%, YCl3: 0.9%, CO2: 6%,
9
1000



H2: Balance




(2c)
AlCl3: 8%, YCl3: 0.6%, CO2: 7%,
8
1020



H2: Balance




(2d)
AlCl3: 10%, YCl3: 0.4%,
7
1020



CO2: 8%, H2: Balance



















TABLE 17









Tool
Lower layer of hard coating layer [Ti compound layer]













substrate
First layer
Second layer
Third layer
Fourth layer












Type
symbol
(μm)
(μm)
(μm)
(μm)
















Coated tool
B1
2a
TiN
1-TiCN
TiN
TiCNO


of the


(1)
 (17.5)
(1) 
(0.5)


present
B2
2A
TiCN
1-TiCN
TiCO
—


invention


(1)
 (8.5)
(0.5)



B3
2b
TiN
1-TiCN
TiC
TiCNO





(1)
(4)
(4) 
(1) 



B4
2B
TiC
1-TiCN
—
—





(1)
(9)



B5
2c
TiN
1-TiCN
TiCNO
—





(1)
 (4.5)
(0.5)



B6
2C
TiN
1-TiCN
TiC
TiCNO





 (0.5)
 (1.5)
(0.5)
(0.5)



B7
2d
TiN
1-TiCN
TiC
TiCNO





 (0.5)
(10) 
(2) 
(0.3)



B8
2D
TiN
TiCN
—
—





(1)
(19) 



B9
2e
TiC
1-TiCN
TiCO
—





 (0.5)
(9)
(0.5)



B10
2E
TiN
TiC
TiCN
TiCO





(1)
(1)
(7) 
(1) 



B11
2A
TiN
1-TiCN
TiCNO
TiCO





 (0.3)
(5)
(0.7)
(0.1)



B12
2a
TiN
1-TiCN
TiCO
—





(1)
(10) 
(0.5)



B13
2B
TiN
1-TiCN
TiN
TiCNO





 (0.5)
(12) 
(0.5)
(0.2)



B14
2b
TiN
1-TiCN
TiCNO
—





 (0.6)
(7)
(0.3)



B15
2C
TiN
1-TiCN
TiCN
TiCO





 (0.4)
(3)
(0.5)
(0.1)





(Numbers in the parentheses of lower layer column indicate target layer thickness)















TABLE 18









Hard coating layer



Intermediate layer [Reformed α-type Al2O3layer]

















Frequency ratio






Tilt angle division
of tilt angle



Tool

Target
where (0001) plane
division of 0



substrate
Formation symbol of
layer thickness
shows highest peak
to 10 degrees












Type
symbol
intermediate layer
(μm)
(Degree)
(%)
















Coated
B1
2a
2A
1
1.50-1.75
60


tool of
B2
2A
2B
1
2.75-3.00
52


the
B3
2b
2C
2
2.00-2.25
65


present
B4
2B
2A
2
5.25-5.50
70


invention
B5
2c
2B
3
2.25-2.50
83



B6
2C
2B
3
3.50-3.75
97



B7
2d
2C
4
4.25-4.50
84



B8
2D
2C
4
3.25-3.50
86



B9
2e
2A
5
2.00-2.25
89



B10
2E
2B
5
5.25-5.50
82



B11
2A
2B
2
2.25-2.50
72



B12
2a
2C
2
1.75-2.00
83



B13
2B
2A
3
0.50-0.75
92



B14
2b
2B
2
0.25-0.50
88



B15
2C
2C
3
1.25-1.50
85












Hard coating layer



Upper layer [Reformed AlTiO layer]















Tilt angle division




Content ratio of
Target
where (0001) plane



Formation symbol of
Y [Y/(Al + Y)]
layer thickness
shows highest peak











Type
upper layer
(atomic ratio
(μm)
(Degree)















Coated
B1
2A
0.01
6
1.50-1.75


tool of
B2
2B
0.004
2
2.75-3.00


the
B3
2C
0.001
3
2.25-2.50


present
B4
2D
0.0005
14
5.25-5.50


invention
B5
2C
0.001
15
2.50-2.75



B6
2A
0.01
10
3.25-3.50



B7
2B
0.04
6
4.25-4.50



B8
2C
0.001
7
3.25-3.50



B9
2D
0.0005
4
2.00-2.25



B10
2E
0.0006
8
5.00-5.25



B11
2F
0.0008
5
2.25-2.50



B12
2E
0.0006
6
1.50-1.75



B13
2F
0.0008
4
0.50-0.75



B14
2E
0.0006
3
0.25-0.50



B15
2E
0.0006
5
1.25-1.50












Hard coating layer



Upper layer [Reformed AlTiO layer]












Frequency ratio
Crystal grain ratio





of tilt angle
Having Σ3 coinci-
Surface ratio of
Surface



division of 0
dence site lattice in-
flat hexagonal
roughness



to 10 degrees
terface therein
crystal grain
Ra













Type
(%)
(Area %)
(Area %)
(μm)


















Coated
B1
72
64
10
 0.3 *



tool of
B2
66
61
5
0.4



the
B3
71
72
21
0.5



present
B4
72
59
9
0.5



invention
B5
74
70
12
0.6




B6
95
83
18
0.9




B7
85
76
26
0.8




B8
88
77
22
0.7




B9
70
69
15
 0.05




B10
84
75
39
0.6




B11
75
81
35
 0.2 *




B12
87
82
42
 0.1 *




B13
96
89
72
0.5




B14
91
79
67
 0.3 *




B15
88
83
62
0.5







(Note)



The mark * in the column “Surface roughness” indicates that wet blasting processing was performed.















TABLE 19









Hard coating layer



Intermediate layer [Conventional α-type Al2O3layer]















Frequency ratio





Tilt angle division
of tilt angle




Target
where (0001) plane
division of 0



Formation symbol of
layer thickness
shows highest peak
to 10 degrees











Type
intermediate layer
(μm)
(Degree)
(%)















Comparative
B1
—
—
—
—


coated tool
B2
—
—
—
—



B3
—
—
—
—



B4
—
—
—
—



B5
—
—
—
—



B6
—
—
—
—



B7
—
—
—
—



B8
—
—
—
—



B9
—
—
—
—



B10
—
—
—
—


Reference
B11
2A
2
1.50-1.75
55


coated tool
B12
2B
7
2.00-2.25
63



B13
2C
10 
3.00-3.25
48



B14
2A
8
1.25-1.50
65



B15
2B
5
1.75-2.00
71












Hard coating layer



Upper layer [Conventional AlYO layer]















Tilt angle division




Content ratio of
Target
where (0001) plane



Formation symbol of
Y [Y/(Al + Y)]
layer thickness
shows highest peak











Type
upper layer
(atomic ratio
(μm)
(Degree)















Comparative
B1
2a
0.01
7
15.50-15.75


coated tool
B2
2b
0.004
3
17.75-20.00



B3
2c
0.001
5
37.00-37.25



B4
2d
0.0005
16
30.00-30.25



B5
2c
0.001
18
17.50-17.75



B6
2d
0.0005
13
2.025-20.50



B7
2a
0.01
10
25.50-25.75



B8
2b
0.004
11
32.50-32.75



B9
2c
0.001
9
34.00-34.25



B10
2d
0.0005
13
35.50-35.75


Reference
B11
—
—
—
—


coated tool
B12
—
—
—
—



B13
—
—
—
—



B14
—
—
—
—



B15
—
—
—
—












Hard coating layer



Upper layer [Conventional AlYO layer]












Frequency ratio
Crystal grain ratio





of tilt angle
having Σ3 coinci-
Surface ratio of
Surface



division of 0
dence site lattice in-
flat hexagonal
roughness



to 10 degrees
terface therein
crystal grain
Ra











Type
(%)
(Area %)
(Area %)
(μm)















Comparative
B1
14
5
0
0.6


coated tool
B2
9
3
0
  0.05 *



B3
3
4
0
0.5



B4
5
10
0
0.7



B5
4
6
3
0.8



B6
6
3
0
0.6



B7
3
0
5
 0.1 *



B8
7
2
0
0.6



B9
2
3
0
 0.3 *



B10
5
4
11
0.6


Reference
B11
—
—
—
—


coated tool
B12
—
—
—
—



B13
—
—
—
—



B14
—
—
—
—



B15
—
—
—
—





(Note)


The mark * in the column “Surface roughness” indicates that wet blasting processing was performed.

















TABLE 20









Flank wear width (mm)

Cutting test result (min)
















Cutting
Cutting
Cutting


Cutting
Cutting
Cutting



condition
condition
condition


condition
condition
condition














Type
(A)
(B)
(C)
Type
(A)
(B)
(C)



















Coated tool
B1
0.20
0.18
0.19
Comparative
B1
2.1 *
3.0 
2.9 


of the
B2
0.35
0.33
0.31
coated tool
B2
0.4 *
0.4 *
0.2 *


present
B3
0.26
0.24
0.23

B3
0.5 *
0.5 *
1.0 *


invention
B4
0.34
0.32
0.27

B4
0.6 *
0.5 *
0.4 *



B5
0.32
0.30
0.28

B5
0.8 *
0.6 *
0.4 *



B6
0.31
0.28
0.29

B6
0.6 *
0.5 *
0.5 *



B7
0.25
0.25
0.24

B7
1.8 *
1.6 *
1.5 *



B8
0.27
0.27
0.22

B8
1.8 *
1.7 *
1.6 *



B9
0.26
0.24
0.23

B9
1.9 *
1.6 
1.4 *



B10
0.19
0.19
0.17

B10
2.5 
2.4 *
2.3 



B11
0.16
0.14
0.13
Reference
B11
2.5 
2.5 *
2.4 



B12
0.15
0.14
0.14
coated tool
B12
2.0 *
2.6 
2.2 



B13
0.14
0.12
0.13

B13
1.0 *
1.5 *
2.5 



B14
0.17
0.15
0.14

B14
2.2 *
2.1 *
2.6 



B15
0.17
0.16
0.15

B15
2.2 
2.0 *
1.8 *





Cutting test results of comparative coated tools and reference coated tools show cutting times (min) until the tools come to the end of their usable lifespan due to chipping or flank wear (usable lifespan determination criterion: Flank wear width of 0.5 mm).


In addition, mark * in columns indicates a case where tools come to the end of their usable lifespan due to chipping.






From the results shown in Tables 18 to 20, as for the coated tools B1 to B15 of the present invention, the (0001) plane orientation rate of the reformed α-type Al2O3 layers which are the intermediate layers of the hard coating layers show a high ratio of 45% or more, and have excellent high-temperature strength. In addition, the reformed AlYO layers which constitute the upper layers have the texture of the flat-plate polygonal (flat hexagonal) elongated crystal grains, and the (0001) plane orientation rate show a high ratio of 60% or more, the surface ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are as high as 60% or more, or post-processing is performed on the reformed AlYO layers and the surface smoothness thereof is further improved. Thereby, the reformed AlYO layers have superior high-temperature strength, and strength within the crystal grains, and have superior surface flatness. As a result, in high-speed intermittent cutting work accompanied by high heat generation, and intermittent impact loading acts on the cutting edge, the hard coating layers exhibit superior chipping resistance, show excellent cutting performance for a long-term use, and allows a more prolonged usable lifespan.
On the other hand, it is clear that the comparative coated tools B1 to B10 in which the hard coating layers are composed of the AlYO layer and the conventional Ti compound layers and the reference coated tools B11 to B15 in which the hard coating layers are composed of the Ti compound layers and the conventional α-type Al2O3 layers, come to the end of their usable lifespan in a relatively short time due to occurrence of chipping, promotion of abrasion, or the like.
Example 3
The following powders, each having a mean particle size within a range of 2 to 4 μm, were prepared as raw materials: WC powder, TiC powder, ZrC powder, VC powder, TaC powder, NbC powder, Cr3C2 powder, TiN powder, TaN powder, and Co powder. These raw powders were compounded with each other in the compounding compositions shown in Table 21, mixed with each other in an acetone solution having wax added thereto for 24 hours using a ball mill, and were then dried under reduced pressure. Thereafter, the resultant powder mixture was press-formed into a green compact having a predetermined shape at a pressure of 98 MPa. The green compact was then sintered in a vacuum under the following conditions: a pressure of 5 Pa, a predetermined temperature within a range of 1370° C. to 1470° C., and a holding duration of 1 hour. After sintering, cutting edges were subjected to honing (R: 0.07 mm) to manufacture bodies 3A to 3E made of WC-based cemented carbide and having a throwaway tip shape defined in ISO CNMG120408MA.
Additionally, the following powders, each having a mean particle size within a range of 0.5 to 2 μm, were prepared as raw materials for substrates: TiCN (TiC/TiN=50/50 in weight ratio) powder, Mo2C power, ZrC power, NbC powder, TaC powder, WC power, Co powder and Ni powder. These raw powders were compounded with each other in the compounding compositions shown in Table 22, were wet-mixed with each other for 24 hours using a ball mill, and were dried. Thereafter, the resulting powder mixture was press-formed into a green compact at a pressure of 98 MPa. The green compact was then sintered in a nitrogen atmosphere under the following conditions: a pressure of 1.3 kPa, a temperature of 1540° C., and a holding duration of 1 hour. After sintering, cutting edges were subjected to honing (R: 0.07 mm) to manufacture bodies 3a to 3e made of TiCN-based cermet and having a tip shape defined in ISO Standard CNMG120408MA.
Subsequently, these bodies 3A to 3E and the bodies 3a to 3e were loaded into a normal chemical vapor deposition apparatus.
(a) First, Ti compound layers with target layer thicknesses shown in Table 27 were vapor-deposited as lower layers of hard coating layers under the conditions shown in Table 23 (1-TiCN in Table 23 shows the formation conditions of TiCN layers with a longitudinal growth crystalline structure disclosed in Japanese Unexamined Patent Application Publication No. 6-8010, and the others show the formation conditions of a normal granular crystalline structure).
(b) Subsequently, reformed α-type Al2O3 layers with target layer thicknesses shown in Table 28 were vapor-deposited as intermediate layers of the hard coating layers under the conditions shown in Table 24.
(c) Next, coated tools C1 to C15 of the present invention were manufactured, respectively, by vapor-depositing reformed AlZrO layers with target layer thicknesses similarly shown in Table 28 as upper layers of hard coating layers according to the vapor deposition conditions shown in Table 25.
For the purpose of comparison, comparative coated tools C1 to C10 (equivalent to the conventional coated tool 2) provided with hard coating layers composed of Ti compound layers and conventional AlZrO layers with target layer thicknesses shown in Table 29 were manufactured, respectively, by forming lower layers of hard coating layers under the conditions shown in Table 23 and forming upper layers under the conditions (equivalent to the vapor deposition conditions of the conventional AlZrO layers disclosed in PTL 3)) shown in Table 26.
The type of the bodies, the type of the lower layers, and the thickness of the lower layers in the comparative coated tools C1 to C10 are the same as those of the coated tools C1 to C10 of the present invention, respectively.
Moreover, for reference, reference coated tools C11 to C15 (equivalent to the conventional coated tool 1) provided with hard coating layers composed of Ti compound layers and conventional α-type Al2O3 layers with target layer thicknesses shown in Table 29 were manufactured, respectively, by forming lower layers of hard coating layers under the conditions shown in Table 23 and forming α-type Al2O3 layers under the conditions (equivalent to the vapor deposition conditions of the conventional α-type Al2O3 layers disclosed in PTL 1) shown in Table 26.
The type of the bodies, the type of the lower layers, and the thickness of the lower layers in the reference coated tools C11 to C15 are the same as those of the coated tools C11 to C15 of the present invention, respectively.
Post-processing composed of wet blasting processing with projection pressure 0.15 MPa and Al2O3 grains of 200 meshes was performed on the surfaces of some reformed AlZrO layers of the coated tools of the present invention, and the surfaces of some conventional AlZrO layers of the comparative coated tools. As the post-processing, polishing processing using an elastic grind stone may be adopted.
Tables 28 and 29 show the values of the surface roughness (Ra (μm)) of the reformed AlZrO layers (those marked by * in Table 28) of the coated tools of the present invention which were subjected to post-processing and the conventional AlZrO layers (those marked by * in Table 29) of the comparative coated tools. (For reference, the values of Ra regarding the coated tools of the present invention and the comparative coated tools which were not subjected to post-processing are also shown in Tables 28 and 29.)
Subsequently, as for the reformed α-type Al2O3 layers which constitute the intermediate layers of the hard coating layers of the coated tools C1 to C15 of the present invention, the reformed AlZrO layers which constitute the upper layers of the hard coating layers, the conventional AlZrO layers of the comparative coated tools C1 to C10, and the α-type Al2O3 layers of the reference coated tools C11 to C15, tilt angle frequency distribution graphs were plotted, respectively, using the field-emission-type scanning electron microscope.
The tilt angle frequency distribution graphs were plotted by setting the respective layers in the coated tools C1 to C15 of the present invention, the comparative coated tools C1 to C10, and the reference coated tools C11 to C15 within a lens barrel of the field-emission-type scanning electron microscope, with the surfaces of the layers as polished surfaces; individually irradiated crystal grains having a hexagonal crystal lattice present within the measurement range of each polished surface with an electron beam having an acceleration voltage of 15 kV with an irradiating current of 1 nA at an angle of incidence of 70 degrees with respect to each polished surface, thereby measuring the tilt angle of the normal line to the (0001) plane, which is a crystal plane of each crystal grain, to the normal line to each polished surface, at intervals of 0.1 μm/step for a region 30×50 μm, using the electronic backscattering diffraction image apparatus; and on the basis of these measurement results, dividing the measured tilt angles which are within a range of 0 to 45 degrees among the measured tilt angles at every pitch of 0.25 degrees, and summing the frequencies present within the respective divisions.
As an example of the tilt angle frequency distribution graphs, FIG. 10 shows a tilt angle frequency distribution graph of the (0001) plane of a reformed α-type Al2O3 layer which constitutes an intermediate layer of a hard coating layer of a coated tool C14 of the present invention.
The “surface” in this invention includes not only a face parallel to the surface of a base, but also a face which inclines to the surface of the base, for example, the cutting face of a layer.
As a result, in the obtained tilt angle frequency distribution graphs of the reformed α-type Al2O3 layers and reformed AlZrO layers of the coated tools of the present invention, the conventional AlZrO layers of the comparative coated tools C1 to C10, and the conventional α-type Al2O3 layers of the reference coated tools C11 to C15, as shown in Tables 28 and 29, respectively, the distributions of the measured tilt angles of the (0001) plane in the reformed α-type Al2O3 layers and reformed AlZrO layers of the coated tools of the present invention show a tilt angle frequency distribution graph in which the highest peak appears in the tilt angle division within a range of 0 to 10 degrees, respectively. On the other hand, the distribution of the measured tilt angles of the (0001) plane in the conventional AlZrO layers of the comparative coated tools C1 to C10 shows a tilt angle frequency distribution graph in which the highest peak does not present in an unbiased manner within a range of 0 to 45 degrees.
Tables 28 and 29 show the ratios of the frequencies present in the tilt angle division within a range of 0 to 10 degrees, which are accounted for in the overall tilt angle frequency distribution graph.
Subsequently, as for the reformed AlZrO layers which constitute the upper layers of the coated tools C1 to C15 of the present invention, and the conventional AlZrO layers of the comparative coated tools C1 to C10, the crystal grain structure and the constituent atom sharing lattice point configuration were inspected using the field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus. First, when the reformed AlZrO layers of the coated tools C1 to C15 of the present invention and the conventional AlZrO layers of the comparative coated tools C1 to C10 were observed using the field-emission-type scanning electron microscope, the flat-plate polygonal (including flat hexagonal) and elongated crystal grain structure of a large grain size shown typically in FIGS. 11A and 11B were observed in the coated tools C1 to C15 of the present invention (FIG. 11A is a schematic view of the texture of the coated tools C1 to C9 of the present invention as seen within the plane perpendicular to the layer thickness direction, and FIG. 11C is a schematic view of the texture composed of flat hexagonal and elongated crystal grains of a large grain size, of the coated tools C10 to C15 of the present invention as seen within the plane perpendicular to the layer thickness direction). On the other hand, as shown typically in FIGS. 13A and 13B, a polygonal and elongated crystal grain structure was observed in the comparative coated tools C1 to C10. However, the grain size of each crystal grain was small as compared to that of the present invention, and as being clear from FIG. 13B, pyramidal irregularities were formed in the layer surface (FIGS. 13A and 13B are schematic views of the texture of the comparative coated tool C1).
Subsequently, as for the reformed AlZrO layers of the coated tools C1 to C15 of the present invention, and the conventional AlZrO layers of the comparative coated tools C1 to C10, the area ratios of crystal grains in which the Σ3 coincidence site lattice interfaces are present inside the crystal grains which constitute each layer were measured.
First, as for the reformed AlZrO layers of the coated tools C1 to C15 of the present invention, when the respective layers are within a lens barrel of the field-emission-type scanning electron microscope, with the surfaces of the layers as polished surfaces; crystal grains having a hexagonal crystal lattice present within the measurement range of each polished surface are individually irradiated with an electron beam having an acceleration voltage of 15 kV with an irradiating current of 1 nA at an angle of incidence of 70 degrees with respect to each polished surface, thereby measuring the angle at which the normal line to each of crystal lattice planes of the crystal grains crosses the normal line to each base surface, at intervals of 0.1 μm/step for a region 30×50 μm, using the electronic backscattering diffraction image apparatus; and from these measurement results, the crystal orientation relationship between adjacent crystal lattices is calculated, and the distribution of lattice points (constituent atom sharing lattice points) where respective constituent atoms which constitute a crystal lattice interface sharing one constituent atom between the crystal lattices is calculated; and a constituent atom sharing lattice point configuration in which N (here, N is any even number equal to or greater than 2 in a crystal structure of a corundum-type hexagonal close-packing crystal, but when the upper limit of N is 28 from the viewpoint of a distribution frequency, even numbers 4, 8, 14, 24, and 26 do not exist) lattice points which do not share any constituent atoms between the constituent atom sharing lattice points are present is expressed by ΣN+1, the area ratios of crystal grain in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains among all the crystal grains present within the measurement range of the reformed AlZrO layers were obtained, and the values of the area ratios were shown in Table 28 as a Σ3 coincidence site lattice interface ratio (%).
Next, even as for the conventional AlZrO layers of the comparative coated tools C1 to C10, by the same method as the case of the coated tools of the present inventions, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains among all the crystal grains present within the measurement range of the conventional reformed AlZrO layers were obtained, and the values of the area ratios were shown in Table 29 as a Σ3 coincidence site lattice interface ratio (%).
As shown in Tables 28 and 29, in the reformed AlZrO layers of the coated tools C1 to C15 of the present invention, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are 60% or more. On the other hand, in the conventional AlZrO layers of the comparative coated tools C1 to C10, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are 40% or less. It can be understood from this that the rate at which the Σ3 coincidence site lattice interfaces are present inside crystal grains is very small.
Subsequently, as for the reformed AlZrO layers of the coated tools C1 to C15 of the present invention, and the conventional AlZrO layers of the comparative coated tools C1 to C10, the area ratios of flat hexagonal crystal grains of a large grain size present within the plane perpendicular to the layer thickness direction were obtained using the field-emission-type scanning electron microscope. These values are shown in Tables 28 and 29.
Here, the “flat hexagonal crystal grains of a large grain size” means polygonal crystal grains in which the mean value of ten grains is 3 to 8 μm when the diameter of grains present within the plane perpendicular to the layer thickness direction observed by the field-emission-type scanning electron microscope is measured, and six vertex angles whose angle of vertex is 100 to 140° are provided.
Subsequently, although the thicknesses of the respective constituent layers in the hard coating layers of the coated tools C1 to C15 of the present invention, the comparative coated tools C1 to C10, and the reference coated tools C11 to C15 were measured using the scanning electron microscope (longitudinal-section measurement), substantially the same mean layer thicknesses (mean value of five-point measurements) as the target layer thicknesses were shown in all cases.
Next, all the coated tools C1 to C15 of the present invention, the comparative coated tools C1 to C10, and the reference coated tools C11 to C15 were screw-fixed to a tip portion of a bite made of tool steel by a fixing jig, and in this state, were subjected to a dry high-speed intermittent cutting test (normal cutting speed is 200 m/min) on bearing steel under the following conditions (referred to as cutting condition A):
Workpiece: a round bar of JIS-SUJ2 (HRC62) with four longitudinal grooves equally-spaced in the length direction,
Cutting speed: 250 m/min,
Depth of cut: 1.5 mm,
Feed rate: 0.15 mm/rev, and
Cutting time: 5 minutes,
a dry high-speed intermittent cutting test (normal cutting speed is 200 m/min) on alloy tool steel under the following conditions (referred to as cutting condition B):
Workpiece: a round bar of JIS-SKD11 (HRC58) with four longitudinal grooves equally-spaced in the length direction,
Cutting speed: 300 m/min,
Depth of cut: 1.5 mm,
Feed rate: 0.15 mm/rev, and
Cutting time: 5 minutes, and
a dry high-speed intermittent cutting test (normal cutting speed is 150 m/min) on carbon tool steel under the following conditions (referred to as cutting condition C):
Workpiece: a round bar of JIS-SK3 (HRC61) with four longitudinal grooves equally-spaced in the length direction,
Cutting speed: 250 m/min,
Depth of cut: 1.5 mm,
Feed rate: 0.15 mm/rev, and
Cutting time: 5 minutes, and
the flank wear widths of the cutting edges were measured in all the cutting tests. These test results are shown in Table 30.









TABLE 21









Compounding composition (Mass %)

















Type
Co
TiC
ZrC
VC
TaC
NbC
Cr3C2
TiN
TaN
WC





















Tool
3A
7
—
—
—
—
—
—
—
—
Balance


substrate
3B
5.7
—
—
—
1.5
0.5
—
1.2
—
Balance



3C
5.7
2.3
—
—
—
—
1 
—
—
Balance



3D
8.5
—
0.5
—
—
—
0.5
—
—
Balance



3E
12.5
2 
—
—
—
—
—
1 
2
Balance


















TABLE 22









Compounding composition (Mass %)















Type
Co
Ni
ZrC
TaC
NbC
Mo2C
WC
TiCN



















Tool
3a
12
6
—
10
—
10
16
Balance


substrate
3b
7
7
—
 5
—
  7.5
—
Balance



3c
5
—
—
—
1
 6
10
Balance



3d
9
6
—
11
2
—
—
Balance



3e
8
5
1
 8
—
10
10
Balance

















TABLE 23







Hard coating layer (Lower layer)
Formation conditions (Reaction atmosphere










Composition
pressure given in kPa and temperature given in ° C.)










(Numbers
Reaction atmosphere











Type
indicate atomic ratio)
Composition of reaction gas (Vol. %)
Pressure
Temperature














TiC layer
TiC
TiCl4: 4.2%, CH4: 8.5%, H2: Balance
7
1020


TiN layer (First
TiN
TiCl4: 4.2%, N2: 30%, H2: Balance
30
900


layer)






TiN layer (Other
TiN
TiCl4: 4.2%, N2: 35%, H2: Balance
50
1040


layer)






I—TiC0.5N0.5 layer
TiC0.5N0.5
TiCl4: 4.2%, N2: 20%, CH3CN: 0.6%, H2: Balance
7
900


TiCN layer
TiC0.5N0.5
TiCl4: 4.2%, N2: 20%, CH4: 4%, H2: Balance
12
1020


TiCO layer
TiC0.5O0.5
TiCl4: 4.2%, CO: 4%, H2: Balance
7
1020


TiCNO layer
TiC0.3N0.3O0.4
TiCl4: 4.2%, CO: 3%, CH4: 3%, N2: 20%, H2: Balance
20
1020


α-Type Al2O3 layer
α-Al2O3
AlCl3: 2.2%, CO2: 5.5%, HCl: 2.2%, H2S: 0.2%, H2: Balance
7
1000



















TABLE 24









Neclear thin film formation conditions
Heat treatment










Reaction atmosphere
Reaction atmosphere














Formation

Pressure/
Temper-
Pressure/
Temper-


Type
symbol
Composition of reaction gas (Vol. %)
kPa
ature/° C.
kPa
ature/° C.
















Neclear thin
3A
AlCl3: 3%, CO2: 0.5%, C2H4:
3
800
3
1100


film (3A)

0.01%, H2: Balance


Neclear thin
3B
AlCl3: 6%, CO2: 1.5%, C2H4:
7
750
7
1200


film (3B)

0.12%, H2: Balance


Neclear thin
3C
AlCl3: 10%, CO2: 3%, C2H4:
13
900
13
1000


film (3C)

0.3%, H2: Balance





*Formation conditions of normal α-type Al2O3 layer after formation of various kinds of neclear thin films are described in Table 23














TABLE 25








Formation conditions (Reaction atmosphere


Reformed
pressure given in kPa and temperature given in ° C.)









AlZrO layer

Reaction atmosphere










Formation symbol
Composition of reaction gas (Vol. %)
Pressure
Temperature














3A
First step
AlCl3: 1%, ZrCl4: 0.07%, HCl: 3%, CO2: 2%, H2S: 0.25%, H2: Balance
3
1020



Second step
AlCl3: 6%, ZrCl4: 1.2%, HCl; 3%, CO2: 5%, H2S: 0.4%, H2: Balance
3
940


3B
First step
AlCl3: 2%, ZrCl4: 0.1%, HCl; 1%, CO2: 3%, H2S: 0.30%, H2: Balance
4
1030



Second step
AlCl3: 7%, ZrCl4: 1.0%, HCl; 4%, CO2: 6%, H2S: 0.3%, H2: Balance
4
920


3C
First step
AlCl3: 3%, ZrCl4: 0.08%, HCl; 4%, CO2: 4%, H2S: 0.45%, H2: Balance
5
1040



Second step
AlCl3: 8%, ZrCl4: 0.8%, HCl; 4%, CO2: 6%, H2S: 0.25%, H2: Balance
5
980


3D
First step
AlCl3: 4%, ZrCl4: 0.06%, HCl; 5%, CO2: 5%, H2S: 0.35%, H2: Balance
3
1020



Second step
AlCl3: 10%, ZrCl4: 0.6%, HCl; 3%, CO2: 8%, H2S: 0.6%, H2: Balance
3
960


3E
First step
AlCl3: 5%, ZrCl4: 0.05%, HCl; 5%, CO2: 6%, H2S: 0.50%, H2: Balance
4
1050



Second step
AlCl3: 9%, ZrCl4: 0.9%, HCl; 5%, CO2: 5%, H2S: 0.4%, H2: Balance
4
1000


3F
First step
AlCl3: 3%, ZrCl4: 0.1%, HCl; 2%, CO2: 4%, H2S: 0.75%, H2: Balance
5
1020



Second step
AlCl3: 8%, ZrCl4: 0.7%, HCl; 3%, CO2: 4%, H2S: 0.3%, H2: Balance
5
950

















TABLE 26








Formation conditions (Reaction atmosphere


Conventional AlZrO layer
pressure given in kPa and temperature given in ° C.)










Composition (Numbers
Reaction atmosphere











Type
indicate atomic ratio)
Composition of reaction gas (Vol. %)
Pressure
Temperature














Neclear
(Al0.995Zr0.003)2O3
AlCl3: 4%, ZrCl4: 0.02%, CO2: 1.8%, HCl: 1.5%, H2S: 0.05%, H2:
8
850


thin film

Balance




(3a)






Neclear
(Al0.99Zr0.01)2O3
AlCl3: 3.8%, ZrCl4: 0.04%, CO2: 1.8%, HCl: 1.5%, H2S: 0.05%, H2:
8
850


thin film

Balance




(3b)






Neclear
(Al0.98Zr0.02)2O3
AlCl3: 3.5%, ZrCl4: 0.05%, CO2: 1.8%, HCl: 1.5%, H2S: 0.05%, H2:
8
850


thin film

Balance




(3c)






Neclear
(Al0.97Zr0.03)2O3
AlCl3: 3.2%, ZrCl4: 0.06%, CO2: 1.8%, HCl: 1.5%, H2S: 0.05%, H2:
8
850


thin film

Balance




(3d)






Neclear
(Al0.96Zr0.04)2O3
AlCl3: 3%, ZrCl4: 0.08%, CO2: 1.8%, HCl: 1.5%, H2S: 0.05%, H2: Balance
8
850


thin film






(3e)






Neclear
(Al0.955Zr0.045)2O3
AlCl3: 2.6%, ZrCl4: 0.1%, CO2: 1.8%, HCl: 1.5%, H2S: 0.05%, H2:
8
850


thin film

Balance




(3f)






Neclear
(Al0.95Zr0.05)2O3
AlCl3: 2.3%, ZrCl4: 0.13%, CO2: 1.8%, HCl: 1.5%, H2S: 0.05%, H2:
8
850


thin film

Balance




(3g)






Reformed
(Al0.995Zr0.003)2O3
AlCl3: 4%, ZrCl4: 0.02%, CO2: 4%, HCl: 2.5%, H2S: 0.2%, H2: Balance
8
1040


layer(3A)






Reformed
(Al0.99Zr0.01)2O3
AlCl3: 3.8%, ZrCl4: 0.04%, CO2: 4%, HCl: 2.5%, H2S: 0.2%, H2: Balance
8
1040


layer(3B)






Reformed
(Al0.98Zr0.02)2O3
AlCl3: 3.5%, ZrCl4: 0.05%, CO2: 4%, HCl: 2.5%, H2S: 0.2%, H2: Balance
8
1040


layer(3C)






Reformed
(Al0.97Zr0.03)2O3
AlCl3: 3.2%, ZrCl4: 0.06%, CO2: 4%, HCl: 2.5%, H2S: 0.2%, H2: Balance
8
1040


layer(3D)






Reformed
(Al0.96Zr0.04)2O3
AlCl3: 3%, ZrCl4: 0.08%, CO2: 4%, HCl: 2.5%, H2S: 0.2%, H2: Balance
8
1040


layer(3E)






Reformed
(Al0.955Zr0.045)2O3
AlCl3: 2.6%, ZrCl4: 0.1%, CO2: 4%, HCl: 2.5%, H2S: 0.2%, H2: Balance
8
1040


layer(3F)






Reformed
(Al0.95Zr0.05)2O3
AlCl3: 2.3%, ZrCl4: 0.13%, CO2: 4%, HCl: 2.5%, H2S: 0.2%, H2: Balance
8
1040


layer(3G)



















TABLE 27









Tool
Lower layer of hard coating layer [Ti compound layer]













substrate
First layer
Second layer
Third layer
Fourth layer












Type
symbol
(μm)
(μm)
(μm)
(μm)
















Coated tool
C1
3a
TiN
1-TiCN
TiN
TiCNO


of the


(1)
 (17.5)
(1) 
(0.5)


present
C2
3A
TiCN
1-TiCN
TiCO
—


invention


(1)
 (8.5)
(0.5)



C3
3b
TiN
1-TiCN
TiC
TiCNO





(1)
(4)
(4) 
(1) 



C4
3B
TiC
1-TiCN
—
—





(1)
(9)



C5
3c
TiN
1-TiCN
TiCNO
—





(1)
 (4.5)
(0.5)



C6
3C
TiN
1-TiCN
TiC
TiCNO





 (0.5)
 (1.5)
(0.5)
(0.5)



C7
3d
TiN
1-TiCN
TiC
TiCNO





 (0.5)
(10) 
(2) 
(0.3)



C8
3D
TiN
TiCN
—
—





(1)
(19) 



C9
3e
TiC
1-TiCN
TiCO
—





 (0.5)
(9)
(0.5)



C10
3E
TiN
TiC
TiCN
TiCO





(1)
(1)
(7) 
(1) 



C11
3A
TiN
1-TiCN
TiCNO
TiCO





 (0.3)
(5)
(0.7)
(0.1)



C12
3a
TiN
1-TiCN
TiCO
—





(1)
(10) 
(0.5)



C13
3B
TiN
1-TiCN
TiN
TiCNO





 (0.5)
(12) 
(0.5)
(0.2)



C14
3b
TiN
1-TiCN
TiCNO
—





 (0.6)
(7)
(0.3)



C15
3C
TiN
1-TiCN
TiCN
TiCO





 (0.4)
(3)
(0.5)
(0.1)





(Numbers in the parentheses of lower layer column indicate target layer thickness)















TABLE 28









Hard coating layer



Intermediate layer [Reformed α-type Al2O3 layer]

















Frequency ratio






Tilt angle division
of tilt angle



Tool

Target
where (0001) plane
division of 0



substrate
Formation symbol of
layer thickness
shows highest peak
to 10 degrees












Type
symbol
intermediate layer
(μm)
(Degree)
(%)
















Coated
C1
3a
3A
1
1.50-1.75
60


tool of
C2
3A
3B
1
2.75-3.00
52


the
C3
3b
3C
2
2.00-2.25
65


present
C4
3B
3A
2
5.25-5.50
70


invention
C5
3c
3B
3
2.25-2.50
83



C6
3C
3B
3
3.50-3.75
97



C7
3d
3C
4
4.25-4.50
84



C8
3D
3C
4
3.25-3.50
86



C9
3e
3A
5
2.00-2.25
89



C10
3E
3B
5
5.25-5.50
82



C11
3A
3B
2
2.25-2.50
72



C12
3a
3C
2
1.75-2.00
83



C13
3B
3A
3
0.50-0.75
92



C14
3b
3B
2
0.25-0.50
88



C15
3C
3C
3
1.25-1.50
85












Hard coating layer



Upper layer [Reformed AlZrO layer]















Tilt angle division




Content ratio of
Target
where (0001) plane



Formation symbol of
Zr [Zr/(Al + Zr)]
layer thickness
shows highest peak











Type
upper layer
(Atomic ratio)
(μm)
(Degree)















Coated
C1
3A
0.01
5
1.50-1.75


tool of
C2
3B
0.008
2
3.00-3.25


the
C3
3C
0.003
4
2.00-2.25


present
C4
3D
0.002
15
5.25-5.50


invention
C5
3D
0.002
13
2.25-2.50



C6
3C
0.003
10
3.75-4.00



C7
3B
0.009
7
4.25-4.50



C8
3A
0.01
6
3.25-3.50



C9
3B
0.008
14
2.00-2.25



C10
3C
0.003
3
5.25-5.50



C11
3E
0.004
4
2.20-2.25



C12
3F
0.006
5
1.75-2.00



C13
3E
0.004
6
0.50-0.75



C14
3E
0.004
3
0.25-0.50



C15
3F
0.006
4
1.25-1.50












Hard coating layer



Upper layer [Reformed AlZrO layer]












Frequency ratio
Crystal grain ratio





of tilt angle
having Σ3 coinci-
Surface ratio of
Surface



division of 0
dence site lattice in-
flat hexagonal
roughness



to 10 degrees
terface therein
crystal grain
Ra













Type
(%)
(Area %)
(Area %)
(μm)


















Coated
C1
72
65
12
 0.3 *



tool of
C2
68
60
3
0.5



the
C3
74
72
20
0.5



present
C4
71
63
8
0.6



invention
C5
85
77
15
0.8




C6
97
83
18
0.7




C7
86
74
27
 0.2 *




C8
87
79
20
0.6




C9
93
80
14
0.8




C10
89
74
35
 0.1 *




C11
87
82
52
0.5




C12
84
87
63
 0.2 *




C13
95
79
74
0.5




C14
91
83
82
 0.3 *




C15
92
75
54
0.6







(Note)



Then mark * in the column “Surface roughness” indicates that wet blasting processing was performed.















TABLE 29









Hard coating layer



Intermediate layer [Conventional α-type Al2O3 layer]















Frequency ratio





Tilt angle division
of tilt angle




Target
where (0001) plane
division of 0



Formation symbol of
layer thickness
shows highest peak
to 10 degrees











Type
intermediate layer
(μm)
(Degree)
(%)















Comparative
C1
—
—
—
—


coated tool
C2
—
—
—
—



C3
—
—
—
—



C4
—
—
—
—



C5
—
—
—
—



C6
—
—
—
—



C7
—
—
—
—



C8
—
—
—
—



C9
—
—
—
—



C10
—
—
—
—


Reference
C11
3A
2
1.50-1.75
55


coated tool
C12
3B
7
2.00-2.25
63



C13
3C
10 
3.00-3.25
48



C14
3A
8
1.25-1.50
65



C15
3B
5
1.75-2.00
71












Hard coating layer



Upper layer [Conventional AlZrO layer]












Formation symbol of
Content ratio of

Tilt angle division



upper layer
Zr [Zr/
Target
where (0001) plane













Neclear
Reformed
(Al + Zr)]
layer thickness
shows highest peak












Type
thin film
layer
(atomic ratio
(μm)
(Degree)
















Comparative
C1
3a
3A
0.003
3
15.00-15.25


coated tool
C2
3b
3B
0.012
5
20.25-20.50



C3
3c
3C
0.022
10
35.00-35.25



C4
3d
3D
0.03
15
25.50-25.75



C5
3e
3E
0.037
17
27.75-30.00



C6
3f
3F
0.042
14
17.25-17.50



C7
3g
3G
0.05
7
22.00-22.25



C8
3a
3A
0.003
8
23.25-23.50



C9
3b
3B
0.011
6
32.25-32.50



C10
3c
3C
0.021
9
34.75-35.00


Reference
C11
—
—
—
—
—


coated tool
C12
—
—
—
—
—



C13
—
—
—
—
—



C14
—
—
—
—
—



C15
—
—
—
—
—












Hard coating layer



Upper layer [Conventional AlZrO layer]












Frequency ratio
Crystal grain ratio





of tilt angle
Having Σ3 coinci-
Surface ratio of
Surface



division of 0
dence site lattice in-
flat hexagonal
roughness



to 10 degrees
terface therein
crystal grain
Ra











Type
(%)
(Area %)
(Area %)
(μm)















Comparative
C1
15
10
0
0.5


coated tool
C2
10
7
0
 0.2 *



C3
5
8
0
0.6



C4
17
15
0
0.8



C5
3
20
0
0.9



C6
8
17
0
0.8



C7
7
14
0
 0.1 *



C8
6
12
0
0.6



C9
5
3
0
 0.2 *



C10
12
2
0
0.6


Reference
C11
—
—
—
—


coated tool
C12
—
—
—
—



C13
—
—
—
—



C14
—
—
—
—



C15
—
—
—
—





(Note)


The mark * in the column “Surface roughness” indicates that wet blasting processing was performed.

















TABLE 30









Flank wear width (mm)

Cutting test result (min)
















Cutting
Cutting
Cutting


Cutting
Cutting
Cutting



condition
condition
condition


condition
condition
condition














Type
(A)
(B)
(C)
Type
(A)
(B)
(C)



















Coated tool
C1
0.28
0.27
0.25
Comparative
C1
1.4 
1.7
1.5


of the
C2
0.44
0.40
0.42
cutting tool
C2
2.8 
3.5
3.2


present
C3
0.35
0.31
0.32

C3
2.5 *
2.7
2.8


invention
C4
0.45
0.43
0.42

C4
1.3 *
 1.8 *
 1.7 *



C5
0.46
0.42
0.42

C5
1.5 *
 1.9 *
 1.6 *



C6
0.34
0.32
0.33

C6
1.4 *
 1.6 *
 1.4 *



C7
0.41
0.37
0.38

C7
3.2 
4.0
3.8



C8
0.28
0.25
0.27

C8
2.9 *
3.4
 3.2 *



C9
0.27
0.24
0.26

C9
3.0 
3.8
3.5



C10
0.45
0.42
0.44

C10
2.8 *
3.2
 3.0 *



C11
0.18
0.16
0.17
Reference
C11
2.0 
 2.0 *
 1.8 *



C12
0.17
0.15
0.15
cutting tool
C12
3.1 *
3.3
3.2



C13
0.16
0.14
0.14

C13
2.2 
2.5
2.3



C14
0.29
0.25
0.26

C14
3.1 
3.4
3.3



C15
0.14
0.11
0.13

C15
2.3 
2.6
2.4





Cutting test results of comparative coated tools and reference coated tools show cutting times (min) until the tools come to the end of their usable lifespan due to chipping or flank wear (usable lifespan determination criterion: Flank wear width of 0.5 mm).


In addition, mark * in columns indicates a case where tools come to the end of their usable lifespan due to chipping.






From the results shown in Tables 28 to 30, as for the coated tools C1 to C15 of the present invention, the (0001) plane orientation rate of the reformed α-type Al2O3 layers which are the intermediate layers of the hard coating layers show a high ratio of 45% or more, and have excellent high-temperature strength. In addition, the reformed AlZrO layers which constitute the upper layers have the texture of the flat-plate polygonal (flat hexagonal) elongated crystal grains, and the (0001) plane orientation rate show a high ratio of 60% or more, the surface ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are as high as 60% or more, or post-processing is performed on the reformed AlZrO layers and the surface smoothness thereof is further improved. Thereby, the reformed AlZrO layers have superior high-temperature strength, and strength within the crystal grains, and have superior surface flatness. As a result, in high-speed intermittent cutting work of high-hardness steel, such as quenching materials for alloy tool steel or bearing steel, accompanied by high heat generation, and intermittent impact loading acts on the cutting edge, the hard coating layers exhibit superior chipping resistance, show excellent cutting performance for a long-term use, and allows a more prolonged usable lifespan.
On the other hand, it is clear that the comparative coated tools C1 to C10 in which the hard coating layers are composed of the AlZrO layer and the conventional Ti compound layers and the reference coated tools C11 to C15 in which the hard coating layers are composed of the Ti compound layers and the conventional α-type Al2O3 layers, come to the end of their usable lifespan in a relatively short time due to occurrence of chipping, promotion of abrasion, or the like.
As described above, even in high-speed intermittent cutting work of high-hardness steel accompanied by high heat generation, and intermittent and impacting high load acts repeatedly on the cutting edge as well as in cutting work of various kinds of steel or cast iron, or the like under normal conditions, the coated tools of this invention exhibit excellent chipping resistance without occurrence of chipping, and show excellent cutting performance for a prolonged period of time. Therefore, it is possible to satisfactorily cope with the demands for high performance of a cutting device, for labor saving and energy saving in cutting work, and cost reduction.
Example 4
The following powders, each having a mean particle size within a range of 2 to 4 μm, were prepared as raw materials: WC powder, TiC powder, ZrC powder, VC powder, TaC powder, NbC powder, Cr3C2 powder, TiN powder, and Co powder. These raw powders were compounded with each other in the compounding compositions shown in Table 31, mixed with each other in an acetone solution having wax added thereto for 24 hours using a ball mill, and were then dried under reduced pressure. Thereafter, the resultant powder mixture was press-formed into a green compact having a predetermined shape at a pressure of 105 MPa. The green compact was then sintered in a vacuum under the following conditions: a pressure of 5 Pa, a predetermined temperature within a range of 1370° C. to 1470° C., and a holding duration of 1 hour. After sintering, cutting edges were subjected to honing (R: 0.07 mm) to manufacture bodies 4A to 4E made of WC-based cemented carbide and having a throwaway tip shape defined in ISO CNMG120408.
Additionally, the following powders, each having a mean particle size within a range of 0.5 to 2 μm, were prepared as raw materials: TiCN (TiC/TiN=50/50 in weight ratio) powder, Mo2C power, ZrC power, NbC powder, TaC powder, WC power, Co powder and Ni powder. These raw powders were compounded with each other in the compounding compositions shown in Table 22, were wet-mixed with each other for 24 hours using a ball mill, and were dried. Thereafter, the resulting powder mixture was press-formed into a green compact at a pressure of 98 MPa. The green compact was then sintered in a nitrogen atmosphere under the following conditions: a pressure of 1.3 kPa, a temperature of 1540° C., and a holding duration of 1 hour. After sintering, cutting edges were subjected to honing (R: 0.07 mm) to manufacture bodies 4a to 4e made of TiCN-based cermet and having a tip shape defined in ISO CNMG120408.
Subsequently, these bodies 4A to 4E and the bodies 4a to 4e were loaded into a normal chemical vapor deposition apparatus.
(a) First, Ti compound layers with target layer thicknesses shown in Table 37 were vapor-deposited as lower layers of hard coating layers under the conditions shown in Table 33 (1-TiCN in Table 33 shows the formation conditions of TiCN layers with a longitudinal growth crystalline structure disclosed in Japanese Unexamined Patent Application Publication No. 6-8010, and the others show the formation conditions of a normal granular crystalline structure).
(b) Subsequently, reformed Al2O3 layers with target layer thicknesses shown in Table 38 were vapor-deposited as intermediate layers of the hard coating layers under the conditions shown in Table 34.
(c) Next, coated tools D1 to D15 of the present invention were manufactured, respectively, by vapor-depositing reformed Cr-containing Al2O3 layers with target layer thicknesses similarly shown in Table 38 as upper layers of hard coating layers according to the vapor deposition conditions (initial conditions or film formation conditions) shown in Table 35.
For the purpose of comparison, comparative coated tools D1 to D15 were manufactured, respectively, by vapor-depositing Ti compound layers with target layer thicknesses shown in Table 37 under the conditions shown in Table 33 as lower layers of hard coating layers, and then vapor-depositing conventional Cr-containing Al2O3 layers with target layer thicknesses shown in Table 39 under the conditions (neclear formation conditions and film formation conditions, equivalent to the vapor deposition conditions of the conventional Cr-containing Al2O3 layers disclosed in PTL 5) shown in Table 36 as upper layers of the hard coating layers.
The type of the bodies, the type of the lower layers, and the thickness of the lower layers in the conventional coated tools D1 to D15 are the same as those of the coated tools D1 to D15 of the present invention, respectively.
Post-processing composed of wet blasting processing with projection pressure 0.15 MPa and Al2O3 grains of 200 meshes was performed on the surfaces of some reformed Cr-containing Al2O3 layers of the coated tools of the present invention, and the surfaces of some conventional Cr-containing Al2O3 layers of the comparative coated tools. As the post-processing, polishing processing using an elastic grind stone may be adopted.
Tables 38 and 39 show the values of the surface roughness (Ra (μm)) of the reformed Cr-containing Al2O3 layers (those marked by * in Table 38) of the coated tools of the present invention which were subjected to post-processing and the conventional Cr-containing Al2O3 layers (those marked by * in Table 39) of the conventional coated tools. (For reference, the values of Ra regarding the coated tools of the present invention and the conventional coated tools which were not subjected to post-processing are also shown in Tables 38 and 39.)
Subsequently, as for the reformed Al2O3 layers which constitute the intermediate layers of the hard coating layers of the coated tools D1 to D15 of the present invention, the reformed Cr-containing Al2O3 layers which constitute the upper layers of the hard coating layers, and the conventional Cr-containing Al2O3 layers of the conventional coated tools D1 to D15, tilt angle frequency distribution graphs were plotted, respectively, using the field-emission-type scanning electron microscope.
The tilt angle frequency distribution graphs were plotted by setting the respective layers in the coated tools D1 to D15 of the present invention, and the conventional coated tools D1 to D15 within a lens barrel of the field-emission-type scanning electron microscope, with the surfaces of the layers as polished surfaces; individually irradiated crystal grains having a hexagonal crystal lattice present within the measurement range of each polished surface with an electron beam having an acceleration voltage of 15 kV with an irradiating current of 1 nA at an angle of incidence of 70 degrees with respect to each polished surface, thereby measuring the tilt angle of the normal line to the (0001) plane, which is a crystal plane of each crystal grain, to the normal line to each polished surface, at intervals of 0.1 μm/step for a region 30×50 using the electronic backscattering diffraction image apparatus; and on the basis of these measurement results, dividing the measured tilt angles which are within a range of 0 to 45 degrees among the measured tilt angles at every pitch of 0.25 degrees, and summing the frequencies present within the respective divisions.
As an example of the tilt angle frequency distribution graphs, FIG. 14 shows a tilt angle frequency distribution graph of the (0001) plane of a reformed α-type Al2O3 layer which constitutes an intermediate layer of a hard coating layer of a coated tool D14 of the present invention. The “surface” in this invention includes not only a face parallel to the surface of a base, but also a face which inclines to the surface of the base, for example, the cutting face of a layer.
As a result, in the obtained tilt angle frequency distribution graphs of the reformed Al2O3 layers and reformed Cr-containing Al2O3 layers of the coated tools of the present invention, and the conventional Cr-containing Al2O3 layers of the conventional coated tools D1 to D15, as shown in Tables 38 and 39, respectively, the distributions of the measured tilt angles of the (0001) plane in the reformed Al2O3 layers and reformed Cr-containing Al2O3 layers of the coated tools of the present invention show a tilt angle frequency distribution graph in which the highest peak appears in the tilt angle division within a range of 0 to 10 degrees, respectively.
Similarly, the distribution of the measured tilt angles of the (0001) plane in the conventional reformed Cr-containing Al2O3 layers of the conventional coated tools D1 to D15 also shows a tilt angle frequency distribution graph in which the highest peak appears in the tilt angle division within a range of 0 to 10 degrees
Tables 38 and 39 show the ratios of the frequencies present in the tilt angle division within a range of 0 to 10 degrees, which are accounted for in the overall tilt angle frequency distribution graph.
Subsequently, as for the reformed Cr-containing Al2O3 layers which constitute the upper layers of the coated tools D1 to D15 of the present invention, and the conventional Cr-containing Al2O3 layers of the conventional coated tools D1 to D15, the crystal grain structure and the constituent atom sharing lattice point configuration were inspected using the field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus.
First, when the reformed Cr-containing Al2O3 layers of the coated tools D1 to D15 of the present invention and the conventional Cr-containing Al2O3 layers of the conventional coated tools D1 to D15 were observed using the field-emission-type scanning electron microscope, the flat-plate polygonal (including flat hexagonal) and elongated crystal grain structure of a large grain size shown typically in FIGS. 15A and 15B were observed in the coated tools D1 to D15 of the present invention (FIG. 15A is a schematic view of the texture of the coated tool D1 of the present invention as seen within the plane perpendicular to the layer thickness direction, and FIG. 15C is a schematic view of the texture composed of flat hexagonal and elongated crystal grains of a large grain size, of the coated tools D11 of the present invention as seen within the plane perpendicular to the layer thickness direction).
On the other hand, as shown typically in FIGS. 17A and 17B, a polygonal and elongated crystal grain structure was observed in the conventional coated tools D1 to D15. However, the grain size of each crystal grain was small as compared to that of the present invention, and as being clear from FIG. 17B, pyramidal irregularities were formed in the layer surface (FIGS. 17A and 17B are schematic views of the texture of the conventional coated tool 1).
Subsequently, as for the reformed Cr-containing Al2O3 layers of the coated tools D1 to D15 of the present invention, and the conventional Cr-containing Al2O3 layers of the conventional coated tools D1 to D15, the area ratios of crystal grains in which the Σ3 coincidence site lattice interfaces are present inside the crystal grains which constitute each layer were measured.
First, as for the reformed Cr-containing Al2O3 layers of the coated tools D1 to D15 of the present invention, when the respective layers are within a lens barrel of the field-emission-type scanning electron microscope, with the surfaces of the layers as polished surfaces; crystal grains having a hexagonal crystal lattice present within the measurement range of each polished surface are individually irradiated with an electron beam having an acceleration voltage of 15 kV with an irradiating current of 1 nA at an angle of incidence of 70 degrees with respect to each polished surface, thereby measuring the angle at which the normal line to each of crystal lattice planes of the crystal grains crosses the normal line to each base surface, at intervals of 0.1 μm/step for a region 30×50 μm, using the electronic backscattering diffraction image apparatus; and from these measurement results, the crystal orientation relationship between adjacent crystal lattices is calculated, and the distribution of lattice points (constituent atom sharing lattice points) where respective constituent atoms which constitute a crystal lattice interface sharing one constituent atom between the crystal lattices is calculated; and a constituent atom sharing lattice point configuration in which N (here, N is any even number equal to or greater than 2 in a crystal structure of a corundum-type hexagonal close-packing crystal, but when the upper limit of N is 28 from the viewpoint of a distribution frequency, even numbers 4, 8, 14, 24, and 26 do not exist) lattice points which do not share any constituent atoms between the constituent atom sharing lattice points are present is expressed by ΣN+1, the area ratios of crystal grain in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains among all the crystal grains present within the measurement range of the reformed Cr-containing Al2O3 layers were obtained, and the values of the area ratios were shown in Table 38 as Σ3 coincidence site lattice interface ratio (%).
Next, even as for the conventional Cr-containing Al2O3 layers of the conventional coated tools D1 to D15, by the same method as the case of the coated tools of the present inventions, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains among all the crystal grains present within the measurement range of the conventional reformed Cr-containing Al2O3 layers were obtained, and the values of the area ratios were shown in Table 39 as a Σ3 coincidence site lattice interface ratio (%).
As shown in Tables 38 and 39, in the reformed Cr-containing Al2O3 layers of the coated tools D1 to D15 of the present invention, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are 60% or more. On the other hand, in the conventional Cr-containing Al2O3 layers of the conventional coated tools D1 to D15, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are 40% or less. It can be understood from this that the rate at which the Σ3 coincidence site lattice interfaces are present inside crystal grains is very small.
Subsequently, as for the reformed Cr-containing Al2O3 layers of the coated tools D1 to D15 of the present invention, and the conventional Cr-containing Al2O3 layers of the conventional coated tools D1 to D15, the area ratios of flat hexagonal crystal grains of a large grain size present within the plane perpendicular to the layer thickness direction were obtained using the field-emission-type scanning electron microscope. These values are shown in Tables 38 and 39. Here, the “flat hexagonal crystal grains of a large grain size” means polygonal crystal grains in which “the mean value of ten grains is 3 to 8 μm when the diameter of grains present within the plane perpendicular to the layer thickness direction observed by the field-emission-type scanning electron microscope is measured, and six vertex angles whose angle of vertex is 100 to 140° are provided”.
Subsequently, although the thicknesses of the respective constituent layers in the hard coating layers of the coated tools D11 to D15 of the present invention, and the conventional coated tools D11 to D15 were measured using the scanning electron microscope (longitudinal-section measurement), substantially the same mean layer thicknesses (mean value of five-point measurements) as the target layer thicknesses were shown in all cases.
Next, all the coated tools D1 to D15 of the present invention and the conventional coated tools D1 to D15 were screw-fixed to a tip portion of a bite made of tool steel by a fixing jig, and in this state, were subjected to a wet high-speed high-feed-rate cutting test (normal cutting speed and feed rate are 120 m/min, and 0.3 mm/rev, respectively) on stainless steel under the following conditions (referred to as cutting condition A):
Workpiece: a round bar of JIS-SUS316,
Cutting speed: 240 m/min,
Depth of cut: 1.0 mm,
Feed rate: 0.45 mm/rev, and
Cutting time: 5 minutes,
a wet high-speed high-feed-rate cutting test (normal cutting speed and feed rate are 150 m/min, and 0.4 mm/rev, respectively) on ductile cast iron under the following conditions (referred to as cutting condition B):
Workpiece: a round bar of JIS-FCD700,
Cutting speed: 240 m/min,
Depth of cut: 1.0 mm,
Feed rate: 0.7 mm/rev, and
Cutting time: 5 minutes,
a wet high-speed high-feed-rate cutting test (normal cutting speed and feed rate are 80 m/min, and 2.5 mm/rev, respectively) on high manganese steel under the following conditions (referred to as cutting condition C):
Workpiece: a round bar of JIS-SMn438,
Cutting speed: 120 m/min,
Depth of cut: 5.5 mm,
Feed rate: 0.3 mm/rev, and
Cutting time: 5 minutes, and
the flank wear widths of the cutting edges were measured in all the cutting tests. These test results are shown in Table 40.








TABLE 31








Compounding composition (Mass %)
















Type
Co
TiC
ZrC
VC
TaC
NbC
Cr3C2
TiN
WC




















Tool
4A
7
1.5
0.5
—
—
0.5
—
1.5
Balance


substrate
4B
5.7
—
—
—
1.5
0.5
—
—
Balance



4C
5.7
—
—
—
—
—
—
—
Balance



4D
9.5
8 
—
—
—
7.5
—
—
Balance



4E
12.5
—
—
0.5
—
—
0.5
—
Balance

















TABLE 32








Compounding composition (Mass %)















Type
Co
Ni
ZrC
TaC
NbC
Mo2C
WC
TiCN



















Tool
4a
12
6
—
10
—
10
15
Balance


substrate
4b
7
7
—
 5
—
7.5
2
Balance



4c
5
2
—
—
1
6
8
Balance



4d
9
6
—
11
2
—
2
Balance



4e
8
5
1
 8
—
10
8
Balance

















TABLE 33







Hard coating layer (Lower layer)
Formation conditions (Reaction atmosphere










Composition
pressure given in kPa and temperature given in ° C.)










(Numbers
Reaction atmosphere











Type
indicate atomic ratio)
Composition of reaction gas (Vol. %)
Pressure
Temperature














TiC layer
TiC
TiCl4: 4.2%, CH4: 8.5%, H2: Balance
7
1020


TiN layer (First
TiN
TiCl4: 4.2%, N2: 30%, H2: Balance
30
900


layer)






TiN layer (Other
TiN
TiCl4: 4.2%, N2: 35%, H2: Balance
50
1040


layer)






I—TiC0.5N0.5 layer
TiC0.5N0.5
TiCl4: 4.2%, N2: 20%, CH3CN: 0.6%, H2: Balance
7
900


TiCN layer
TiC0.5N0.5
TiCl4: 4.2%, N2: 20%, CH4: 4%, H2: Balance
12
1020


TiCO layer
TiC0.5O0.5
TiCl4: 4.2%, CO: 4%, H2: Balance
7
1020


TiCNO layer
TiC0.3N0.3O0.4
TiCl4: 4.2%, CO: 3%, CH4: 3%, N2: 20%, H2: Balance
20
1020


















TABLE 34








Neclear thin film formation conditions
Heat treatment










Intermediate layer

Reaction atmosphere
Reaction atmosphere












(Reformed Al2O3layer)

Pressure/
Temper-
Pressure/
Temper-


Formation symbol
Composition of reaction gas (Vol %)
kPa
ature/° C.
kPa
ature/° C.
















Neclear thin
4A
AlCl3: 3%, CO2: 0.5%, C2H4:
3
800
3
1100


film (4A)

0.01%, H2: Balance






Neclear thin
4B
AlCl3: 6%, CO2: 1.5%, C2H4:
7
750
7
1200


film (4B)

0.12%, H2: Balance






Neclear thin
4C
AlCl3: 10%, CO2: 3%, C2H4:
13
900
13
1000


film (4C)

0.3%, H2: Balance






α-Type Al2O3
—
AlCl3: 2.2%, CO2: 5.5%, HCl:
7
1000
—
—


layer(*)

2.2%, H2S: 0.2%, H2: Balance





(Note)


Reaction gas composition and reaction atmosphere of the column “α-type Al2O3 layer(*)” indicate formation conditions of a normal α-type Al2O3 layer after formation of neclear thin film (4A) to 4(C).














TABLE 35







Formation symbol of
Formation conditions (Reaction atmosphere pressure


upper layer (Reformed
given in kPa and temperature given in ° C.)









Cr-containing Al2O3

Reaction atmosphere










layer)
Composition of reaction gas (Vol. %)
Pressure
Temperature














4A
Initial condition
AlCl3: 4%, CrCl3: 0.04%, CO2: 8%, HCl: 1.5%, H2S: 0.15%, H2: Balance
8
970



Film formation
AlCl3: 4%, CrCl3: 0.04%, CO2: 8%, HCl; 1.5%, H2S: 0.15%, H2: Balance
8
1020



condition





4B
Initial condition
AlCl3: 3.8% CrCl3: 0.08%, CO2: 8%, HCl; 1.5%, H2S: 0.15%, H2: Balance
10
940



Film formation
AlCl3: 3.8%, CrCl3: 0.08%, CO2: 8%, HCl; 1.5%, H2S: 0.15%, H2: Balance
10
1020



condition





4C
Initial condition
AlCl3: 3.3%, CrCl3: 0.17%, CO2: 7%, HCl; 3%, H2S: 0.2%, H2: Balance
6
960



Film formation
AlCl3: 3.3%, CrCl3: 0.17%, CO2: 7%, HCl; 3%, H2S: 0.2%, H2: Balance
6
1030



condition





4D
Initial condition
AlCl3: 3%, CrCl3: 0.23%, CO2: 7%, HCl; 2%, H2S: 0.1%, H2: Balance
9
950



Film formation
AlCl3: 3%, CrCl3: 0.23%, CO2: 7%, HCl; 2%, H2S: 0.1%, H2: Balance
9
1040



condition





4E
Initial condition
AlCl3: 2.3%, CrCl3: 0.26%, CO2: 6%, HCl; 2%, H2S: 0.05%, H2: Balance
7
930



Film formation
AlCl3: 2.3%, CrCl3: 0.26%, CO2: 6%, HCl; 2%, H2S: 0.05%, H2: Balance
7
1050



condition

















TABLE 36







Formation symbol
Formation condition (Reaction atmosphere


of upper layer
pressure given in kPa and temperature given in ° C.)









(Conventional

Reaction atmosphere










AlTiO layer)
Composition of reaction gas (Vol. %)
Pressure
Temperature














4a
Neclear formation
AlCl3: 4%, CrCl3: 0.04%, CO2: 8%, HCl: 1.5%, H2S: 0.2%, H2: Balance
8
750



condition






Film formation
AlCl3: 4%, CrCl3: 0.04%, CO2: 8%, HCl: 1.5%, H2S: 0.2%, H2: Balance
8
1020



condition





4b
Neclear formation
AlCl3: 3.8%, CrCl3: 0.08%, CO2: 8%, HCl: 1.5%, H2S: 0.2%, H2: Balance
10
800



condition






Film formation
AlCl3: 3.8%, CrCl3: 0.08%, CO2: 8%, HCl: 1.5%, H2S: 0.2%, H2: Balance
10
1020



condition





4c
Neclear formation
AlCl3: 3.3%, CrCl3: 0.17%, CO2: 7%, HCl: 2%, H2S: 0.15%, H2: Balance
7
840



condition






Film formation
AlCl3: 3.3%, CrCl3: 0.17%, CO2: 7%, HCl: 2%, H2S: 0.15%, H2: Balance
7
1030



condition





4d
Neclear formation
AlCl3: 3%, CrCl3: 0.23%, CO2: 7%, HCl: 2.5%, H2S: 0.1%, H2: Balance
7
860



condition






Film formation
AlCl3: 2.3%, CrCl3: 0.26%, CO2: 6%, HCl: 3%, H2S: 0.05%, H2: Balance
7
1030



condition





4e
Neclear formation
AlCl3: 4%, CrCl3: 0.04%, CO2: 8%, HCl: 1.5%, H2S: 0.15%, H2: Balance
6
900



condition






Film formation
AlCl3: 4%, CrCl3: 0.04%, CO2: 8%, HCl: 1.5%, H2S: 0.15%, H2: Balance
6
1050



condition


















TABLE 37








Tool
Lower layer of hard coating layer [Ti compound layer]













substrate
First layer
Second layer
Third layer
Fourth layer


Type
symbol
(μm)
(μm)
(μm)
(μm)
















Coated tool
D1
4a
TiN
1-TiCN
TiN
TiCNO


of the


(1)
 (17.5)
(1) 
(0.5)


present
D2
4A
TiCN
1-TiCN
TiCO
—


invention


(1)
 (8.5)
(0.5)




D3
4b
TiN
1-TiCN
TiC
TiCNO





(1)
(4)
(4) 
(1) 



D4
4B
TiC
1-TiCN
—
—





(1)
(9)





D5
4c
TiN
1-TiCN
TiCNO
—





(1)
 (4.5)
(0.5)




D6
4C
TiN
1-TiCN
TiC
TiCNO





 (0.5)
 (1.5)
(0.5)
(0.5)



D7
4d
TiN
1-TiCN
TiC
TiCNO





 (0.5)
(10) 
(2) 
(0.3)



D8
4D
TiN
TiCN
—
—





(1)
(19) 





D9
4e
TiC
1-TiCN
TiCO
—





 (0.5)
(9)
(0.5)




D10
4E
TiN
TiCN
TiCN
TiCO





(1)
(1)
(7) 
(1) 



D11
4A
TiN
1-TiCN
TiCNO
TiCO





 (0.3)
(5)
(0.7)
(0.1)



D12
4a
TiN
1-TiCN
TiCO
—





(1)
(10) 
(0.5)




D13
4B
TiN
1-TiCN
TiN
TiCNO





 (0.5)
(12) 
(0.5)
(0.2)



D14
4b
TiN
1-TiCN
TiCNO
—





 (0.6)
(7)
(0.3)




D15
4C
TiN
1-TiCN
TiCN
TiCO





 (0.4)
(3)
(0.5)
(0.1)





(Numbers in the parentheses of lower layer column indicate target layer thickness)














TABLE 38








Hard coating layer



Intermediate layer [Reformed Al2O3 layer]

















Frequency ratio






Tilt angle division
of tilt angle



Tool

Target
where (0001) plane
division of 0



substrate
Formation symbol of
layer thickness
shows highest peak
to 10 degrees


Type
symbol
intermediate layer
(μm)
(Degree)
(%)
















Coated
D1
4a
4A
D1
1.50-1.75
60


tool of
D2
4A
4B
D1
2.75-3.00
52


the
D3
4b
4C
D2
2.00-2.25
65


present
D4
4B
4A
D2
5.25-5.50
70


invention
D5
4c
4B
D3
2.25-2.50
83



D6
4C
4B
D3
3.50-3.75
97



C7
4d
4C
D4
4.25-4.50
84



D8
4D
4C
D4
3.25-3.50
86



D9
4e
4A
D5
2.00-2.25
89



D10
4E
4B
D5
5.25-5.50
82



D11
4A
4B
D2
2.25-2.50
72



D12
4a
4C
D2
1.75-2.00
83



D13
4B
4A
D3
0.50-0.75
92



D14
4b
4B
D2
0.25-0.50
88



D15
4C
4C
D3
1.25-1.50
85












Hard coating layer



Upper layer [Reformed Cr-containing Al2O3 layer]















Tilt angle division




Content ratio of
Target
where (0001) plane



Formation symbol of
Cr [Cr/(Al + Cr)]
layer thickness
shows highest peak


Type
upper layer
(Atomic ratio)
(μm)
(Degree)















Coated
D1
4A
0.01
5
1.25-1.50


tool of
D2
4C
0.05
2
3.25-3.50


the
D3
4B
0.02
4
2.00-2.25


present
D4
4A
0.01
15
5.50-5.75


invention
D5
4C
0.05
13
2.50-2.75



D6
4B
0.02
10
3.75-4.00



C7
4D
0.07
7
4.75-5.00



D8
4E
0.10
6
3.25-3.50



D9
4C
0.05
14
2.00-2.25



D10
4D
0.07
3
5.50-5.75



D11
4C
0.05
4
2.25-2.50



D12
4E
0.10
5
1.50-1.75



D13
4D
0.07
6
0.50-0.75



D14
4B
0.02
3
0.00-0.25



D15
4C
0.05
4
1.25-1.50












Hard coating layer



Upper layer [Reformed Cr-containing Al2O3 layer]












Frequency ratio
Crystal grain ratio





of tilt angle
Having Σ3 coinci-
Surface ratio of
Surface



division of 0
dence site lattice in-
flat hexagonal
roughness



to 10 degrees
terface therein
crystal grain
Ra













Type
(%)
(Area %)
(Area %)
(μm)

















Coated
D1
64
63
14
* 0.3 



tool of
D2
60
60
3
0.4



the
D3
66
65
21
0.5



present
D4
62
64
9
0.6



invention
D5
73
68
17
0.5




D6
80
81
19
0.4




C7
75
72
30
* 0.2 




D8
78
73
23
0.4




D9
81
76
16
0.5




D10
79
69
37
* 0.1 




D11
72
68
55
0.4




D12
76
72
66
* 0.2 




D13
91
84
75
0.5




D14
82
80
84
* 0.3 




D15
85
85
59
0.4





(Note)


The mark * in the column “Surface roughness” indicates that wet blasting processing was performed.














TABLE 39








Hard coating layer



Intermediate layer

















Frequency ratio






Tilt angle division
of tilt angle



Tool

Target
where (0001) plane
division of 0



substrate
Formation symbol of
layer thickness
shows highest peak
to 10 degrees


Type
symbol
intermediate layer
(μm)
(Degree)
(%)
















Comparative
C1
4a
—
—
—
—


coated
C2
4A
—
—
—
—


tool
C3
4b
—
—
—
—



C4
4B
—
—
—
—



C5
4c
—
—
—
—



C6
4C
—
—
—
—



C7
4d
—
—
—
—



C8
4D
—
—
—
—



C9
4e
—
—
—
—



C10
4E
—
—
—
—



C11
4A
—
—
—
—



C12
4a
—
—
—
—



C13
4B
—
—
—
—



C14
4b
—
—
—
—



C15
4C
—
—
—
—












Hard coating layer



Upper layer [Conventional Cr-containing Al2O3 layer]















Tilt angle division




Content ratio of
Target
where (0001) plane



Formation symbol of
Cr [Cr/(Al + Cr)]
layer thickness
shows highest peak


Type
upper layer
(Atomic ratio)
(μm)
(Degree)















Comparative
C1
4a
0.01
5
4.50-4.75


coated
C2
4c
0.05
2
3.00-3.25


tool
C3
4b
0.02
4
4.75-5.00



C4
4a
0.01
15
5.75-6.00



C5
4c
0.05
13
2.25-2.50



C6
4b
0.02
10
5.25-5.50



C7
4d
0.07
7
6.50-6.75



C8
4e
0.10
6
8.00-8.25



C9
4c
0.05
14
1.75-2.00



C10
4d
0.07
3
7.50-7.75



C11
4c
0.05
4
0.00-0.25



C12
4e
0.10
5
 9.75-10.00



C13
4d
0.07
6
8.75-9.00



C14
4b
0.02
3
6.00-6.25



C15
4c
0.05
4
0.75-1.00












Hard coating layer



Upper layer [Conventional Cr-containing Al2O3 layer]












Frequency ratio
Crystal grain ratio





of tilt angle
Having Σ3 coinci-
Surface ratio of
Surface



division of 0
dence site lattice in-
flat hexagonal
roughness



to 10 degrees
terface therein
crystal grain
Ra













Type
(%)
(Area %)
(Area %)
(μm)

















Comparative
C1
75
2
0
* 0.3 



coated
C2
60
5
0
0.5



tool
C3
82
8
0
0.6




C4
86
12
0
0.9




C5
56
7
0
0.8




C6
89
16
0
0.8




C7
74
10
5
* 0.3 




C8
54
7
0
0.7




C9
58
8
0
0.8




C10
61
13
0
* 0.2 




C11
47
3
0
0.6




C12
45
0
0
* 0.3 




C13
50
9
0
0.6




C14
85
17
0
* 0.2 




C15
49
5
0
0.6





(Note)


The mark * in the column “Surface roughness” indicates that wet blasting processing was performed.
















TABLE 40








Flank wear width (mm)

Cutting test result (min)
















Cutting
Cutting
Cutting


Cutting
Cutting
Cutting



condition
condition
condition


condition
condition
condition














Type
(A)
(B)
(C)
Type
(A)
(B)
(C)



















Coated tool
D1
0.3
0.28
0.34
Comparative
D1
* 2.6 
* 3.5 
* 2.1 


of the
D2
0.26
0.24
0.29
coated tool
D2
3.7
3.9
3  


present
D3
0.19
0.19
0.21

D3
4.2
4.4
2.6


invention
D4
0.22
0.2
0.24

D4
* 1.4 
* 2.5 
* 1.1 



D5
0.19
0.17
0.2

D5
* 2.1 
* 3.3 
* 1.7 



D6
0.23
0.21
0.26

D6
3.9
4.2
* 2.3 



D7
0.28
0.25
0.29

D7
* 2.2 
* 3.4 
* 1.9 



D8
0.3
0.27
0.3

D8
* 1.6 
* 2.7 
* 1.3 



D9
0.26
0.23
0.28

D9
* 1.8 
* 2.9 
* 1.5 



D10
0.28
0.25
0.31

D10
3.4
3.8
2.4



D11
0.31
0.29
0.33
Reference
D11
3.3
3.9
2.2



D12
0.29
0.27
0.32
coated tool
D12
3.6
4  
2.1



D13
0.2
0.18
0.22

D13
4.5
4.8
3.1



D14
0.21
0.18
0.21

D14
4.2
4.5
3.0



D15
0.21
0.2
0.23

D15
4.3
4.6
2.8





Cutting test results of comparative coated tools and reference coated tools show cutting times (min) until the tools come to the end of their usable lifespan due to chipping or flank wear (usable lifespan determination criterion: Flank wear width of 0.5 mm).


In addition, the mark * in columns indicates a case where tools come to the end of their usable lifespan due to chipping.






From the results shown in Tables 38 to 40, as for the coated tools D1 to D15 of the present invention, the (0001) plane orientation rate of the reformed α-type Al2O3 layers which are the intermediate layers of the hard coating layers show a high ratio of 45% or more, and have excellent high-temperature strength. In addition, the reformed Cr-containing Al2O3 layers which constitute the upper layers have the texture of the flat-plate polygonal (flat hexagonal) elongated crystal grains, and the (0001) plane orientation rate show a high ratio of 60% or more, the surface ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are as high as 60% or more, or post-processing is performed on the Cr-containing Al2O3 layers and the surface smoothness thereof is further improved. Thereby, the Cr-containing Al2O3 layers have superior high-temperature strength, and strength within the crystal grains, and have superior surface flatness. As a result, in high-speed heavy cutting work of difficult-to-cut materials, such as stainless steel or ductile cast iron, accompanied by high heat generation, and high load resulting from a high feed rate and a high depth of cut acts on the cutting edge, the hard coating layers exhibit superior chipping resistance, show excellent abrasion resistance for a long-term use, and allows a more prolonged usable lifespan.
On the other hand, it is clear that the comparative coated tools D1 to D15 in which the hard coating layers are composed of the Ti compound layers and the conventional Cr-containing Al2O3 layers come to the end of their usable lifespan in a relatively short time due to occurrence of chipping, or the like.
Example 5
The following powders, each having a mean particle size within a range of 2 to 4 μm, were prepared as raw materials: WC powder, TiC powder, ZrC powder, VC powder, TaC powder, NbC powder, Cr3C2 powder, TiN powder, TaN powder, and Co powder. These raw powders were compounded with each other in the compounding compositions shown in Table 1, mixed with each other in an acetone solution having wax added thereto for 24 hours using a ball mill, and were then dried under reduced pressure. Thereafter, the resultant powder mixture was press-formed into a green compact having a predetermined shape at a pressure of 98 MPa. The green compact was then sintered in a vacuum under the following conditions: a pressure of 5 Pa, a predetermined temperature within a range of 1370° C. to 1470° C., and a holding duration of 1 hour. After sintering, cutting edges were subjected to honing (R: 0.07 mm) to manufacture bodies 1A to 1E made of WC-based cemented carbide and having a throwaway tip shape defined in ISO CNMG120408MA.
Additionally, the following powders, each having a mean particle size within a range of 0.5 to 2 μm, were prepared as raw materials for substrates: TiCN (TiC/TiN=50/50 in weight ratio) powder, Mo2C power, ZrC power, NbC powder, TaC powder, WC power, Co powder and Ni powder. These raw powders were compounded with each other in the compounding compositions shown in Table 2, were wet-mixed with each other for 24 hours using a ball mill, and were dried. Thereafter, the resulting powder mixture was press-formed into a green compact at a pressure of 98 MPa. The green compact was then sintered in a nitrogen atmosphere under the following conditions: a pressure of 1.3 kPa, a temperature of 1540° C., and a holding duration of 1 hour. After sintering, cutting edges were subjected to honing (R: 0.07 mm) to manufacture bodies 1a to 1e made of TiCN-based cermet and having a tip shape defined in ISO Standard CNMG120408MA.
Subsequently, these bodies 1A to 1E and the bodies 1a to 1e were loaded into a normal chemical vapor deposition apparatus.
(a) First, Ti compound layers with target layer thicknesses shown in Table 41 were vapor-deposited as lower layers of hard coating layers under the conditions shown in Table 3 (1-TiCN in Table 3 shows the formation conditions of TiCN layers with a longitudinal growth crystalline structure disclosed in Japanese Unexamined Patent Application Publication No. 6-8010, and the others show the formation conditions of a normal granular crystalline structure).
(b) Subsequently, reformed α-type Al2O3 layers with target layer thicknesses shown in Table 44 were vapor-deposited as intermediate layers of the hard coating layers under the conditions shown in Table 4.
(c) Next, coated tools E1 to BE5 of the present invention were manufactured, respectively, by vapor-depositing reformed AlBO layers with target layer thicknesses similarly shown in Table 44 as upper layers of hard coating layers according to the vapor deposition conditions shown in Table 42.
For the purpose of comparison, comparative coated tools E1 to E10 (equivalent to the conventional coated tool 6) provided with hard coating layers composed of Ti compound layers and conventional AlBO layers with target layer thicknesses shown in Table 45 were manufactured, respectively, by forming lower layers of hard coating layers under the conditions shown in Table 3 and forming upper layers under the conditions (equivalent to the vapor deposition conditions of the conventional AlBO layers disclosed in PTL 6)) shown in Table 43.
The type of the bodies, the type of the lower layers, and the thickness of the lower layers in the comparative coated tools E1 to E10 are the same as those of the coated tools E1 to E10 of the present invention, respectively.
Moreover, for reference, reference coated tools E11 to E15 (equivalent to the conventional coated tool 1) provided with hard coating layers composed of Ti compound layers and conventional α-type Al2O3 layers with target layer thicknesses shown in Table 45 were manufactured, respectively, by forming lower layers of hard coating layers under the conditions shown in Table 3 and forming α-type Al2O3 layers under the conditions (equivalent to the vapor deposition conditions of the conventional α-type Al2O3 layers disclosed in PTL 1) shown in Table 4.
The type of the bodies, the type of the lower layers, and the thickness of the lower layers in the reference coated tools E11 to E15 are the same as those of the coated tools E11 to E15 of the present invention, respectively.
Post-processing composed of wet blasting processing with projection pressure 0.15 MPa and Al2O3 grains of 200 meshes was performed on the surfaces of some reformed AlBO layers of the coated tools of the present invention, and the surfaces of some conventional AlBO layers of the comparative coated tools. As the post-processing, polishing processing using an elastic grind stone may be adopted.
Tables 44 and 45 show the values of the surface roughness (Ra (μm)) of the reformed AlBO layers (those marked by * in Table 44) of the coated tools of the present invention which were subjected to post-processing and the conventional AlBO layers (those marked by * in Table 45) of the comparative coated tools. (For reference, the values of Ra regarding the coated tools of the present invention and the comparative coated tools which were not subjected to post-processing are also shown in Tables 44 and 45.)
Subsequently, as for the reformed α-type Al2O3 layers which constitute the intermediate layers of the hard coating layers of the coated tools E1 to E15 of the present invention, the reformed AlBO layers which constitute the upper layers of the hard coating layers, the conventional AlBO layers of the comparative coated tools E1 to E10, and the α-type Al2O3 layers of the reference coated tools E11 to E15, tilt angle frequency distribution graphs were plotted, respectively, using the field-emission-type scanning electron microscope.
The tilt angle frequency distribution graphs were plotted by setting the respective layers in the coated tools E1 to E15 of the present invention, the comparative coated tools E1 to E10, and the reference coated tools E11 to E15 within a lens barrel of the field-emission-type scanning electron microscope, with the surfaces of the layers as polished surfaces; individually irradiated crystal grains having a hexagonal crystal lattice present within the measurement range of each polished surface with an electron beam having an acceleration voltage of 15 kV with an irradiating current of 1 nA at an angle of incidence of 70 degrees with respect to each polished surface, thereby measuring the tilt angle of the normal line to the (0001) plane, which is a crystal plane of each crystal grain, to the normal line to each polished surface, at intervals of 0.1 μm/step for a region 30×50 μm, using the electronic backscattering diffraction image apparatus; and on the basis of these measurement results, dividing the measured tilt angles which are within a range of 0 to 45 degrees among the measured tilt angles at every pitch of 0.25 degrees, and summing the frequencies present within the respective divisions.
The “surface” in this invention includes not only a face parallel to the surface of a base, but also a face which inclines to the surface of the base, for example, the cutting face of a layer.
As a result, in the obtained tilt angle frequency distribution graphs of the reformed α-type Al2O3 layers and reformed AlBO layers of the coated tools of the present invention, the conventional AlBO layers of the comparative coated tools E1 to E10, and the conventional α-type Al2O3 layers of the reference coated tools B11 to B15, as shown in Tables 44 and 45, respectively, the distributions of the measured tilt angles of the (0001) plane in the reformed α-type Al2O3 layers and reformed AlBO layers of the coated tools of the present invention show a tilt angle frequency distribution graph in which the highest peak appears in the tilt angle division within a range of 0 to 10 degrees, respectively. On the other hand, the distribution of the measured tilt angles of the (0001) plane in the conventional AlBO layers of the comparative coated tools E1 to E10 shows a tilt angle frequency distribution graph in which the highest peak does not present in an unbiased manner within a range of 0 to 45 degrees.
Tables 44 and 45 show the ratios of the frequencies present in the tilt angle division within a range of 0 to 10 degrees, which are accounted for in the overall tilt angle frequency distribution graph.
Subsequently, as for the reformed AlBO layers which constitute the upper layers of the coated tools E1 to E15 of the present invention, and the conventional AlBO layers of the comparative coated tools E1 to E10, the crystal grain structure and the constituent atom sharing lattice point configuration were inspected using the field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus. First, when the reformed AlBO layers of the coated tools E1 to E15 of the present invention and the conventional AlBO layers of the comparative coated tools E1 to E10 were observed using the field-emission-type scanning electron microscope, the flat-plate polygonal (including flat hexagonal) and elongated crystal grain structure of a large grain size were observed in the coated tools E1 to E15 of the present invention. On the other hand, a polygonal and elongated crystal grain structure was observed in the comparative coated tools E1 to E10. However, the grain size of each crystal grain was small as compared to that of the present invention, and pyramidal irregularities were formed in the layer surface.
Subsequently, as for the reformed AlBO layers of the coated tools E1 to E15 of the present invention, and the conventional AlBO layers of the comparative coated tools E1 to E10, the area ratios of crystal grains in which the Σ3 coincidence site lattice interfaces are present inside the crystal grains which constitute each layer were measured.
First, as for the reformed AlBO layers of the coated tools E1 to E15 of the present invention, when the respective layers are within a lens barrel of the field-emission-type scanning electron microscope, with the surfaces of the layers as polished surfaces; crystal grains having a hexagonal crystal lattice present within the measurement range of each polished surface are individually irradiated with an electron beam having an acceleration voltage of 15 kV with an irradiating current of 1 nA at an angle of incidence of 70 degrees with respect to each polished surface, thereby measuring the angle at which the normal line to each of crystal lattice planes of the crystal grains crosses the normal line to each base surface, at intervals of 0.1 μm/step for a region 30×50 μm, using the electronic backscattering diffraction image apparatus; and from these measurement results, the crystal orientation relationship between adjacent crystal lattices is calculated, and the distribution of lattice points (constituent atom sharing lattice points) where respective constituent atoms which constitute a crystal lattice interface sharing one constituent atom between the crystal lattices is calculated; and a constituent atom sharing lattice point configuration in which N (here, N is any even number equal to or greater than 2 in a crystal structure of a corundum-type hexagonal close-packing crystal, but when the upper limit of N is 28 from the viewpoint of a distribution frequency, even numbers 4, 8, 14, 24, and 26 do not exist) lattice points which do not share any constituent atoms between the constituent atom sharing lattice points are present is expressed by ΣN+1, the area ratios of crystal grain in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains among all the crystal grains present within the measurement range of the reformed AlBO layers were obtained, and the values of the area ratios were shown in Table 44 as Σ3 coincidence site lattice interface ratio (%).
Next, even as for the conventional AlBO layers of the comparative coated tools E1 to E10, by the same method as the case of the coated tools of the present inventions, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains among all the crystal grains present within the measurement range of the conventional reformed AlBO layers were obtained, and the values of the area ratios were shown in Table 45 as Σ3 coincidence site lattice interface ratio (%).
As shown in Tables 44 and 45, in the reformed AlBO layers of the coated tools E1 to E15 of the present invention, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are 60% or more. On the other hand, in the conventional AlBO layers of the comparative coated tools E1 to E10, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are 40% or less. It can be understood from this that the rate at which the Σ3 coincidence site lattice interfaces are present inside crystal grains is very small.
Subsequently, as for the reformed AlBO layers of the coated tools E1 to E15 of the present invention, and the conventional AlBO layers of the comparative coated tools E1 to E10, the area ratios of flat hexagonal crystal grains of a large grain size present within the plane perpendicular to the layer thickness direction were obtained using the field-emission-type scanning electron microscope. These values are shown in Tables 44 and 45.
Here, the “flat hexagonal crystal grains of a large grain size” means polygonal crystal grains in which the mean value of ten grains is 3 to 8 μm when the diameter of grains present within the plane perpendicular to the layer thickness direction observed by the field-emission-type scanning electron microscope is measured, and six vertex angles whose angle of vertex is 100 to 140° are provided.
Subsequently, although the thicknesses of the respective constituent layers in the hard coating layers of the coated tools E1 to E15 of the present invention, the comparative coated tools E1 to E10, and the reference coated tools E11 to E15 were measured using the scanning electron microscope (longitudinal-section measurement), substantially the same mean layer thicknesses (mean value of five-point measurements) as the target layer thicknesses were shown in all cases.
Next, all the coated tools E1 to E15 of the present invention, the comparative coated tools E1 to E10, and the reference coated tools E11 to E15 were screw-fixed to a tip portion of a bite made of tool steel by a fixing jig, and in this state, were subjected to a dry high-speed intermittent cutting test (normal cutting speed is 200 m/min) on bearing steel under the following conditions (referred to as cutting condition A):
Workpiece: a round bar of JIS-SUJ2 (HRC62) with four longitudinal grooves equally-spaced in the length direction,
Cutting speed: 250 m/min,
Depth of cut: 1.5 mm,
Feed rate: 0.15 mm/rev, and
Cutting time: 5 minutes,
a dry high-speed intermittent cutting test (normal cutting speed is 200 m/min) on alloy tool steel under the following conditions (referred to as cutting condition B):
Workpiece: a round bar of JIS-SKD11 (HRC58) with four longitudinal grooves equally-spaced in the length direction,
Cutting speed: 300 m/min,
Depth of cut: 1.5 mm,
Feed rate: 0.15 mm/rev, and
Cutting time: 5 minutes, and
a dry high-speed intermittent cutting test (normal cutting speed is 150 m/min) on carbon tool steel under the following conditions (reference to as cutting condition C):
Workpiece: a round bar of JIS-SK3 (HRC61) with four longitudinal grooves equally-spaced in the length direction,
Cutting speed: 250 m/min,
Depth of cut: 1.5 mm,
Feed rate: 0.15 mm/rev, and
Cutting time: 5 minutes, and the flank wear widths of the cutting edges were measured in all the cutting tests. These test results are shown in Table 46.









TABLE 41








Tool
Lower layer of hard coating layer[Ti compound layer]













substrate
First layer
Second layer
Third layer
Fourth layer


Type
symbol
(μm)
(μm)
(μm)
(μm)
















Coated tool
E1
1a
TiN
1-TiCN
TiN
TiCNO


of the


(1)
 (17.5)
(1) 
(0.5)


present
E2
1A
TiCN
1-TiCN
TiCO
—


invention


(1)
 (8.5)
(0.5)




E3
1b
TiN
1-TiCN
TiC
TiCNO





(1)
(4)
(4) 
(1) 



E4
1B
TiC
1-TiCN
—
—





(1)
(9)





E5
1c
TiN
1-TiCN
TiCNO
—





(1)
 (4.5)
(0.5)




E6
1C
TiN
1-TiCN
TiC
TiCNO





 (0.5)
 (1.5)
(0.5)
(0.5)



E7
1d
TiN
1-TiCN
TiC
TiCNO





 (0.5)
(10) 
(2) 
(0.3)



E8
1D
TiN
TiCN
—
—





(1)
(19) 





E9
1e
TiC
1-TiCN
TiCO
—





 (0.5)
(9)
(0.5)




E10
1E
TiN
TiC
TiCN
TiCO





(1)
(1)
(7) 
(1) 



E11
1A
TiN
1-TiCN
TiCNO
TiCO





 (0.3)
(5)
(0.7)
(0.1)



E12
1a
TiN
1-TiCN
TiCO
—





(1)
(10) 
(0.5)




E13
1B
TiN
1-TiCN
TiN
TiCNO





 (0.5)
(12) 
(0.5)
(0.2)



E14
1b
TiN
1-TiCN
TiCNO
—





 (0.6)
(7)
(0.3)




E15
1C
TiN
1-TiCN
TiCN
TiCO





 (0.4)
(3)
(0.5)
(0.1)





(Numbers in the parentheses of lower layer column indicate target layer thickness)














TABLE 42







B-containing
Formation condition (Reaction atmosphere


α-type
pressure given in kPa and temperature given in ° C.)









Al2O3 layer

Reaction atmosphere










Formation symbol
Composition of reaction gas (Vol. %)
Pressure
Temperature














5A
First step
AlCl3: 1%, BCl3: 0%, HCl: 1%, CO2: 2%, H2S: 0.25%, H2: Balance
6
960



Second step
AlCl3: 6%, BCl3: 0.2%, HCl: 3%, CO2: 5%, H2S: 0.4%, H2: Balance
6
1000


5B
First step
AlCl3: 2%, BCl3: 0.01%, HCl: 2%, CO2: 4%, H2S: 0.3%, H2: Balance
7
980



Second step
AlCl3: 7%, BCl3: 0.08%, HCl: 4%, CO2: 6%, H2S: 0.3%, H2: Balance
7
990


5C
First step
AlCl3: 3%, BCl3: 0.005%, HCl: 3%, CO2: 5%, H2S: 0.4%, H2: Balance
10
1000



Second step
AlCl3: 8%, BCl3: 0.07%, HCl: 4%, CO2: 6%, H2S: 0.25%, H2: Balance
10
970


5D
First step
AlCl3: 5%, BCl3: 0%, HCl: 5%, CO2: 5%, H2S: 0.4%, H2: Balance
8
1010



Second step
AlCl3: 10%, BCl3: 0.02%, HCl: 3%, CO2: 8%, H2S: 0.6%, H2: Balance
8
1010


5E
First step
AlCl3: 2%, BCl3: 0.005%, HCl: 4%, CO2: 5%, H2S: 0.6%, H2: Balance
7
1000



Second step
AlCl3: 6%, BCl3: 0.1%, HCl: 5%, CO2: 4%, H2S: 0.25%, H2: Balance
7
960


5F
First step
AlCl3: 3%, BCl3: 0.01%, HCl: 4%, CO2: 6%, H2S: 0.75%, H2: Balance
6
1010



Second step
AlCl3: 8%, BCl3: 0.2%, HCl: 4%, CO2: 8%, H2S: 0.3%, H2: Balance
6
980

















TABLE 43







Conventional
Formation condition (Reaction atmosphere pressure


B-containing Al2O3
given in kPa and temperature given in ° C.)









layer

Reaction atmosphere










Formation Number
Composition of reaction gas (Vol. %)
Pressure
Temperature





5a
AlCl3: 1.6%, CO2: 4%, BCl3: 0.15%, Ar: 23%, N2: 58% H2: Balance
101.3 kPa
1060


5b
AlCl3: 1.6%, CO2: 4%, BCl3: 0.15%, Ar: 81%, H2: Balance
101.3 kPa
1060


5c
AlCl3: 1.6%, CO2: 4%, BCl3: 0.6%, Ar: 81%, H2: Balance
101.3 kPa
1060


5d
AlCl3: 1.6%, CO2: 4%, BCl3: 0.07%, Ar: 81%, H2: Balance
101.3 kPa
1060


5e
AlCl3: 3.2%, CO2: 4%, HCl; 4%, BCl3: 0.3% CO: 16%, H2: Balance
   4 kPa
1020

















TABLE 44








Hard coating layer









Upper layer [B-containing











α-type Al2O3 layer]



Intermediate layer [α-type Al2O3 layer]
Frequency ratio
















Tilt angle division
of tilt angle



Tool

Target
where (0001) plane
division of 0



substrate
Formation symbol of
layer thickness
shows highest peak
to 10 degrees


Type
symbol
intermediate layer
(μm)
(Degree)
(%)
















Coated
E1
1a
1A
1
1.50-1.75
45


tool of
E2
1A
1B
1
0.00-0.25
78


the
E3
1b
1C
2
0.50-0.75
84


present
E4
1B
1A
2
0.25-0.50
75


invention
E5
1c
1B
3
4.50-4.75
91



E6
1C
1B
3
1.25-1.50
73



E7
1d
1C
4
3.00-3.25
71



E8
1D
1C
4
 9.75-10.00
63



E9
1e
1A
5
5.50-5.75
75



E10
1E
1B
5
2.50-2.75
84



E11
1A
1B
2
0.50-0.75
81



E12
1a
1C
2
0.75-1.00
95



E13
1B
1A
3
1.75-2.00
94



E14
1b
1B
2
2.50-2.75
69



E15
1C
1C
3
6.50-6.75
82












Hard coating layer



Upper layer [B-containing



α-type Al2O3 layer]















Tilt angle division




Content ratio of
Target
where (0001) plane



Formation symbol of
B [B/(Al + B)]
layer thickness
shows highest peak


Type
upper layer
(Atomic ratio)
(μm)
(Degree)















Coated
E1
5A
0.01
2
1.50-1.75


tool of
E2
5A
0.01
4
0.00-0.25


the
E3
5B
0.007
8
0.50-0.75


present
E4
5B
0.007
4
0.25-0.50


invention
E5
5C
0.004
7
4.50-4.75



E6
5C
0.004
13
1.25-1.50



E7
5D
0.001
3
3.00-3.25



E8
5D
0.001
4
 9.75-10.00



E9
5A
0.01
9
5.50-5.75



E10
5A
0.01
15
2.50-2.75



E11
5E
0.008
6
0.50-0.75



E12
5E
0.008
9
0.75-1.00



E13
5F
0.006
3
1.75-2.00



E14
5F
0.006
8
2.50-2.75



E15
5E
0.008
5
6.50-6.75












Hard coating layer



Upper layer [B-containing



α-type Al2O3 layer]












Frequency ratio
Crystal grain ratio





of tilt angle
Having Σ3 coinci-
Surface ratio of




division of 0
dence site lattice in-
flat hexagonal
Surface



to 10 degrees
terface therein
crystal grain
roughness Ra













Type
(%)
(Area %)
(Area %)
(μm)

















Coated
E1
60
60
7
 0.1*



tool of
E2
84
66
12
0.4



the
E3
90
82
27
0.5



present
E4
80
75
17
 0.2*



invention
E5
91
84
15
0.5




E6
79
74
21
 0.3*




E7
77
72
22
0.4




E8
68
64
13
0.4




E9
88
89
34
0.6




E10
93
94
33
0.7




E11
89
91
77
0.5




E12
97
96
85
0.5




E13
99
97
96
0.4




E14
71
82
35
0.4




E15
88
92
69
 0.2*

















TABLE 45








Hard coating layer



Intermediate layer [α-type Al2O3 layer]















Frequency ratio





Tilt angle division
of tilt angle




Target
where (0001) plane
division of 0



Formation symbol of
layer thickness
shows highest peak
to 10 degrees


Type
intermediate layer
(μm)
(Degree)
(%)















Comparative
E1
—
—
—
—


coated
E2
—
—
—
—


tool
E3
—
—
—
—



E4
—
—
—
—



E5
—
—
—
—



E6
—
—
—
—



E7
—
—
—
—



E8
—
—
—
—



E9
—
—
—
—



E10
—
—
—
—


Reference
E11
1A
2
1.50-1.75
55


coated
E12
1B
7
2.00-2.25
63


tool
E13
1C
10 
3.00-3.25
48



E14
1A
8
1.25-1.50
65



E15
1B
5
1.75-2.00
71












Hard coating layer



Upper layer [B-containing α-type Al2O3 layer]













Content ratio

Tilt angle division




of B [B/(B +
Target
where (0001) plane



Formation symbol of
Zr)]
layer thickness
shows highest peak


Type
upper layer
(atomic ratio
(μm)
(Degree)















Comparative
E1
5a
0.1
12
15.50-15.75


coated
E2
5b
0.1
8
19.75-20.00


tool
E3
5c
0.1
10
35.00-35.25



E4
5d
0.4
17
27.50-27.75



E5
5e
0.05
7
17.00-17.25



E6
5a
0.1
3
22.50-22.75



E7
5b
0.1
5
23.75-24.00



E8
5c
0.1
9
32.25-35.50



E9
5d
0.4
11
34.50-34.75



E10
5e
0.05
20
35.50-35.75


Reference
E11

—
—
—


coated
E12

—
—
—


tool
E13

—
—
—



E14

—
—
—



E15

—
—
—












Hard coating layer



Upper layer [B-containing α-type Al2O3 layer]












Frequency ratio
Crystal grain ratio





of tilt angle
Having Σ3 coinci-
Surface ratio of
Surface



division of 0
dence site lattice in-
flat hexagonal
roughness



to 10 degrees
terface therein
crystal grain
Ra


Type
(%)
(Area %)
(Area %)
(μm)















Comparative
E1
14
10
0
0.5


coated
E2
10
5
0
 0.3*


tool
E3
6
3
0
0.5



E4
16
11
0
0.8



E5
4
15
0
0.9



E6
12
14
0
0.8



E7
8
12
5
 0.1*



E8
4
8
0
0.6



E9
3
1
0
 0.05*



E10
9
0
0
0.9


Reference
E11
—
—
—
—


coated
E12
—
—
—
—


tool
E13
—
—
—
—



E14
—
—
—
—



E15
—
—
—
—



















TABLE 46








Flank wear width (mm)

Cutting test result (min)
















Cutting
Cutting
Cutting


Cutting
Cutting
Cutting



condition
condition
condition


condition
condition
condition














Type
(A)
(B)
(C)
Type
(A)
(B)
(C)



















Coated tool
E1
3.3
3.3
3.4
Comparative
E1
1.1 *
1.3
12 *  


of the
E2
1.4
1.6
1.5
coated tool
E2
2.4 
2.5
2.4 


present
E3
1.3
1.3
1.2

E3
1.3 *
 1.1 *
1.5 


invention
E4
1.3
1.2
1.1

E4
2.8 
2.7
1.5 *



E5
2.3
2.2
2.1

E5
2.5 
 1.4 *
2.3 



E6
2.4
2.5
2.4

E6
0.8 *
 1.1 *
0.9 *



E7
1.7
1.5
1.4

E7
1.6 *
3.1
3.2 



E8
2.0
1.8
1.8

E8
2.8 
 1.6 *
2.1 *



E9
2.3
2.2
2.4

E9
1.2 *
 1.3 *
1.1 *



E10
2.3
2.2
2.6

E10
0.6 *
 0.7 *
0.8 *



E11
1.2
1.3
1.0
Reference
E11
3.1 
3.2
2.9 



E12
2.0
1.7
1.8
coated tool
E12
1.4 *
2.4
2.0 *



E13
1.1
1.0
0.9

E13
3.0 
3.1
2.7 



E14
1.8
1.7
1.7

E14
1.5 *
2.5
1.7 *



E15
1.2
1.1
1.1

E15
2.2 *
3.1
2.9 





Cutting test results of comparative coated tools and reference coated tools show cutting times (min) until the tools come to the end of their usable lifespan due to chipping or flank wear (usable lifespan determination criterion: Flank wear width of 0.5 mm).


In addition, the mark * in columns indicates a case where tools come to the end of their usable lifespan due to chipping.






From the results shown in Tables 44 to 46, as for the coated tools E1 to E15 of the present invention, the (0001) plane orientation rate of the reformed α-type Al2O3 layers which are the intermediate layers of the hard coating layers show a high ratio of 45% or more, and have excellent high-temperature strength. In addition, the reformed AlBO layers which constitute the upper layers have the texture of the flat-plate polygonal (flat hexagonal) elongated crystal grains, and the (0001) plane orientation rate show a high ratio of 60% or more, the surface ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are as high as 60% or more, or post-processing is performed on the reformed AlBO layers and the surface smoothness thereof is further improved. Thereby, the reformed AlBO layers have superior high-temperature strength, and strength within the crystal grains, and have superior surface flatness. As a result, in high-speed intermittent cutting work of high-hardness steel, such as quenching materials for alloy tool steel or bearing steel, accompanied by high heat generation, and intermittent impact loading acts on the cutting edge, the hard coating layers exhibit superior chipping resistance, show excellent cutting performance for a long-term use, and allows a more prolonged usable lifespan.
On the other hand, it is clear that the comparative coated tools E1 to E10 in which the hard coating layers are composed of the AlBO layer and the conventional Ti compound layers and the reference coated tools E11 to E15 in which the hard coating layers are composed of the Ti compound layers and the conventional α-type Al2O3 layers, come to the end of their usable lifespan in a relatively short time due to occurrence of chipping, promotion of abrasion, or the like.
As described above, even in high-speed intermittent cutting work of high harness steel accompanied by high heat generation, and intermittent and impacting high load acts repeatedly on the cutting edge as well as in cutting work of various kinds of steel or cast iron, or the like under normal conditions, the coated tools of this invention exhibit excellent chipping resistance without occurrence of chipping, and show excellent cutting performance for a prolonged period of time. Therefore, it is possible to satisfactorily cope with the demands for high performance of a cutting device, for labor saving and energy saving in cutting work, and cost reduction.
Example 6
The following powders, each having a mean particle size within a range of 2 to 4 μm, were prepared as raw materials: WC powder, TiC powder, ZrC powder, VC powder, TaC powder, NbC powder, Cr3C2 powder, TiN powder, TaN powder, and Co powder. These raw powders were compounded with each other in the compounding compositions shown in Table 1, mixed with each other in an acetone solution having wax added thereto for 24 hours using a ball mill, and were then dried under reduced pressure. Thereafter, the resultant powder mixture was press-formed into a green compact having a predetermined shape at a pressure of 98 MPa. The green compact was then sintered in a vacuum under the following conditions: a pressure of 5 Pa, a predetermined temperature within a range of 1370° C. to 1470° C., and a holding duration of 1 hour. After sintering, cutting edges were subjected to honing (R: 0.07 mm) to manufacture bodies 1A to 1E made of WC-based cemented carbide and having a throwaway tip shape defined in ISO CNMG120408MA.
Additionally, the following powders, each having a mean particle size within a range of 0.5 to 2 min, were prepared as raw materials for substrates: TiCN (TiC/TiN-50/50 in weight ratio) powder, Mo2C power, ZrC power, NbC powder, TaC powder, WC power, Co powder and Ni powder. These raw powders were compounded with each other in the compounding compositions shown in Table 2, were wet-mixed with each other for 24 hours using a ball mill, and were dried. Thereafter, the resulting powder mixture was press-formed into a green compact at a pressure of 98 MPa. The green compact was then sintered in a nitrogen atmosphere under the following conditions: a pressure of 1.3 kPa, a temperature of 1540° C., and a holding duration of 1 hour. After sintering, cutting edges were subjected to honing (R: 0.07 mm) to manufacture bodies 1a to 1e made of TiCN-based cermet and having a tip shape defined in ISO Standard CNMG120408MA. Subsequently, these bodies 1A to 1E and the bodies 1a to 1e were loaded into a normal chemical vapor deposition apparatus. (a) First, Ti compound layers with target layer thicknesses shown in Table 47 were vapor-deposited as lower layers of hard coating layers under the conditions shown in Table 3 (1-TiCN in Table 3 shows the formation conditions of TiCN layers with a longitudinal growth crystalline structure disclosed in Japanese Unexamined Patent Application Publication No. 6-8010, and the others show the formation conditions of a normal granular crystalline structure). (b) Subsequently, reformed α-type Al2O3 layers with target layer thicknesses shown in Table 50 were vapor-deposited as intermediate layers of the hard coating layers under the conditions shown in Table 4.
(c) Next, coated tools F1 to F15 of the present invention were manufactured, respectively, by vapor-depositing reformed AlTiZrO layers with target layer thicknesses similarly shown in Table 50 as upper layers of hard coating layers according to the vapor deposition conditions shown in Table 48.
For the purpose of comparison, comparative coated tools F1 to F10 (equivalent to the conventional coated tool 7) provided with hard coating layers composed of Ti compound layers and conventional AlTiZrO layers with target layer thicknesses shown in Table 51 were manufactured, respectively, by forming lower layers of hard coating layers under the conditions shown in Table 3 and forming upper layers under the conditions (equivalent to the vapor deposition conditions of the conventional AlTiZrO layers disclosed in PTL 7)) shown in Table 49.
The type of the bodies, the type of the lower layers, and the thickness of the lower layers in the comparative coated tools F1 to F10 are the same as those of the coated tools F1 to F10 of the present invention, respectively.
Moreover, for reference, reference coated tools F11 to F15 (equivalent to the conventional coated tool 1) provided with hard coating layers composed of Ti compound layers and conventional α-type Al2O3 layers with target layer thicknesses shown in Table 51 were manufactured, respectively, by forming lower layers of hard coating layers under the conditions shown in Table 3 and forming α-type Al2O3 layers under the conditions (equivalent to the vapor deposition conditions of the conventional α-type Al2O3 layers disclosed in PTL 1) shown in Table 4.
The type of the bodies, the type of the lower layers, and the thickness of the lower layers in the reference coated tools F11 to F15 are the same as those of the coated tools F11 to F15 of the present invention, respectively.
Post-processing composed of wet blasting processing with projection pressure 0.15 MPa and Al2O3 grains of 200 meshes was performed on the surfaces of some reformed AlTiZrO layers of the coated tools of the present invention, and the surfaces of some conventional AlTiZrO layers of the comparative coated tools. As the post-processing, polishing processing using an elastic grind stone may be adopted.
Tables 50 and 51 show the values of the surface roughness (Ra (μm)) of the reformed AlTiZrO layers (those marked by * in Table 50) of the coated tools of the present invention which were subjected to post-processing and the conventional AlTiZrO layers (those marked by * in Table 51) of the comparative coated tools. (For reference, the values of Ra regarding the coated tools of the present invention and the comparative coated tools which were not subjected to post-processing are also shown in Tables 50 and 51.)
Subsequently, as for the reformed α-type Al2O3 layers which constitute the intermediate layers of the hard coating layers of the coated tools F1 to F15 of the present invention, the reformed AlTiZrO layers which constitute the upper layers of the hard coating layers, the conventional AlTiZrO layers of the comparative coated tools F1 to F10, and the α-type Al2O3 layers of the reference coated tools F11 to F15, tilt angle frequency distribution graphs were plotted, respectively, using the field-emission-type scanning electron microscope.
The tilt angle frequency distribution graphs were plotted by setting the respective layers in the coated tools F1 to F15 of the present invention, the comparative coated tools F1 to F10, and the reference coated tools F11 to F15 within a lens barrel of the field-emission-type scanning electron microscope, with the surfaces of the layers as polished surfaces; individually irradiated crystal grains having a hexagonal crystal lattice present within the measurement range of each polished surface with an electron beam having an acceleration voltage of 15 kV with an irradiating current of 1 nA at an angle of incidence of 70 degrees with respect to each polished surface, thereby measuring the tilt angle of the normal line to the (0001) plane, which is a crystal plane of each crystal grain, to the normal line to each polished surface, at intervals of 0.1 μm/step for a region 30×50 μm, using the electronic backscattering diffraction image apparatus; and on the basis of these measurement results, dividing the measured tilt angles which are within a range of 0 to 45 degrees among the measured tilt angles at every pitch of 0.25 degrees, and summing the frequencies present within the respective divisions.
The “surface” in this invention includes not only a face parallel to the surface of a base, but also a face which inclines to the surface of the base, for example, the cutting face of a layer.
As a result, in the obtained tilt angle frequency distribution graphs of the reformed α-type Al2O3 layers and reformed AlTiZrO layers of the coated tools of the present invention, the conventional AlTiZrO layers of the comparative coated tools F1 to F10, and the conventional α-type Al2O3 layers of the reference coated tools F11 to F15, as shown in Tables 50 and 51, respectively, the distributions of the measured tilt angles of the (0001) plane in the reformed α-type Al2O3 layers and reformed AlTiZrO layers of the coated tools of the present invention show a tilt angle frequency distribution graph in which the highest peak appears in the tilt angle division within a range of 0 to 10 degrees, respectively. On the other hand, the distribution of the measured tilt angles of the (0001) plane in the conventional AlTiZrO layers of the comparative coated tools F1 to F10 shows a tilt angle frequency distribution graph in which the highest peak does not present in an unbiased manner within a range of 0 to 45 degrees.
Tables 50 and 51 show the ratios of the frequencies present in the tilt angle division within a range of 0 to 10 degrees, which are accounted for in the overall tilt angle frequency distribution graph.
Subsequently, as for the reformed AlTiZrO layers which constitute the upper layers of the coated tools F1 to F15 of the present invention, and the conventional AlTiZrO layers of the comparative coated tools F1 to F10, the crystal grain structure and the constituent atom sharing lattice point configuration were inspected using the field-emission-type scanning electron microscope and the electronic backscattering diffraction image apparatus. First, when the reformed AlTiZrO layers of the coated tools F1 to F15 of the present invention and the conventional AlTiZrO layers of the comparative coated tools F1 to F10 were observed using the field-emission-type scanning electron microscope, the flat-plate polygonal (including flat hexagonal) and elongated crystal grain structure of a large grain size were observed in the coated tools F1 to F15 of the present invention. On the other hand, a polygonal and elongated crystal grain structure was observed in the comparative coated tools F1 to F10. However, the grain size of each crystal grain was small as compared to that of the present invention, and pyramidal irregularities were formed in the layer surface.
Subsequently, as for the reformed AlTiZrO layers of the coated tools F1 to F15 of the present invention, and the conventional AlTiZrO layers of the comparative coated tools F1 to F10, the area ratios of crystal grains in which the Σ3 coincidence site lattice interfaces are present inside the crystal grains which constitute each layer were measured.
First, as for the reformed AlTiZrO layers of the coated tools F1 to F15 of the present invention, when the respective layers are within a lens barrel of the field-emission-type scanning electron microscope, with the surfaces of the layers as polished surfaces; crystal grains having a hexagonal crystal lattice present within the measurement range of each polished surface are individually irradiated with an electron beam having an acceleration voltage of 15 kV with an irradiating current of 1 nA at an angle of incidence of 70 degrees with respect to each polished surface, thereby measuring the angle at which the normal line to each of crystal lattice planes of the crystal grains crosses the normal line to each base surface, at intervals of 0.1 μm/step for a region 30×50 μm, using the electronic backscattering diffraction image apparatus; and from these measurement results, the crystal orientation relationship between adjacent crystal lattices is calculated, and the distribution of lattice points (constituent atom sharing lattice points) where respective constituent atoms which constitute a crystal lattice interface sharing one constituent atom between the crystal lattices is calculated; and a constituent atom sharing lattice point configuration in which N (here, N is any even number equal to or greater than 2 in a crystal structure of a corundum-type hexagonal close-packing crystal, but when the upper limit of N is 28 from the viewpoint of a distribution frequency, even numbers 4, 8, 14, 24, and 26 do not exist) lattice points which do not share any constituent atoms between the constituent atom sharing lattice points are present is expressed by ΣN+1, the area ratios of crystal grain in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains among all the crystal grains present within the measurement range of the reformed AlTiZrO layers were obtained, and the values of the area ratios were shown in Table 50 as Σ3 coincidence site lattice interface ratio (%).
Next, even as for the conventional AlTiZrO layers of the comparative coated tools F1 to F10, by the same method as the case of the coated tools of the present inventions, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains among all the crystal grains present within the measurement range of the conventional reformed AlTiZrO layers were obtained, and the values of the area ratios were shown in Table 51 as a Σ3 coincidence site lattice interface ratio (%).
As shown in Tables 49 and 50, in the reformed AlTiZrO layers of the coated tools F1 to F15 of the present invention, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are 60% or more. On the other hand, in the conventional AlTiZrO layers of the comparative coated tools F1 to F10, the area ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are 40% or less. It can be understood from this that the rate at which the Σ3 coincidence site lattice interfaces are present inside crystal grains is very small.
Subsequently, as for the reformed AlTiZrO layers of the coated tools F1 to F15 of the present invention, and the conventional AlTiZrO layers of the comparative coated tools F1 to F10, the area ratios of flat hexagonal crystal grains of a large grain size present within the plane perpendicular to the layer thickness direction were obtained using the field-emission-type scanning electron microscope. These values are shown in Tables 50 and 51.
Here, the “flat hexagonal crystal grains of a large grain size” means polygonal crystal grains in which the mean value of ten grains is 3 to 8 μm when the diameter of grains present within the plane perpendicular to the layer thickness direction observed by the field-emission-type scanning electron microscope is measured, and six vertex angles whose angle of vertex is 100 to 140° are provided.
Subsequently, although the thicknesses of the respective constituent layers in the hard coating layers of the coated tools F1 to F15 of the present invention, the comparative coated tools F1 to F10, and the reference coated tools F11 to F15 were measured using the scanning electron microscope (longitudinal-section measurement), substantially the same mean layer thicknesses (mean value of five-point measurements) as the target layer thicknesses were shown in all cases.
Next, all the coated tools F1 to F15 of the present invention, the comparative coated tools F1 to F10, and the reference coated tools F11 to F15 were screw-fixed to a tip portion of a bite made of tool steel by a fixing jig, and in this state, were subjected to a dry high-speed intermittent cutting test (normal cutting speed is 200 m/min) on bearing steel under the following conditions (referred to as cutting condition A):
Workpiece: a round bar of JIS-SUJ2 (HRC62) with four longitudinal grooves equally-spaced in the length direction,
Cutting speed: 250 m/min,
Depth of cut: 1.5 mm,
Feed rate: 0.15 mm/rev, and
Cutting time: 5 minutes,
a dry high-speed intermittent cutting test (normal cutting speed is 200 m/min) on alloy tool steel under the following conditions (referred to as cutting condition B):
Workpiece: a round bar of JIS-SKD11 (HRC58) with four longitudinal grooves equally-spaced in the length direction,
Cutting speed: 300 m/min,
Depth of cut: 1.5 mm,
Feed rate: 0.15 mm/rev, and
Cutting time: 5 minutes, and
a dry high-speed intermittent cutting test (normal cutting speed is 150 m/min) on carbon tool steel under the following conditions (referred to as cutting condition C):
Workpiece: a round bar of JIS-SK3 (HRC61) with four longitudinal grooves equally-spaced in the length direction,
Cutting speed: 250 m/min,
Depth of cut: 1.5 mm,
Feed rate: 0.15 mm/rev, and
Cutting time: 5 minutes, and
the flank wear widths of the cutting edges were measured in all the cutting tests. These test results are shown in Table 52.









TABLE 47








Tool
Lower layer of hard coating layer [Ti compound layer]













substrate
First layer
Second layer
Third layer
Fourth layer


Type
symbol
(μm)
(μm)
(μm)
(μm)
















Coated tool
F1
1a
TiN
1-TiCN
TiN
TiCNO


of the


(1)
 (17.5)
(1) 
(0.5)


present
F2
1A
TiCN
1-TiCN
TiCO
—


invention


(1)
 (8.5)
(0.5)




F3
1b
TiN
1-TiCN
TiC
TiCNO





(1)
(4)
(4) 
(1) 



F4
1B
TiC
1-TiCN
—
—





(1)
(9)





F5
1c
TiN
1-TiCN
TiCNO
—





(1)
 (4.5)
(0.5)




F6
1C
TiN
1-TiCN
TiC
TiCNO





 (0.5)
 (1.5)
(0.5)
(0.5)



F7
1d
TiN
1-TiCN
TiC
TiCNO





 (0.5)
(10) 
(2) 
(0.3)



F8
1D
TiN
TiCN
—
—





(1)
(19) 





F9
1e
TiC
1-TiCN
TiCO
—





 (0.5)
(9)
(0.5)




F10
1E
TiN
TiC
TiCN
TiCO





(1)
(1)
(7) 
(1) 



F11
1A
TiN
1-TiCN
TiCNO
TiCO





 (0.3)
(5)
(0.7)
(0.1)



F12
1a
TiN
1-TiCN
TiCO
—





(1)
(10) 
(0.5)




F13
1B
TiN
1-TiCN
TiN
TiCNO





 (0.5)
(12) 
(0.5)
(0.2)



F14
1b
TiN
1-TiCN
TiCNO
—





 (0.6)
(7)
(0.3)




F15
1C
TiN
1-TiCN
TiCN
TiCO





 (0.4)
(3)
(0.5)
(0.1)





(Numbers in the parentheses of lower layer column indicate target layer thickness)














TABLE 48







Ti-and-Zr-
Formation condition (Reaction


containing α-type
atmosphere pressure given in kPa and temperature given in ° C.)









Al2O3 layer

Reaction atmosphere










Formation symbol
Composition of reaction gas (Vol. %)
Pressure
Temperature














6A
First step
AlCl3: 1%, TiCl4: 0.01%, ZrCl4: 0.07%, HCl: 1%, CO2: 2%, H2S: 0.25%, H2: Balance
6
960



Second step
AlCl3: 6%, TiCl4: 0.6%, ZrCl4: 1.2%, HCl: 3%, CO2: 5%, H2S: 0.4%, H2: Balance
6
940


6B
First step
AlCl3: 2%, TiCl4: 0.007%, ZrCl4: 0.1%, HCl: 2%, CO2: 4%, H2S: 0.3%, H2: Balance
7
980



Second step
AlCl3: 7%, TiCl4: 0.45%, ZrCl4: 1.0%, HCl: 4%, CO2: 6%, H2S: 0.3%, H2: Balance
7
960


6C
First step
AlCl3: 3%, TiCl4: 0.005%, ZrCl4: 0.08%, HCl: 3%, CO2: 5%, H2S: 0.4%, H2: Balance
10
1000



Second step
AlCl3: 8%, TiCl4: 0.20%, ZrCl4: 0.8%, HCl: 4%, CO2: 6%, H2S: 0.25%, H2: Balance
10
970


6D
First step
AlCl3: 5%, TiCl4: 0.005%, ZrCl4: 0.06%, HCl: 5%, CO2: 5%, H2S: 0.4%, H2: Balance
8
1010



Second step
AlCl3: 10%, TiCl4: 0.06%, ZrCl4: 0.6%, HCl: 3%, CO2: 8%, H2S: 0.5%, H2: Balance
8
980


6E
First step
AlCl3: 2%, TiCl4: 0%, ZrCl4: 0.05%, HCl: 4%, CO2: 5%, H2S: 0.6%, H2: Balance
7
1000



Second step
AlCl3: 6%, TiCl4: 0.05%, ZrCl4: 0.9%, HCl: 5%, CO2: 4%, H2S: 0.25%, H2: Balance
7
960


6F
First step
AlCl3: 3%, TiCl4: 0%, ZrCl4: 0.1%, HCl: 4%, CO2: 6%, H2S: 0.75%, H2: Balance
6
990



Second step
AlCl3: 10%, TiCl4: 0.06%, ZrCl4: 0.6%, HCl: 4%, CO2: 8%, H2S: 0.3%, H2: Balance
6
940

















TABLE 49







Conventional Ti-



and-Zr-containing
Formation condition (Reaction atmosphere


α-type
pressure given in kPa and temperature given in ° C.)









Al2O3 layer

Reaction atmosphere










Formation symbol
Composition of reaction gas (Vol. %)
Pressure
Temperature













6A
AlCl3: 6%, TiCl4: 0.6%, ZrCl4: 1.2%, CH4: 0.1%, CO2: 5%, H2: Balance
6
940


6B
AlCl3: 7%, TiCl4: 0.45%, ZrCl4: 1.0%, CH4: 0.3%, CO2: 6%, H2: Balance
7
960


6C
AlCl3: 8%, TiCl4: 0.2%, ZrCl4: 0.8%, CH4: 0.5%, CO2: 6%, H2: Balance
10
970


6D
AlCl3: 10%, TiCl4: 0.06%, ZrCl4: 0.6%, CH4: 1%, CO2: 8%, H2: Balance
8
1010

















TABLE 50








Hard coating layer



Intermediate layer [α-type Al2O3 layer]

















Frequency ratio






Tilt angle division
of tilt angle



Tool

Target
where (0001) plane
division of 0



substrate
Formation symbol of
layer thickness
shows highest peak
to 10 degrees


Type
symbol
intermediate layer
(μm)
(Degree)
(%)
















Coated
F1
1a
1A
1
1.50-1.75
45


tool of
F2
1A
1B
1
0.00-0.25
78


the
F3
1b
1C
2
0.50-0.75
84


present
F4
1B
1A
2
0.25-0.50
75


invention
F5
1c
1B
3
4.50-4.75
91



F6
1C
1B
3
1.25-1.50
73



F7
1d
1C
4
3.00-3.25
71



F8
1D
1C
4
 9.75-10.00
63



F9
1e
1A
5
5.50-5.75
75



F10
1E
1B
5
2.50-2.75
84



F11
1A
1B
2
0.50-0.75
81



F12
1a
1C
2
0.75-1.00
95



F13
1B
1A
3
1.75-2.00
94



F14
1b
1B
2
2.50-2.75
69



F15
1C
1C
3
6.50-6.75
82












Hard coating layer



Upper layer [Ti-and-Zr-containing α-typeAl2O3 layer]














Content ratio
Content ratio






of Ti [Al/
of Zr [Zr/

Tilt angle division




(Al + Ti +
(Al + Ti +
Target
where (0001) plane



Formation symbol of
Zr)] (Atomic
Zr)] (Atomic
layer thickness
shows highest peak


Type
upper layer
ratio)
ratio)
(μm)
(Degree)
















Coated
F1
6A
0.01
0.01
2
1.50-1.75


tool of
F2
6A
0.01
0.01
4
0.00-0.25


the
F3
6B
0.0075
0.008
8
0.50-0.75


present
F4
6B
0.0075
0.008
4
0.25-0.50


invention
F5
6C
0.005
0.003
7
4.50-4.75



F6
6C
0.005
0.003
13
1.25-1.50



F7
6D
0.004
0.002
3
3.00-3.25



F8
6D
0.004
0.002
4
 9.75-10.00



F9
6A
0.01
0.01
9
5.50-5.75



F10
6A
0.01
0.01
15
2.50-2.75



F11
6E
0.003
0.004
6
0.50-0.75



F12
6E
0.003
0.004
9
0.75-1.00



F13
6F
0.002
0.002
3
1.75-2.00



F14
6F
0.002
0.002
8
2.50-2.75



F15
6E
0.003
0.004
5
6.50-6.75












Hard coating layer



Upper layer [Ti-and-Zr-containing α-typeAl2O3 layer]












Frequency ratio
Crystal grain ratio





of tilt angle
Having Σ3 coinci-
Surface ratio of
Surface



division of 0
dence site lattice in-
flat hexagonal
roughness



to 10 degrees
terface therein
crystal grain
Ra













Type
(%)
(Area %)
(Area %)
(μm)

















Coated
F1
60
60
5
 0.1*



tool of
F2
83
64
11
0.4



the
F3
88
80
25
0.5



present
F4
79
74
16
 0.2*



invention
F5
90
83
14
0.5




F6
80
75
22
 0.3*




F7
76
71
23
0.4




F8
69
66
14
0.4




F9
86
86
32
0.6




F10
91
95
34
0.7




F11
90
91
78
0.5




F12
96
94
83
0.5




F13
99
98
97
0.4




F14
72
83
35
0.4




F15
89
93
71
 0.2*

















TABLE 51








Hard coating layer



Upper layer [α-typeAl2O3 layer]

















Frequency ratio






Tilt angle division
of tilt angle



Tool

Target
where (0001) plane
division of 0



substrate
Formation symbol of
layer thickness
shows highest peak
to 10 degrees


Type
symbol
intermediate layer
(μm)
(Degree)
(%)
















Comparative
F1
1a
—
—
—
—


coated
F2
1A
—
—
—
—


tool
F3
1b
—
—
—
—



F4
1B
—
—
—
—



F5
1c
—
—
—
—



F6
1C
—
—
—
—



F7
1d
—
—
—
—



F8
1D
—
—
—
—



F9
1e
—
—
—
—



F10
1E
—
—
—
—


Reference
F11
1A
1B
8
0.75-1.00
65


coated
F12
1a
1A
11 
0.75-1.00
95


tool
F13
1B
1C
6
1.75-2.00
94



F14
1b
1B
10 
2.50-2.75
69



F15
1C
1C
8
6.70-6.75
83












Hard coating layer



Upper layer [Ti-andZr-containing α-type Al2O3 layer]














Content ratio
Content ratio






of Ti [Al/
of Zr [Zr/

Tilt angle division




(Al + Ti +
(Al + Ti +
Target
where (0001) plane



Formation symbol of
Zr)] (Atomic
Zr)] (Atomic
layer thickness
shows highest peak


Type
upper layer
ratio)
ratio)
(μm)
(Degree)
















Comparative
F1
6A
0.01
0.01
3
17.00-17.25


coated
F2
6A
0.01
0.01
5
15.50-15.75


tool
F3
6B
0.0075
0.008
10
18.00-18.25



F4
6B
0.0075
0.008
6
20.00-20.25



F5
6C
0.005
0.003
10
25.50-25.75



F6
6C
0.005
0.003
16
37.00-37.25



F7
6D
0.004
0.002
7
33.25-33.50



F8
6D
0.004
0.002
8
25.75-30.00



F9
6A
0.01
0.01
14
27.00-27.25



F10
6A
0.01
0.01
20
17.75-20.00


Reference
F11
—
—
—
—
—


coated
F12
—
—
—
—
—


tool
F13
—
—
—
—
—



F14
—
—
—
—
—



F15
—
—
—
—
—












Hard coating layer



Upper layer [Ti-andZr-containing α-type Al2O3 layer]












Frequency ratio
Crystal grain ratio





of tilt angle
Having Σ3 coinci-
Surface ratio of
Surface



division of 0
dence site lattice in-
flat hexagonal
roughness



to 10 degrees
terface therein
crystal grain
Ra













Type
(%)
(Area %)
(Area %)
(μm)

















Comparative
F1
13
9
0
 0.1*



coated
F2
9
6
0
0.4



tool
F3
7
0
0
0.5




F4
6
2
0
 0.2*




F5
8
4
0
0.5




F6
10
8
0
 0.3*




F7
5
10
0
0.4




F8
3
6
0
0.4




F9
11
12
0
0.6




F10
4
3
0
0.7



Reference
F11
—
—
—
0.5



coated
F12
—
—
—
0.5



tool
F13
—
—
—
0.4




F14
—
—
—
0.4




F15
—
—
—
 0.2*



















TABLE 52








Flank wear width (mm)

Cutting test result (min)
















Cutting
Cutting
Cutting


Cutting
Cutting
Cutting



condition
condition
condition


condition
condition
condition














Type
(A)
(B)
(C)
Type
(A)
(B)
(C)



















Coated tool
F1
0.31
0.32
0.33
Comparative
F1
1.0 *
1.2
 1.1 *


of the
F2
0.13
0.15
0.14
coated tool
F2
2.3 
2.4
2.5


present
F3
0.14
0.14
0.13

F3
1.2 *
 1.0 *
1.6


invention
F4
0.13
0.13
0.12

F4
2.7 
2.8
 1.5 *



F5
0.24
0.23
0.22

F5
2.4 
 1.5 *
2.2



F6
0.25
0.24
0.23

F6
0.9 *
 1.0 *
 0.8 *



F7
0.16
0.14
0.15

F7
1.5 *
2.9
3.1



F8
0.19
0.17
0.18

F8
2.9 
 1.5 *
 2.0 *



F9
0.22
0.22
0.23

F9
1.1 *
 1.2 *
 1.0 *



F10
0.24
0.23
0.25

F10
0.5 *
 0.6 *
 0.7 *



F11
0.13
0.12
0.11
Reference
F11
3.0 
3.1
2.9



F12
0.19
0.18
0.19
coated tool
F12
1.8 *
2.5
 2.0 *



F13
0.12
0.11
0.10

F13
2.9 
3.0
2.8



F14
0.17
0.18
0.18

F14
1.7 *
2.4
 1.9 *



F15
0.12
0.12
0.10

F15
2.0 *
3.0
2.8





Cutting test results of comparative coated tools and reference coated tools show cutting times (min) until the tools come to the end of their usable lifespan due to chipping or flank wear (usable lifespan determination criterion: Flank wear width of 0.5 mm).


In addition, the mark * in columns indicates a case where tools come to the end of their usable lifespan due to chipping.






From the results shown in Tables 50 to 52, as for the coated tools F1 to F15 of the present invention, the (0001) plane orientation rate of the reformed α-type Al2O3 layers which are the intermediate layers of the hard coating layers show a high ratio of 45% or more, and have excellent high-temperature strength. In addition, the reformed AlTiZrO layers which constitute the upper layers have the texture of the flat-plate polygonal (flat hexagonal) elongated crystal grains, and the (0001) plane orientation rate show a high ratio of 60% or more, the surface ratios of crystal grains in which at least one or more Σ3 coincidence site lattice interfaces are present inside the crystal grains are as high as 60% or more, or post-processing is performed on the reformed AlTiZrO layers and the surface smoothness thereof is further improved. Thereby, the reformed AlTiZrO layers have superior high-temperature strength, and strength within the crystal grains, and have superior surface flatness. As a result, in high-speed intermittent cutting work of high-hardness steel, such as quenching materials for alloy tool steel or bearing steel, accompanied by high heat generation, and intermittent impact loading acts on the cutting edge, the hard coating layers exhibit superior chipping resistance, show excellent cutting performance for a long-term use, and allows a more prolonged usable lifespan.
On the other hand, it is clear that the comparative coated tools F1 to F10 in which the hard coating layers are composed of the Ti compound layers and the conventional AlTiZrO layers and the reference coated tools F11 to F15 in which the hard coating layers are composed of the Ti compound layers and the conventional α-type Al2O3 layers, come to the end of their usable lifespan in a relatively short time due to the occurrence of chipping, promotion of abrasion, or the like.
As described above, even in high-speed intermittent cutting work of high-hardness steel accompanied by high heat generation, and intermittent and high impact loading acts repeatedly on the cutting edge as well as in cutting work of various kinds of steel or cast iron, or the like under normal conditions, the coated tools of this invention exhibit excellent chipping resistance without occurrence of chipping, and show excellent cutting performance for a prolonged period of time. Therefore, it is possible to satisfactorily cope with the demands for high performance of a cutting device, for labor saving and energy saving in cutting work, and cost reduction.
INDUSTRIAL APPLICABILITY
As described above, even in high-speed intermittent cutting work accompanied by high heat generation, and intermittent impact loading acts on the cutting edge as well as in cutting work of various kinds of steel or cast iron, or the like under normal conditions, the coated tools of this invention can suppress occurrence of chipping, and exhibit excellent cutting performance for a prolonged period of time. Therefore, it is possible to satisfactorily cope with the demands for high performance of a cutting device, for labor saving and energy saving in cutting work, and cost reduction.

## Claims

1. A surface-coated cutting tool comprising:
a tool substrate made of tungsten carbide-based cemented carbide or titanium carbonitride-based cermet; and
a hard coating layer, which is formed by vapor-depositing in order, a lower layer (a), an intermediate layer (b), and an upper layer (c) on the surface of the tool substrate,
wherein the lower layer (a) is a Ti compound layer composed of one or more of a titanium carbide layer, a titanium nitride layer, a titanium carbonitride layer, a titanium carboxide layer, and a titanium oxycarbonitride layer, all of which are formed by chemical vapor deposition, and having a total mean layer thickness of 3 to 20 μm,
wherein the intermediate layer (b) is an aluminum oxide layer having a mean layer thickness of 1 to 5 μm and having an α-type crystal structure in a chemically vapor-deposited state,
wherein the upper layer (c) is an aluminum oxide layer having a mean layer thickness of 2 to 15 μm and an α-type crystal structure in a chemically vapor-deposited state, the aluminum oxide layer containing one or more kinds of elements selected from a group consisting of Ti, Y, Zr, Cr, and B,
wherein, the intermediate layer (b) has properties indicated by a tilt-angle frequency distribution graph in which the highest peak exists in a tilt angle division ranging 0 to 10° and the total sum of frequencies existing in the range of 0 to 10° occupies a ratio of 45% or more of the total frequencies in the tilt-angle frequency distribution graph, the tilt-angle frequency distribution graph being obtained by utilizing a field-emission-type scanning electron microscope, irradiating electron beams to individual crystal grains with a hexagonal crystal lattice existing in a measurement range of a polished surface of the tool substrate, measuring a tilt angle formed by the normal line to the polished surface and the normal line to (0001) plane as a crystal plane of the crystal grains, sectioning the measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25°, and collecting the frequencies existing in each section,
wherein, the upper layer (c) is an aluminum oxide layer having a texture made of crystal grains with a flat-plate polygonal shape within a plane perpendicular to a layer thickness direction and have an elongated shape in the layer thickness direction within a plane parallel to the layer thickness direction and containing one or more kinds of elements selected from a group consisting of Ti, Y, Zr, Cr, and B, the texture being observed by a field-emission scanning electron microscope,
wherein, the upper layer (c) has properties indicated by a tilt-angle frequency distribution graph in which the highest peak exists in a tilt angle division ranging 0 to 10° and the sum of frequencies existing in the range of 0 to 10° occupies a ratio of 60% or more of the total frequencies in the tilt-angle frequency distribution graph, the tilt-angle frequency distribution graph being obtained by utilizing a field-emission-type scanning electron microscope, irradiating electron beams to individual crystal grains with a hexagonal crystal lattice existing in a measurement range of a polished surface of the tool substrate, measuring a tilt angle formed by the normal line to the polished surface and the normal line to (0001) plane as a crystal plane of the crystal grains, sectioning the measured tilt angles belonging to a range of 0 to 45° every pitch of 0.25°, and collecting the frequencies existing in each section, and
wherein when electron beams are radiated to the individual crystal grains existing within a measurable range of a polished surface of the tool substrate by utilizing a field-emission-type scanning electron microscope and an electron backscatter diffraction imaging device to measure angles formed by normal lines of crystal lattice faces with hexagonal crystal lattices and the normal line to the polished surface, a crystallographic orientation relationship between the adjacent crystal lattices is calculated from the measurement result, and a distribution of lattice points (constituent atom sharing lattice points) in each constituent atom of a crystal lattice interface shares one constituent atom between the crystal lattices is calculated, and when a constituent atom sharing lattice point type in which N lattice points not sharing the constituent atom exist between the constituent atom sharing lattice points (where N is an even number of 2 or more in view of a crystal structure of corundum type hexagonal close packed crystal but does not include even numbers of 4, 8, 14, 24, and 26 when the upper limit of N is set to 28 in view of distribution frequency) is expressed as ΣN+1, the insides of the above mentioned crystal grains, which constitutes the upper layer (c) and occupies 60% or more as an area ratio in the crystal grains of the upper layer, are divided by at least one crystal lattice interface with the constituent atom sharing lattice point type expressed by Σ3, and
the upper layer (c) contains one or more kinds of elements selected from a group consisting of Ti, Y, Zr, Cr, and B.

2. The surface-coated cutting tool according to claim 1,
wherein the upper layer (c) is an aluminum oxide layer containing Ti only.

3. The surface-coated cutting tool according to claim 2,
wherein, when the texture of the upper layer (c) is observed by the field-emission scanning electron microscope, crystal grains which have a flat hexagonal shape within the plane perpendicular to the layer thickness direction and have an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction account for 35% or more of the whole as an area ratio within the plane perpendicular to the layer thickness direction.

4. The surface-coated cutting tool according to claim 2,
wherein the upper layer (c) has a surface roughness (Ra) within a range of 0.05 to 0.3 μm.

5. The surface-coated cutting tool according to claim 1,
wherein the upper layer (c) is an aluminum oxide layer containing Y only.

6. The surface-coated cutting tool according to claim 5,
wherein, when the texture of the upper layer (c) is observed by the field-emission scanning electron microscope, crystal grains which have a flat hexagonal shape within the plane perpendicular to the layer thickness direction and have an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction account for 35% or more of the whole as an area ratio within the plane perpendicular to the layer thickness direction.

7. The surface-coated cutting tool according to claim 5,
wherein the upper layer (c) has a surface roughness (Ra) within a range of 0.05 to 0.3 μm.

8. The surface-coated cutting tool according to claim 1,
wherein the upper layer (c) is an aluminum oxide layer containing Zr only.

9. The surface-coated cutting tool according to claim 8,
wherein, when the texture of the upper layer (c) is observed by the field-emission scanning electron microscope, crystal grains which have a flat hexagonal shape within the plane perpendicular to the layer thickness direction and have an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction account for 35% or more of the whole as an area ratio within the plane perpendicular to the layer thickness direction.

10. The surface-coated cutting tool according to claim 8,
wherein the upper layer (c) has a surface roughness (Ra) within a range of 0.05 to 0.3 μm.

11. The surface-coated cutting tool according to claim 1,
wherein the upper layer (c) is an aluminum oxide layer containing Cr only.

12. The surface-coated cutting tool according to claim 11,
wherein, when the texture of the upper layer (c) is observed by the field-emission scanning electron microscope, crystal grains which have a flat hexagonal shape within the plane perpendicular to the layer thickness direction and have an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction account for 35% or more of the whole as an area ratio within the plane perpendicular to the layer thickness direction.

13. The surface-coated cutting tool according to claim 11,
wherein the upper layer (c) has a surface roughness (Ra) within a range of 0.05 to 0.3 μm.

14. The surface-coated cutting tool according to claim 1,
wherein the upper layer (c) is an aluminum oxide layer containing B only.

15. The surface-coated cutting tool according to claim 14,
wherein, when the texture of the upper layer (c) is observed by the field-emission scanning electron microscope, crystal grains which have a flat hexagonal shape within the plane perpendicular to the layer thickness direction and have an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction account for 35% or more of the whole as an area ratio within the plane perpendicular to the layer thickness direction.

16. The surface-coated cutting tool according to claim 14,
wherein the upper layer (c) has a surface roughness (Ra) within a range of 0.05 to 0.3 μm.

17. The surface-coated cutting tool according to claim 1,
wherein, when the texture of the upper layer (c) is observed by the field-emission scanning electron microscope, crystal grains which have a flat hexagonal shape within the plane perpendicular to the layer thickness direction and have an elongated shape in the layer thickness direction within the plane parallel to the layer thickness direction account for 35% or more of the whole as an area ratio within the plane perpendicular to the layer thickness direction.

18. The surface-coated cutting tool according to claim 1,
wherein the upper layer (c) has a surface roughness (Ra) within a range of 0.05 to 0.3 μm.

19. The surface-coated cutting tool according to claim 1, wherein the aluminum oxide of the intermediate layer (b) is Al2O3.

20. The surface-coated cutting tool according to claim 1, wherein the upper layer (c) is an outermost layer of the surface-coated tool.