# Patent

## Title
Oxide coated cutting insert

## Abstract

A cutting tool insert, particularly useful for machining of cast iron, comprising a body of a hard alloy of cemented carbide, cermet, ceramics, cubic boron nitride based material or high speed steel a hard and wear resistant coating; and at least (Al,Cr)2O3 layer applied to said body is disclosed. Methods of making a cutting tool insert are also disclosed. In addition, methods for machining of cast iron using the cutting tool inserts are disclosed.

## Background
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 12/399,409, filed Mar. 6, 2009, which claims priority to Swedish Application No. 0800540-7 filed Mar. 7, 2008. The entire contents of each of the above-identified applications are hereby incorporated by reference.


FIELD OF THE INVENTION
This invention relates to tools for machining by chip removal. More specifically, the invention relates to cutting tool inserts comprising a body of a hard alloy of cemented carbide, cermet, ceramics, cubic boron nitride based material or high speed steel and a hard and wear resistant oxide coating designed to be used in machining of cast iron, preferably at high cutting speeds. The coating contains one or more layers of which at least one layer is a textured physical vapor deposited (PVD) corundum phase alumina containing chromium (Al,Cr)2O3.
BACKGROUND OF THE INVENTION
The preparation of textured α-Al2O3 layers, produced with chemical vapour deposition (CVD), is disclosed in e.g., EP 603144, EP 1528125, EP 1477581, EP 659153, EP 1655387, EP 659903, EP 738336, EP 1655388, EP 1655392, US 2007/104945, and US 2004/202877.
EP 1479791 discloses a cutting tool containing cemented carbide or cermet, and a hard coating; wherein the hard coating includes an α-Al2O3 layer formed by CVD, with the highest peak, measuring the inclination of the α-Al2O3 basal planes relative to the normal of the surface within a range of 0-10 degrees as determined by electron back scattering diffraction (EBSD).
EP 744473 discloses textured γ-Al2O3 layers produced by PVD.
U.S. Pat. No. 5,310,607 discloses a hard coating including (Al,Cr)2O3 crystals and a chromium content higher than 5 at % wherein the (Al,Cr)2O3 is a single crystal. The coating is deposited at a temperature lower than 900° C. The hard coating is deposited by a CVD or PVD process.
When machining with an alumina coated cemented carbide tool, the cutting edge is worn according to different wear mechanisms, such as chemical wear, abrasive wear, adhesive wear and by edge chipping caused by cracks formed along the cutting edge. The domination of any of the wear mechanisms is determined by the application, and is dependent on properties of the machined material, applied cutting parameters and the properties of the tool material. In general, it is very difficult to improve all tool properties simultaneously, and commercial cemented carbide grades have usually been optimised with respect to one or few of the above mentioned wear types, and have consequently been optimised for specific application areas. This can, for instance, be achieved by controlling the texture of the alumina layer.
What is needed is a wear resistant and hard oxide coated cutting tool with enhanced performance for machining of cast iron. The invention is directed to these, as well as other, important needs.
SUMMARY OF THE INVENTION
Accordingly, the invention is directed to cutting tool inserts comprising a body of a hard alloy of cemented carbide, cermet, ceramics, cubic boron nitride based material or high speed steel and a textured oxide layer of corundum phase (Al,Cr)2O3 with excellent metal machining properties.
In one embodiment, the invention is directed to cutting tool inserts, comprising:

    
    
        a body comprising a hard alloy selected from the group consisting of cemented carbide, cermet, ceramics, cubic boron nitride based material, and high speed steel; and
        a hard and wear resistant coating applied on said body;
        wherein said coating comprises at least one (Al,Cr)2O3 layer;
        wherein said (Al,Cr)2O3 layer has a corundum phase crystalline structure and a composition (Al1-yCry)2O3 with about 0.4≦y≦about 0.6, with a thickness of about 0.5 μm to about 10 μm and a fiber texture, rotational symmetry, in the direction of the coated surface normal with an inclination angle, φ, of the basal planes relative to the coated surface normal is 40°<φ<70° or the inclination angle, φ, for the highest peak in the pole plot is 40°<φ<70° The (Al,Cr)2O3 layer is further characterized having a fiber texture with rotational symmetry in the direction of the coated surface normal with an inclination angle, φ, of the basal planes relative to the coated surface normal or the inclination angle, φ, for the highest peak in the pole plot with about 40°<φ<about 70° as determined by, e.g., electron back scattering diffraction (EBSD) or x-ray diffraction (XRD).
    
    


In other embodiments, the invention is directed to methods of making a cutting tool insert comprising:

    
    
        a body comprising a hard alloy selected from the group consisting of cemented carbide, cermet, ceramics, cubic boron nitride based material, and high speed steel; and
        a hard and wear resistant coating applied on said body;
        wherein said coating comprises at least one (Al,Cr)2O3 layer;
        wherein said (Al,Cr)2O3 layer has a corundum phase crystalline structure and a composition (Al1-yCry)2O3 with about 0.4≦y≦about 0.6, with a thickness of about 0.5 μm to about 10 μm and a fiber texture, rotational symmetry, in the direction of the coated surface normal with an inclination angle, φ, of the basal planes relative to the coated surface normal is 40°<φ<70° or the inclination angle, φ, for the highest peak in the pole plot is 40°<φ<70′;
    
    


said method comprising the step of:

    
    
        depositing on said body said (Al,Cr)2O3 layer by cathodic arc evaporation using Al+Cr-cathodes with a composition of about (40 at % Al+60 at % Cr) and about (60 at % Al+40 at % Cr), an evaporation current between about 50 A and about 200 A depending on the cathode size in an atmosphere comprising a gas selected from the group consisting of Ar, O2, and combinations thereof, at a total pressure of about 1.0 Pa to about 5.0 Pa, a bias of about −50 V to about −200 V, and a deposition temperature of about 400° C. and about 600° C.
    
    


In yet other embodiments, the invention is directed to methods for machining of cast iron, comprising the step of:
using a cutting tool insert described herein at a cutting speed of about 75-600 m/min, with an average feed, per tooth in the case of milling, of about 0.08-0.5 mm.



BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention. In the drawings:
FIG. 1A shows a schematic view of the hexagonal crystal structure with the a-axis (100), b-axis (010) and c-axis (001) marked.
FIG. 1B shows a schematic view of the fibre texture with (S) coated surface, (φi) inner and (φo) outer inclination angle of the c-axis (001) of the hexagonal structure (FIG. 1A) and the normal (n) to the coated surface.
FIG. 2 shows a schematic side view of the deposition chamber showing (1) vacuum chamber, (2a) cathode material A, (2b) cathode material B, (3) fixture, (4) power supply for biasing, (5a) cathodic arc power supply (5b) cathodic arc power supply, (6) inlet for process gas and (7) outlet for vacuum pump.
FIG. 3 shows a scanning electron micrograph in secondary mode of a fractured cross section of a coating according to the invention. (A) body, (B) bonding layer, (C) (Al,Cr)O layer, (D) (Al,Cr)N layer and (E) TiN layer.
FIG. 4 shows an x-ray diffraction pattern of a textured (Al,Cr)2O3 layer. The peaks of cemented carbide are marked with solid lines whereas the peaks originating from (Al,Cr)2O3 with dashed lines.
FIG. 5A shows (001) pole figure and FIG. 5B shows (001) pole plot graph of a (Al,Cr)2O3 layer according to the invention.



DETAILED DESCRIPTION OF THE INVENTION
The invention is directed, in one aspect, to cutting tool inserts, particularly useful for machining of cast iron, comprising a body of a hard alloy of cemented carbide, cermet, ceramics, cubic boron nitride based material or high speed steel a hard and wear resistant coating; and at least (Al,Cr)2O3 layer applied to said body is disclosed. The coating, with a total thickness of about 2-20 μm comprises one or several layers, at least one of which is an (Al,Cr)2O3 layer with a thickness of about 1-5 μm having a corundum phase crystalline structure and a composition (Al1-yCry)2O3 with 0.4≦y≦about 0.6. The (Al,Cr)2O3 layer is further characterized having a fiber texture with rotational symmetry in the direction of the coated surface normal with an inclination angle, φ, of the basal planes relative to the coated surface normal or the inclination angle, φ, for the highest peak in the pole plot with about 40°<φ<about 70° as determined by, e.g., electron back scattering diffraction (EBSD) or x-ray diffraction (XRD).
According to the present invention, there is provided a cutting tool for machining by chip removal, particularly useful in metal cutting of cast iron, comprising a body of a hard alloy of cemented carbide, cermet, ceramics, cubic boron nitride based material or high speed steel onto which a coating is deposited comprising:
preferably a first (innermost) bonding layer (FIG. 3, layer B) of, e.g., TiN or (Al,Cr)N preferably less than about 0.5 μm according to prior art;

    
    
        a layer of (Al1-yCry)2O3 with about 0.4≦y≦about 0.6, preferably y is about 0.5, with a thickness of about 0.5-10 μm, preferably about 1-5 μm, most preferably about 2-4 μm, with textured columnar grains. The (Al,Cr)2O3 layer has a corundum structure formed by PVD and a fiber texture with rotational symmetry in the direction of the coated surface normal with an inclination angle, φ, (FIG. 1B) of the basal planes relative to the coated surface normal (FIG. 5A) or the inclination angle, φ, for the highest peak in the pole plot (FIG. 5B) with about 40°<φ<about 70°, preferably about 50°<φ<about 60° as determined by, e.g., electron back scattering diffraction (EBSD) or x-ray diffraction (XRD).
    
    


The (Al,Cr)O layer has a compressive stress level of about −4.5<σ<about −0.5 GPa, preferably of about −3.0<σ<about −1.0 GPa.
The composition, y, of (Al1-yCry)2O3 is determined by, e.g., energy dispersive spectroscopy (EDS) or wavelength dispersive X-ray spectroscopy (WDS).
The body may further be coated with an inner single- and/or multilayer coating of, e.g. TiN, TiC, Ti(C,N), (Al,Cr)N or (Ti,Al)N, preferably (Ti,Al)N, (Al,Cr)N, and/or an outer single- and/or multilayer coating of, e.g. TiN, TiC, Ti(C,N), (Al,Cr)N or (Ti,Al)N, preferably (Ti,Al)N, (Al,Cr)N, to a total thickness, including the thickness of the (Al,Cr)2O3 layer, of about 1 to 20 μm, preferably about 1 to 10 μm and most preferably about 2 to 7 μm according to prior art.
The deposition method for the layer of the present invention is based on cathodic arc evaporation of an alloy or composite cathode under the following conditions; (Al,Cr)2O3 layers are grown using Al+Cr-cathodes with a composition between about (40 at % Al+60 at % Cr) and about (60 at % Al+40 at % Cr) and preferably between about (45 at % Al+55 at % Cr) and about (55 at % Al+45 at % Cr). The evaporation current is between about 50 A and about 200 A depending on the cathode size and preferably between about 60 A and about 90 A using cathodes of 63 mm in diameter. The layers are grown in an Ar+O2 atmosphere, preferably in a pure O2 atmosphere at a total pressure of about 1.0 Pa to 5.0 Pa, preferably about 1.0 Pa to about 3.5 Pa. The bias is about −50 V to about −200 V, preferably about −100 V to about −150V. The deposition temperature is between about 400° C. and about 600° C., preferably between about 400° C. and about 500° C.
The invention also relates to the use of cutting tool inserts according to the above for machining cast iron at cutting speeds of about 75-600 m/min, preferably about 150-500 m/min, with an average feed, per tooth in the case of milling, of about 0.08-0.5 mm, preferably about 0.1-0.4 mm depending on cutting speed and insert geometry.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are now described. All publications mentioned hereunder are incorporated herein by reference. Unless mentioned otherwise, the techniques employed or contemplated herein are standard methodologies well known to one of ordinary skill in the art. The materials, methods, and examples are illustrative only and not limiting.
The present invention is further defined in the following Examples, in which all parts and percentages are by weight and degrees are Celsius, unless otherwise stated. It should be understood that these examples, while indicating preferred embodiments of the invention, are given by way of illustration only. From the above discussion and these examples, one skilled in the art can ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.
EXAMPLES
Example 1
Grade A: Cemented carbide inserts with the composition 5 wt % Co and balance WC, were used.
Before deposition, the inserts were cleaned in ultrasonic baths of an alkali solution and alcohol. The system was evacuated to a pressure of less than 2.0×10−3 Pa, after which the body were sputter cleaned with Ar ions. At first, a bonding layer of TiN with a thickness of 0.2 μm followed by a textured (Al,Cr)2O3 layer of thickness 2.5 μm, were grown by cathodic arc evaporation of an alloyed (50 at % Al+50 at % Cr) cathode, 63 mm in diameter (position (2a) and (2b) in FIG. 2) in 99.995% pure O2 atmosphere at a total pressure of 2 Pa and a deposition temperature of about 450° C. to a total coating thickness of 3 μm. The evaporation current was 75 A and the bias was held at −75 V during depositions. Finally, a top colour coating consisting of 0.3 μm (Al,Cr)N and 0.2 μm TiN was applied.
A fractured cross-section SEM micrograph of the coating is shown in FIG. 3 with (A) body, (B) bonding layer, (C) (Al,Cr)O layer, (D) (Al,Cr)N layer and (E) TiN layer.
The XRD patterns of the as-deposited layers were obtained using CuKα-radiation and a θ-2θ configuration. FIG. 4 shows the XRD pattern of a coating according to the invention with a textured corundum phase alumina (Al,Cr)2O3 layer. The peaks originating from the (Al,Cr)2O3 layer are marked with dashed lines whereas the peaks of cemented carbide are marked with solid lines.
The EBSD pole figure (FIG. 5A) and pole plot graph (FIG. 5B) of the as-deposited corundum phase (Al,Cr)2O3 layers in the c-axis (001) direction (FIG. 1A), respectively, showing a fiber texture (rotational symmetry) in the direction of the coated surface normal (FIG. 1B) with an inclination angle, φ (FIG. 1B), of the basal planes relative to the coated surface normal between 40 and 70°. The highest peak in the pole plot is around 58°. The EBSD data were obtained using a LEO Ultra 55 scanning electron microscope operated at 20 kV equipped with a HKL Nordlys II EBSD detector and evaluated with the Channel 5 software.
The residual stress, σ, of the (Al,Cr)2O3 coating was evaluated by XRD measurements using the sin2 ψ method. The measurements were performed using CrKα-radiation on the (Al,Cr)2O3 (116)-reflection. The residual stress value was 2.5±0.3 GPa as evaluated using a Poisson's ratio of ν=0.26 and Young's modulus of E=420 GPa.
The composition, y=0.50, of (Al1-yCry)2O3 was estimated by energy dispersive spectroscopy (EDS) analysis using a LEO Ultra 55 scanning electron microscope with a Thermo Noran EDS detector operating at 10 kV. The data were evaluated using a Noran System Six (NSS ver 2) software.
Example 2
Grade B: A layer of 3.0 μm Ti0.34Al0.66N was deposited by PVD on cemented carbide inserts with the composition 5 wt % Co and balance WC, according to prior art.
Example 3
Grade C: A coating consisting of 3.0 μm Ti(C,N)+3 μm alfa-Al2O3 was deposited by CVD on cemented carbide inserts with the composition 5 wt % Co and balance WC, according to prior art.
Example 4
Grades A, B and C were tested in machining in cast iron.
















Operation
Turning







Material
SS0732



Insert type
CNMG120408-MR7



Cutting speed
325 m/min



Feed
0.3 mm



Depth of cut
2.5 mm







Results
Tool life (min)







Grade A (grade according to invention)
12.1



Grade B
failed



Grade C
10.4










The test was stopped at the same maximum flank wear. The wear resistance was much improved with the grade according to the invention.
Example 5
Grades A, B and C were tested in machining in cast iron.
















Operation
Interrupted turning







Material
SS0732



Insert type
CNMG120408-MR7



Cutting speed
300 m/min



Feed
0.3 mm



Depth of cut
2.5 mm







Results
Tool life (cycles)







Grade A (grade according to invention)
15



Grade B
 2



Grade C
14










The test was stopped at the same maximum flank wear. The wear resistance was much improved with the grade according to the invention.
When ranges are used herein for physical properties, such as molecular weight, or chemical properties, such as chemical formulae, all combinations and subcombinations of ranges specific embodiments therein are intended to be included.
The disclosures of each patent, patent application, and publication cited or described in this document are hereby incorporated herein by reference, in their entirety.
Those skilled in the art will appreciate that numerous changes and modifications can be made to the preferred embodiments of the invention and that such changes and modifications can be made without departing from the spirit of the invention. It is, therefore, intended that the appended claims cover all such equivalent variations as fall within the true spirit and scope of the invention.

## Claims

1. A method of making a cutting tool insert comprising:
a body comprising a hard alloy selected from the group consisting of cemented carbide, cermet, ceramics, cubic boron nitride based material, and high speed steel; and
a hard and wear resistant coating applied on said body;
wherein said coating comprises at least one (Al,Cr)2O3 layer;
wherein said (Al,Cr)2O3 layer has a corundum phase crystalline structure and a composition (Al1-yCry)2O3 with about 0.4≦y≦about 0.6, with a thickness of about 0.5 μm to about 10 μm and a fiber texture, rotational symmetry, in the direction of the coated surface normal with an inclination angle, φ, of the basal planes relative to the coated surface normal is 40°<φ<70° or the inclination angle, φ, for the highest peak in the pole plot is 40°<φ<70′;
said method comprising the step of:
depositing on said body said (Al,Cr)2O3 layer by cathodic arc evaporation using Al+Cr-cathodes with a composition of about (40 at % Al+60 at % Cr) and about (60 at % Al+40 at % Cr), an evaporation current between about 50 A and about 200 A depending on the cathode size in an atmosphere comprising a gas selected from the group consisting of Ar, O2, and combinations thereof, at a total pressure of about 1.0 Pa to about 5.0 Pa, a bias of about −50 V to about −200 V, and a deposition temperature of about 400° C. and about 600° C.

2. The method according to claim 1,
depositing said (Al,Cr)2O3 layer by cathodic arc evaporation using Al+Cr-cathodes with a composition of about (45 at % Al+55 at % Cr) and about (55 at % Al+45 at % Cr), an evaporation current between about 60 A and about 90 A depending on the cathode size in an atmosphere that is O2 at a total pressure of about 1.0 Pa to about 3.5 Pa, a bias of about −100 V to about −150V and a deposition temperature of about 400° C. and about 500° C.

3. The method for machining of cast iron, comprising:
machining with a cutting tool insert according to claim 1 at a cutting speed of about 75-600 m/min, with an average feed, per tooth in the case of milling, of about 0.08-0.5 mm.

4. The method for machining of cast iron, comprising:
machining with a cutting tool insert according to claim 1 at a cutting speed of about 150-500 m/min, with an average feed, per tooth in the case of milling, of about 0.1-0.4 mm.