Diamond-coated tool member, substrate thereof and method for producing same

Abstract: A tool member includes a tungsten-carbide-based cemented-carbide substrate and a diamond coating deposited on the substrate. The substrate has two diffraction peaks Kα₁ and Kα₂ indexed by index of plane (211) for tungsten carbide in X-ray diffraction. The peaks satisfy the relationship of l₁/l₂ ≦ 35, where l₁ and l₂ are heights of the peaks Kα₁ and Kα₂ measured from a base of a trough between the two diffraction peaks. For manufacturing the tool member, a green compact is first sintered to provide a tungsten-carbide-based cemented-carbide substrate. Subsequently the substrate is ground and subsequently heat-­ treated at a temperature between 1000 °C and 1600 °C in a vacuum or in a non-oxdizing atmosphere. Thereafter, a diamond coating is formed on the substrate by vapor-deposition method.

Description: BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to a tool member having a tungsten carbide (WC) based cemented carbide substrate and a diamond coating deposited thereon, in which the bonding strength between the diamond coating and the substrate is extremely high. Prior Art A conventional diamond-coated tool member of tungsten carbide based cemented carbide, which is used for tools such as a cutting insert, an end mill, a drill, and the like, is produced by grinding an outermost portion of a tungsten carbide based cemented carbide substrate, subsequently subjecting the substrate to chemical etching with dilute nitric acid, sulfuric acid, and the like to remove cobalt (Co) existing in the outermost portion of the substrate, and forming a diamond coating having an average layer thickness of 0.5 µm - 20 µm on the substrate by a known vapor deposition method. The tungsten carbide based cemented carbide substrate has generally the following composition in terms of % by weight, excluding unavoidable impurities: cobalt as a binder phase forming component: 1% to 25% optionally, as a dispersed phase forming component, at least one material selected from the group consisting of carbides of metals selected from Groups IV A , V A , and VI A of the Periodic Table and their solid solutions: 0.5% to 30%; and tungsten carbide as the dispersed phase forming component comprising the remainder of the composition. Patent Abstracts of Japan, Vol, 12, No. 263 (C-514) (3110), JP-A-63-45 372, discloses a tool member having a tungsten carbide base sintered hard alloy base body comprising 1 to 4 weight % Co powder, balance being tungsten carbide. This member comprises a diamond coating synthesized in a vapor phase under a low pressure after sintering the moulding. EP-A-0 254 560 discloses a gaseous phase synthesized diamond and a method for synthesizing the same. For the manufacture of diamond having a high completeness, it is important to control the surface temperature of a substrate to be coated. Thus, the diamond can be coated on the surface of the substrate in good reproducibility. In the conventional diamond-coated tool member of tungsten carbide based cemented carbide mentioned above, however, the bonding strength between the diamond coating and the substrate is low. Therefore, when the tools formed of the tool members are used for interrupted cutting of Al-Si alloy or the like or for heavy-duty cutting such as high feed cutting and deep cutting, the diamond coating is susceptible to separation from the substrate, and the tool life is relatively short. M. Yagi describes in Science and Technology of New Diamond, edited by S. Santo, et al, KTK Scientific Publishers/Terra Scientific Publishing Co., 1990, on pages 399-404 the cutting performance of diamond deposited tool on Al-18 mass%Si alloy. The effects of surface conditionings of the substrate (WC-4%Co) on adhesion strength were investigated. It was found that the cutting performance of the diamond-deposited tools in the as-sintered state was the best when compared with the etched state and the ground state. The reason was considered to be that the Co content of the surface was lowered and as a result precipitation of graphite between the diamond film and the substrate was decreased. SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a diamond-coated tool member of tungsten carbide based cemented carbide substrate, in which the bonding strength between the diamond coating and the substrate is extremely high. Another object of the invention is to provide a tungsten carbide based cemented carbide substrate suitably used to produce the aforesaid diamond-coated tool member. A further object of the invention is to provide a process for producing the aforesaid tool member. According to a first aspect of the present invention, there is provided a tool member having a tungsten carbide based cemented carbide substrate and a diamond coating deposited on the substrate, said tungsten carbide based cemented carbide containing, apart from unavoidable impurities, 1 to 25 % by weight of cobalt as a binder phase forming component and balance tungsten carbide as a dispersed phase forming component, the substrate having two diffraction peaks Kα 1 and Kα 2 indexed by index of plane (211) for tungsten carbide in X-ray diffraction, wherein the two diffraction peaks Kα 1 and Kα 2 form a trough between them and satisfy the relationship of I 1 /I 2 ≦ 35, where I 1 and I 2 are heights of the two peaks Kα 1 and Kα 2 measured from a base of said trough, whereby bonding strength between the substrate and the diamond coating is increased. According to a second aspect of the present invention, there is provided a tungsten carbide based cemented carbide substrate for diamond-coated tool member, the substrate including an outermost portion having a ground and then heat-treated surface which is cobalt-etched and having two diffraction peaks K α1 and K α2 indexed by index of plane (211) for tungsten carbide in X-ray diffraction, wherein the two diffraction peaks Kα 1 and Kα 2 form a trough between them and satisfy the relationship of 1 1 /1 2 ≦ 35, where I 1 and I 2 are heights of the two peaks Kα 1 and Kα 2 measured from a base of said trough, wherein said tungsten carbide based cemented carbide contains, apart from unavoidable impurities, 1-25% by weight of cobalt as a binder phase forming component and balance tungsten carbide as as dispersed phase forming component, wherein said substrate is free of an eta-phase. According to a third aspect of the present invention, there is provided a method for producing a diamond-coated tool member of tungsten carbide based cemented carbide, wherein said tungsten carbide based cemented carbide contains, apart from unavoidable impurities, 1-25% by weight of cobalt as a binder phase forming component and balance tungsten carbide as as dispersed phase forming component, comprising the steps of: (i) sintering a green compact to produce a tungsten carbide based cemented carbide substrate; (ii) subsequently forming a diamond coating on the substrate by vapour deposition method; characterized by the steps of: grinding the tungsten carbide based cemented carbide substrate; and subsequently heat-treating the ground carbide substrate at a temperature between 1000°C and 1600°C in a vacuum or in a non-oxidizing atmosphere between said grinding step and said diamond coating step; and subjecting the substrate to chemical etching to remove cobalt existing in an outermost portion of the substrate between the heat-treating step and the diamond coating step, wherein said tungsten carbide based cemented carbide contains, apart from unavoidable impurities, 1-25% by weight of cobalt as a binder phase forming component and balance tungsten carbide as a dispersed phase forming component and wherein said substrate is free of an eta-phase. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is an illustration showing X-ray diffraction peaks indexed by index of plane (211) for tungsten carbide in the case of subjecting a substrate of a tool member in accordance with the present invention to X-ray diffraction. DETAILED DESCRIPTION OF THE INVENTION The inventors have observed that conventional diamond-coated tungsten carbide based cemented carbide has the low bonding strength between the diamond coating and the substrate, because the debris of tungsten carbide produced during the grinding operation adheres to the surface of the substrate, so that this debris tends to cause separation of the diamond coating from the substrate. According to the further investigation the inventors have found that if heat-treatment operation is carried out after tungsten carbide based cemented carbide is ground, the debris of tungsten carbide produced during the grinding operation dissolves into the binder phase and precipitates on the undissolved tungsten carbide. As a result, tungsten carbide of the surface causes the grain growth and the surface becomes rough, and the internal stress of the surface produced by the grinding operation is reduced. Thus, when the diamond coating is formed on the heat-treated substrate to provide a diamond-coated tool member, the bonding strength between the diamond coating and the substrate is extremely increased. According to a subsequent analysis, it has also been found that the substrate of the above diamond-coated tool member has two diffraction peaks Kα 1 and Kα 2 indexed by index of plane (211) for tungsten carbide in X-ray diffraction, and that the two diffraction peaks Kα 1 and Kα 2 satisfies the relationship of I 1 /I 2 ≦ 35, where I 1 and I 2 are heights of the peaks Kα 1 and Kα 2 measured from the base of the trough between the two diffraction peaks Kα 1 and Kα 2 . In contrast, in the conventional diamond-coated tool member, the substrate has one or two diffraction peaks indexed by index of plane (211) for tungsten carbide in X-ray diffraction, and even in the case of the conventional one having the two diffraction peaks Kα 1 and Kα 2 , the ratio of I 1 /I 2 exceeds 35. A manufacturing method of the aforesaid diamond-coated tool member of the present invention involves blending starting material powders into a prescribed composition to provide a green compact, sintering the green compact at a temperature of from 1350 °C to 1500 °C to produce a tungsten carbide based cemented carbide substrate, subsequently forming a diamond coating on the substrate by a vapor deposition method, and subsequently grinding the tungsten carbide based cemented carbide substrate, subsequently heat-treating the ground substrate at a temperature between 1000°C and 1600°C for a prescribed period of time in a vacuum or in a non-oxidizing atmosphere, between the grinding and the diamond coating steps, subjecting the substrate to chemical etching to remove cobalt existing in the outermost portion of the substrate between the heat-treating and the diamond coating steps, and subsequently subjecting the surface of the substrate to ultrasonic waves to activate the surface by hard particles such as diamond powder. With the above heat-treatment operation, the debris of tungsten carbide produced during the grinding operation dissolves into the binder phase and precipitates on the undissolved tungsten carbide. As a result, tungsten carbide of the surface causes the grain growth and the surface becomes rough, and the internal stress of the surface produced by the grinding operation is reduced. Thus, the substrate of the diamond-coated tool member becomes to have two diffraction peaks Kα 1 and Kα 2 which satisfy the relationship of I 1 /I 2 ≦ 35, where I 1 and I 2 are heights of the peaks Kα 1 and Kα 2 measured from the base of the trough between the two diffraction peaks Kα 1 and Kα 2 , and the bonding strength between the diamond coating and the substrate is extremely increased. In the foregoing, if the heat-treating temperature is set to be below 1000 °C, the substrate does not have two diffraction peaks separated from each other, so that the desired bonding strength between the diamond coating and the substrate is not obtained. On the other hand, if the temperature exceeds 1600 °C, crystal grains of the substrate become bulky, so that the mechanical strength of the substrate is decreased. What is worse, the surface of the substrate becomes extraordinarily rough, so that the substrate cannot be used for manufacturing a tool member. In addition, the period of time of the heat-treatment is 30 minutes to 90 minutes, in the case where the tool member is a cutting insert. Furthermore, thc tungsten carbide based cemented carbide of thc substrate contains, excluding unavoidable impurities, 1 % by weight to 25 % by weight of cobalt as a binder phase forming component and balance tungsten carbide as a dispersed phase forming component. If the cobalt content is less than 1 % by weight, the desired toughness and mechanical strength is not obtained. On the other hand, if the substrate contains more than 25 % by weight of cobalt, the wear resistance of the substrate is extremely decreased. Particularly, in the case of a tool member for cutting, the cobalt content in the substrate is preferably not more than 10 % by weight. The aforesaid substrate may further contain, as a dispersed phase forming component, 0.5 % by weight to 30 % by weight of at least one material selected from the group consisting of carbides, nitrides and carbo-nitrides of metals selected from Groups IV A , V A , and VI A of the Periodic Table, and their solid solutions. The carbides, the nitrides, and so on are added for the purpose of increasing wear resistance in the substrate, and their total content should preferably be 0.5 % by weight to 30 % by weight. If the content of the carbides, the nitrides, and so on is less than 0.5 % by weight, sufficient wear resistance cannot be obtained. On the other hand, if the substrate contains more than 30 % by weight of the carbides, the nitrides, and so on, the toughness of the substrate becomes extremely decreased. The diamond coating according to the present invention has an average layer thickness of 0.5 µm to 20 µm. If the diamond layer thickness is less than 0.5 µm, the diamond coating fails to have a desired wear resistance. If the thickness is more than 20 µm, the diamond coating is susceptible to chipping and subsequent separation from the substrate. As described above, in the diamond-coated tool member of tungsten carbide based cemented carbide in accordance with the present invention, bonding strength between a tungsten carbide based cemented carbide substrate and a diamond coating of the tool member is extremely high. This will make the tool life relatively long. Therefore, the diamond-coated tool member has superior cutting performance for extended periods where the tool member is used in cutting tools mentioned above, various dies, printer-heads and wear-resistant tools such as a guide roller for a hot rolling mill, a seaming roll for a tube mill, and the like. The diamond-coated tool member of tungsten carbide based cemented carbide in accordance with the present invention and the process for producing the same will be described in detail by way of an example. Example There were prepared starting material powders of tungsten carbide powders, metal-carbides powders, and Co powder, each powder having a predetermined average particle size between 0.5 µm and 10 µm. These starting material powders were blended with each other into the compositions given in Table 1. After wet-mixing the starting material powders together for 72 hours in a ball mill and drying, thc powders were pressed under a pressure of 1.5 ton/cm 2 into green compacts. The green compacts thus obtained were sintered under the following conditions: ambient pressure: 1.3 Pa (1 x 10 -2 torr); heating temperature: predetermined temperature between 1350 °C and 1500 °C; retaining time: 90 minutes, into the tungsten carbide based cemented carbide substrates having substantially the same compositions as the blended compositions. The surface portion of each tungsten carbide based cemented carbide substrate was ground by a grinding machine into a cutting-insert substrate shaped in conformity with SPGN 120308 of the ISO standards. Subsequently, the cutting insert substrate was heat-treated under the following conditions: ambient pressure: 1.3 Pa (1 × 10 -2 torr) heating temperature: predetermined temperature between 1000 °C and 1600 °C retaining time: 30 minutes to 90 minutes. The cobalt existing in the outermost portions of the heat-treated substrates was removed by etching with 5% solution of nitric acid for 5 minutes. The surfaces of the cutting insert substrates were then, subjected to X-ray diffraction analysis under the following conditions: lamp: Cu filter: Ni lamp voltage: 40 kV lamp current: 40 mA time constant: 5 recorder rate: 40 mm/2 (degree) recorder full scale: 10000 cps. The cutting insert substrates having the Co-removed surface portions were dipped and activated in a dispersion solution of diamond powders, each powder having an average particle size of 15 µm, in alcohol under the following conditions: ultrasonic frequency of 2000 Hz; power output of 240 W; retaining time: 15 minutes. The substrate was then inserted in a tube reactor of quartz having a 120 mm diameter with a filament made of W (metal) and was subjected to vapor-deposition reaction for the predetermined time between 3 hours and 10 hours under the following conditions: ambient pressure: 35 torr, temperature of the substrate: 850 °C, ambient gas: CH 4 /H 2 =0.01, to form a diamond coating having an average thickness shown in Table 1 on the surface of the cutting-insert substrate. Thus, the diamond-coated cutting inserts of tungsten carbide based cemented carbide in accordance with the present invention, the cutting inserts of this invention 1 - 23 were obtained. In the cutting inserts of this invention 1, 2, 5, 9, and 10, the chemical etching operation for removing the cobalt existing in the outermost portion of the substrate was omitted. In the cutting inserts of this invention 9, 10, 15, 16, 20, 21, and 23, the activating operation by using ultrasonic wave was omitted. The cutting inserts of this invention 1 - 23 thus obtained were again subjected to the X-ray diffraction analysis under the same conditions described above. Namely, the substrate before diamond coating and the cutting insert after diamond coating were both subjected to the X-ray diffraction analysis. In the X-ray diffraction analysis, the substrate and the cutting insert showed two diffraction peaks Kα 1 , Kα 2 indexed by index of plane (211) for tungsten carbide as illustrated in Fig. 1. According to the two peaks Kα 1 , Kα 2 . the ratio of I 1 /I 2 was calculated as to the cutting inserts of this invention and are shown in Table 1. For comparison purposes, comparative cutting inserts 1 - 23 having the same compositions as the cutting inserts of this invention 1 - 23, respectively, were manufactured under almost the same processes and conditions as in the cutting inserts of this invention, but the heat-treating operation (between 1000 °C and 1600 °C) after grinding the tungsten carbide based cemented carbide substrate was omitted. Both of the comparative cutting insert substrate before diamond coating and the cutting insert after diamond coating were also subjected to the X-ray diffraction analysis under the same conditions described above. Next, the cutting inserts of this invention 1 - 23 and the comparative cutting inserts 1 - 23 were subjected to a dry-type milling test. The conditions were as follows: Workpiece: Al - 12% Si alloy steel block Cutting speed: 550 m/minute Depth of cut: 1.5 mm Feed rate: 0.15 mm/tooth Cutting time: 30 minutes. The cutting inserts of this invention 1 - 23 and the comparative cutting inserts 1 - 23 were subjected to a dry-type turning test. The conditions were as follows: Workpiece: Al - 12% Si alloy steel bar Cutting speed: 1000 m/minute Depth of cut: 1 mm Feed rate: 0.2 mm/revolution Cutting time: 30 minutes. The cutting inserts having corners were examined for separation. The number of corners in which the diamond coatings had separated from the cutting-insert substrates is given in Table 1 out of a total of 10. According to the results given in Table 1, all the cutting inserts of this invention had the two diffraction peaks Kα 1 , Kα 2 , indexed by index of plane (211 for tungsten carbide in X-ray diffraction, which satisfy the relationship of I 1 /I 2 ≦ 35. The cutting inserts of this invention showed superior cutting performance such as little separation of the diamond coating separated from the cutting-insert substrate and having wear resistance under the drastic cutting-conditions of continuous high-speed cutting or high-feed cutting, because bonding strength between the diamond coating and the tungsten carbide based cemented carbide substrate was great high. On the contrary, in the X-ray diffraction analysis of the comparative cutting inserts, the comparative cutting inserts had one or two diffraction peaks Kα 1 , Kα 2 and the ratio I 1 /I 2 was not less than 35. The diamond coatings were separated from the surface portions of the tungsten carbide based cemented carbide substrates in more than half of the comparative cutting inserts, and extreme wear was observed because bonding strength between the diamond coating and the cutting-insert substrate was not sufficient.

Claims: A tool member having a tungsten carbide based cemented carbide substrate and a diamond coating deposited on the substrate, characterized in that: said tungsten carbide based cemented carbide contains, apart from unavoidable impurities, 1% by weight to 25% by weight of cobalt as a binder phase forming component and balance tungsten carbide as a dispersed phase forming component; the substrate includes an outermost portion having a ground and then heat-treated surface which is cobalt-etched; the substrate has two diffraction peaks Kα 1 and Kα 2 indexed by index of plane (211) for tungsten carbide in X-ray diffraction; and the two diffraction peaks Kα 1 and Kα 2 form a trough between them and satisfy the relationship of I i /I 2 ≤ 35, where l 1 and l 2 are heights of the peaks Kα 1 and Kα 2 measured from a base of said trough, whereby a bonding strength between the substrate and the diamond coating is increased, wherein said substrate is free of an eta-phase. A tool member as recited in claim 1, wherein the diamond coating has an average layer thickness of 0.5µm to 20 µm. A tool member as recited in claim 1 or 2, wherein the tungsten carbide based cemented carbide comprises 0.5% by weight to 30% by weight of at least one material selected from the group consisting of carbides, nitrides and carbo-nitrides of metals selected from Groups IVA, VA and VIA of the Periodic Table, and solid solutions of said carbides, nitrides and carbo-nitrides, as a dispersed phase forming component, and balance tungsten carbide as the dispersed phase forming component. A tungsten carbide based cemented carbide substrate for a diamond coated tool member, characterized in that: the substrate includes an outermost portion having a ground and then heat-treated surface which is cobalt-etched ; the substrate has two diffraction peaks Kα 1 and Kα 2 indexed by index of plane (211) for tungsten carbide in X-ray diffraction; and the two diffraction peaks Kα 1 and Kα 2 form a trough between them and satisfy the relationship of l 1 /l 2 ≤ 35, where l 1 and l 2 are heights of the peaks Kα 1 and Kα 2 measured from a base of said trough, wherein said tungsten carbide based cemented carbide contains, apart from unavoidable impurities, 1-25% by weight of cobalt as a binder phase forming component and balance tungsten carbide as a dispersed phase forming component, wherein said substrate is free of an eta-phase. A method for producing a tool member having a tungsten carbide based cemented carbide substrate and a diamond coating deposited on the substrate, comprising the steps of: (i) sintering a green compact to produce a tungsten carbide based cemented carbide substrate; and (ii) subsequently forming a diamond coating on the substrate by vapour deposition method; characterized by the steps of grinding the tungsten carbide based cemented carbide substrate and subsequently heat-treating the ground substrate at a temperature between 1000°C and 1600°C in a vacuum or in a non-oxidizing atmosphere between said grinding step and said diamond coating step, and subjecting the substrate to chemical etching to remove cobalt existing in an outermost portion of the substrate between the heat-treating step and the diamond coating step, wherein said tungsten carbide based cemented carbide contains, apart from unavoidable impurites, 1-25% by weight of cobalt as a binder phase forming component and balance tungsten carbide as a dispersed phase forming component and wherein said substrate is free of an eta-phase. A method as recited in claim 5 further comprising subjecting the substrate to ultrasonic waves to activate the surface of the substrate by hard particles between the chemical etching step and the diamond coating step.

Inventors: ETO HIROYUKI, KIKUCHI NORIBUMI, NAKAHARA KEI, OKAMURA TOSHIHIKO, SAKURAI KEIICHI, YOSHIMURA HIRONORI, ETO, HIROYUKI, KIKUCHI, NORIBUMI, NAKAHARA, KEI, OKAMURA, TOSHIHIKO, SAKURAI, KEIICHI, YOSHIMURA, HIRONORI, ETO, HIROYUKI C/O CHUO-KENKYUSHO, KIKUCHI, NORIBUMI C/O CHUO-KENKYUSHO, OKAMURA, TOSHIHIKO C/O TOKYO-SEISAKUSHO, SAKURAI, KEIICHI C/O TOKYO-SEISAKUSHO, YOSHIMURA, HIRONORI C/O TOKYO-SEISAKUSHO
Applicants: MITSUBISHI MATERIALS CORP, MITSUBISHI MATERIALS CORPORATION
Application year: 1989
Main classification: C23C16
IPC codes: C23C16, C23C14