Abstract:
A new and refined method to produce α-Al 2 O 3  layers in a temperature range of from about 750 to about 1000° C. with a controlled growth texture and substantially enhanced wear resistance and toughness than the prior art is disclosed. The α-Al 2 O 3  layer of the present invention is formed on a bonding layer of (Ti,Al)(C,O,N) with increasing aluminium content towards the outer surface. Nucleation of α-Al 2 O 3  is obtained through a nucleation step being composed of short pulses and purges consisting of Ti/Al-containing pulses and oxidising pulses. The α-Al 2 O 3  layer according to the present invention has a thickness ranging from about 1 to about 20 μm and is composed of columnar grains. The length/width ratio of the alumina grains is from about 2 to about 12, preferably from about 4 to about 8. The layer is characterized by a strong (104) growth texture, measured using XRD, and by low intensity of (012), (110), (113), (024) and (116) diffraction peaks.

Description:
RELATED APPLICATION DATA 
     This application is a divisional application of U.S. application Ser. No. 11/265,797, filed Nov. 2, 2005, which claims priority under 35 U.S.C. §119 and/or §365 to Swedish Application No. 0402693-6, filed Nov. 5, 2004, the entire contents of each of these applications are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to a coated cutting tool insert designed to be used in metal machining. The substrate is a cemented carbide, cermet, ceramics or cBN on which a hard and wear resistant coating is deposited. The coating exhibits an excellent adhesion to the substrate covering all functional parts thereof. The said coating is composed of one or more refractory layers of which at least one layer is a strongly textured alpha-alumina (α-Al 2 O 3 ) deposited in the temperature range of from about 750 to about 1000° C. 
     A crucial step in the deposition of different Al 2 O 3  polymorphs is the nucleation step. κ-Al 2 O 3  can be grown in a controlled way on {111} surfaces of TiN, Ti(C,N) or TiC having the fcc structure. TEM has confirmed the growth mode which is that of the close-packed (001) planes of κ-Al 2 O 3  on the close-packed {111} planes of the cubic phase with the following epitaxial orientation relationships: (001) κ //(111) TiX ; [100] κ //[112] TiX . An explanation and a model for the CVD growth of metastable κ-Al 2 O 3  have proposed earlier (Y. Yoursdshahyan, C. Ruberto, M. Halvarsson, V. Langer, S. Ruppi, U. Rolander and B. I. Lundqvist, Theoretical Structure Determination of a Complex Material: κ-Al 2 O 3 ,  J. Am. Ceram. Soc.  82(6)(1999)1365-1380). 
     When properly nucleated, κ-Al 2 O 3  layers can be grown to a considerable thickness (greater than about 10 μm). The growth of even thicker layers of κ-Al 2 O 3  can be ensured through re-nucleation on thin layers of, for example TiN, inserted in the growing κ-Al 2 O 3  layer. When nucleation is ensured, the κ→α transformation can be avoided during deposition by using a relatively low deposition temperature (less than about 1000° C.). During metal cutting, the κ→α a phase transformation has confirmed to occur resulting in flaking of the coating. In addition, there are several other reasons why α-Al 2 O 3  should be preferred in many metal cutting applications. As shown earlier α-Al 2 O 3  exhibits better wear properties in cast iron (U.S. Pat. No. 5,137,774). 
     However, the stable α-Al 2 O 3  phase has been found to be more difficult to be nucleated and grown at reasonable CVD temperatures than the metastable κ-Al 2 O 3 . It has been experimentally confirmed that α-Al 2 O 3  can be nucleated, for example, on Ti 2 O 3  surfaces, bonding layers of (Ti,Al)(C,O) or by controlling the oxidation potential using CO/CO 2  mixtures as shown in U.S. Pat. No. 5,654,035. The bottom line in all these approaches is that nucleation must not take place on the 111-surfaces of TiC, TiN, Ti(C,N) or Ti(C,O,N), otherwise κ-Al 2 O 3  is obtained. 
     It should also be noted that in the prior-art methods higher deposition temperatures (about 1000° C.) are usually used to deposit α-Al 2 O 3 . When the nucleation control is not complete, as is the case in many prior-art products, the produced α-Al 2 O 3  layers have, at least partly, been formed as a result of the κ-Al 2 O 3 →α-Al 2 O 3  phase transformation. This is especially the case when thick Al 2 O 3  layers are considered. These kinds of α-Al 2 O 3  layers are composed of larger grains with transformation cracks. These layers exhibit much lower mechanical strength and ductility than the α-Al 2 O 3  layers that are composed of nucleated α-Al 2 O 3 . Consequently, there is a need to develop techniques to control the nucleation step of α-Al 2 O 3 . 
     The control of the α-Al 2 O 3  polymorph in industrial scale was achieved in the beginning of the 1990&#39;s with commercial products based on U.S. Pat. No. 5,137,774. Later modifications of this patent have been used to deposit α-Al 2 O 3  with preferred coating textures. In U.S. Pat. No. 5,654,035, an alumina layer textured in the (012) direction and in U.S. Pat. No. 5,980,988 in the (110) direction are disclosed. In U.S. Pat. No. 5,863,640, a preferred growth either along (012), or (104) or (110) is disclosed. U.S. Pat. No. 6,333,103 describes a modified method to control the nucleation and growth of α-Al 2 O 3  along the (10(10)) direction. US20020155325A1 describes a method to obtain a strong (300) texture in α-Al 2 O 3  using a texture modifying agent (ZrCl 4 ) The processes discussed above use all high deposition temperatures of about 1000° C. 
     US 2004/0028951A1 describes a new state-of-the-art technique to achieve a pronounced (012) texture. The commercial success of this kind of product demonstrates the importance to refine the CVD process of α-Al 2 O 3  towards fully controlled textures. 
     It is well established that the water gas shift reaction, in the absence of H 2 S or other dopants, is the critical rate-limiting step for Al 2 O 3  formation, and to a great extent, controls the minimum temperature at which Al 2 O 3  can be deposited. Further it is well established that the water-gas shift reaction is very sensitive for deposition pressure. 
     Extensive work has been done to deposit CVD Al 2 O 3  at lower temperatures. Several Al 2 O 3  layers using other than AlCl 3 —CO 2 —H 2  system have been investigated, including AlCl 3 —CO—CO 2 , AlCl 3 -C 2 H 5 OH, AlCl 3 —N 2 O—H 2 , AlCl 3 —NH 3 —CO 2 , AlCl 3 —O 2 —H 2 O, AlCl 3 —O 2 —Ar, AlX 3 —CO 2  (where X is Cl, Br, I), AlX 3 —CO 2 —H 2  (where X is Cl, Br, I), AlBr 3 —NO—H 2 —N 2  and AlBr 3 —NO—H 2 —N 2 . It is emphasised that these studies have been carried out without dopants (such as H 2 S) and the effect of the deposition pressure has not been elucidated. 
     It is worth noting that none of these systems have been commercially successful. Consequently, to provide a CVD process for depositing Al 2 O 3  layers at temperatures below those currently used on a commercial scale is therefore highly desirable. 
     U.S. Pat. No. 6,572,991 describes a method to deposit γ-Al 2 O 3  at low deposition temperatures. This work clearly shows that it is possible to obtain Al 2 O 3  layers in the medium temperature range from the AlCl 3 —CO 2 —H 2  system. However, in this work it was not realised that nucleation surface controls the phase composition of Al 2 O 3  and that deposition of α-Al 2 O 3  is thus possible at lower deposition temperatures. In the prior-art, it was considered impossible to deposit α-Al 2 O 3  at low temperatures and it was believed that γ-Al 2 O 3  and κ-Al 2 O 3  were the unavoidable low temperature phases. 
     OBJECTS AND SUMMARY OF THE INVENTION 
     It is an object of the present invention is to provide a new, improved alumina layer where the α-Al 2 O 3  phase is of nucleated α-Al 2 O 3  with a strong, fully controlled (104) growth texture. According to the present invention, α-Al 2 O 3  with the controlled (104) texture can be obtained within a wide temperature range from about 750 to about 1000° C., which can be considered surprising. 
     In one aspect of the invention, there is provided a cutting tool insert of a substrate at least partially coated with a coating with a total thickness of from about 10 to about 40 μm, of one or more refractory layers of which at least one layer is an alumina layer, said alumina layer being composed of columnar α-Al 2 O 3  grains with texture coefficients
         a) TC(104) greater than about 2.0;   b) TC(012), TC(110), TC(113), TC(024) all less than about 1.0.;   c) TC(116) less than about 1.2;       

     The texture coefficient TC(hkl) is defined as 
     
       
         
           
             
               TC 
               ⁡ 
               
                 ( 
                 hkl 
                 ) 
               
             
             = 
             
               
                 
                   I 
                   ⁡ 
                   
                     ( 
                     hkl 
                     ) 
                   
                 
                 
                   
                     I 
                     O 
                   
                   ⁡ 
                   
                     ( 
                     hkl 
                     ) 
                   
                 
               
               ⁢ 
               
                 
                   { 
                   
                     
                       1 
                       n 
                     
                     ⁢ 
                     
                       ∑ 
                       
                         
                           I 
                           ⁡ 
                           
                             ( 
                             hkl 
                             ) 
                           
                         
                         
                           
                             I 
                             O 
                           
                           ⁡ 
                           
                             ( 
                             hkl 
                             ) 
                           
                         
                       
                     
                   
                   } 
                 
                 
                   - 
                   1 
                 
               
             
           
         
       
     
     where
         I(hkl)=measured intensity of the (hkl) reflection   I o (hkl)=standard intensity according to JCPDS card no 46-1212   n=number of reflections used in the calculation (hkl) reflections used are: (012), (104), (110), (113), (024), (116).       

     In another aspect of the invention, there is provided a method of coating a substrate with an Al 2 O 3  layer wherein the α-Al 2 O 3  layer is composed of columnar α-Al 2 O 3  grains with a texture coefficient TC (104) greater than about 2 comprising depositing a (Ti,Al)(C,O,N) bonding layer on said substrate to provide a nucleation surface for said Al 2 O 3 , subjecting said nucleation surface to a modification treatment of a pulse treatment with a mixture of TiCl 4 , AlCl 3  and H 2 , a purge with a neutral gas and an oxidizing pulse of a gas mixture including N 2  and CO 2  in a ratio of from about 450 to about 650, repeating the modification treatment and depositing α-Al 2 O 3  having a texture coefficient TC(104) greater than about 2 at a temperature of from about 750 to about 1000° C. 
     The alumina layer with strong texture outperforms the prior art with random or other less developed and incompletely controlled textures. Further, increased toughness can be obtained when deposition is carried out at lower temperatures. Compared with prior-art products the α-Al 2 O 3  layer according the present invention is essentially free from transformation stresses, consisting of columnar, defect free, α-Al 2 O 3  grains with low dislocation density and with improved cutting properties. The texture-controlled α-Al 2 O 3  layers deposited at medium temperature (about 800° C.) show enhanced toughness. 
    
    
     
       DESCRIPTION OF THE DRAWINGS AND FIGURES 
         FIG. 1  shows a cross-section SEM image (magnification 5000×) of a typical alumina layer according to the present invention deposited on a MTCVD-Ti(C,N) layer. The alumina layer is composed of columnar grains. It is dense with no detectable porosity. 
         FIG. 2  shows a cross-section SEM image of a typical layer according the prior-art (magnification 6000×) deposited on a MTCVD-Ti(C,N) layer. The alumina layer is composed of large nearly equiaxed grains. Porosity is visible in the alumina layer. Interfacial porosity between the alumina layer and the Ti(C,N) layer is also visible. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A method to deposit α-Al 2 O 3  with a strong (104) texture in a temperature range of from about 750 to about 1000° C. is described. The invention utilizes short pulses of precursors followed by purging steps with an inert gas such as Ar. After the purge another precursor is applied as a short pulse. In addition to the texture control, the method can be used to produce finer grain sizes by increasing the number of nucleation sites. 
     Al 2 O 3  layers according to the present invention outperform the prior-art and are especially suitable be used in toughness demanding stainless steel application such as interrupted cutting, turning with coolant and especially intermittent turning with coolant. The other area is cast iron where the edge strength of this kind of alumina layer is superior to the prior art. 
     Ti(C,N) is used as an intermediate layer, which can be obtained either by conventional CVD or MTCVD, preferably by MTCVD. The present invention makes it possible to deposit α-Al 2 O 3  at same temperature as is used to deposit the intermediate MTCVD Ti(C,N) layer. Consequently, the heating-up period can be omitted after MTCVD. 
     To nucleate α-Al 2 O 3  with the specified texture, several steps are needed. First, on the Ti(C,N) layer a bonding layer characterised by the presence of an Al concentration gradient is deposited. Nitrogen and CH 3 CN are applied during deposition of this bonding layer. The aluminium content on the surface of this layer is considerably, about 30%, higher than in the bonding layer according to U.S. Pat. No. 5,137,774 (prior-art) and the bonding layer is obviously containing nitrogen. The surface of this bonding layer is subjected to an additional treatment(s). 
     Nucleation is started with a AlCl 3 /TiCl 4 /H 2  pulse with a duration of 5 minutes. After that an Ar purge (duration about 5 minutes) is applied in order to remove excess Cl −  from the surface. After this, an oxidizing pulse is applied using a CO 2 /H 2 /N 2 /Ar (Co 2 =about 0.15%, H 2 =about 10%, N 2  about 25%, Ar=balance) gas mixture at a pressure of from about 50 to about 500 mbar, to a temperature of from about 750° to about 1000° C., depending on the temperature of the subsequent alumina deposition. In addition to a relatively low oxidation potential of the gas mixture, the oxidizing step has to relatively short, from about 0.5 to about 5 minutes to secure (104) nucleation. These steps should be repeated several times, preferably from about 2 to about 5 times in sequence to increase the amount of α-Al 2 O 3  nuclei. It is noted that if pulsating nucleation is used, one has to find an optimized combination between the duration of the individual steps and the amount of the steps, otherwise too low or excessive oxidization may be obtained. A person skilled in the art can find the correct procedure by trial and error. 
     The key to obtain the specified growth texture is the control of the oxidation potential of the CO 2 /H 2 /N 2 /Ar mixture by adjustment of the N 2 :CO 2  ratio. This ratio should be from about 450 to about 650, preferably from about 450 to about 550. The use of controlled oxygen potential in combination with the correct time and number of pulses enables the correct nucleation mode. Typical pulse times may range from about 10 seconds to about 5 minutes depending on the duration of the pulse. The oxidising pulse is again followed by an Ar purge. These steps should be repeated several times, preferably from about 2 to about 5 times, in sequence to increase the amount of α-Al 2 O 3  nuclei. Excessive oxidisation must be avoided. A person skilled in the art can find the best and optimised combination between the duration and the amount of the steps. 
     Detailed Description of the Nucleation Steps
         1. Depositing a bonding layer from about 0.1 to about 1 μm thick in a gas mixture of from about 2 to about 3% TiCl 4 , AlCl 3  increasing from about 0.5 to about 5%, from about 3 to about 7% CO, from about 1 to about 3% CO 2 , from about 2 to about 10% N 2  and balance H 2  at from about 750 to about 1000° C., preferably at about 800° C. and at a pressure of from about 50 to about 200 mbar.   2. Purging by Ar for about 5 min.   3. Treating the bonding layer in a gas mixture of from about 1 to about 2% TiCl 4  and from about 2 to about 4% AlCl 3  in hydrogen for about 2 to about 60 min at from about 750 to about 1000° C., preferably at about 800° C. and at a pressure of from about 50 to about 200 mbar.   4. Purging by Ar for 5 about min.   5. Treating in a gas mixture of from about 0.1 to about 0.15% CO 2  (preferably about 0.15%), from about 10 to about 30% N 2  (preferably from about 22.5 to about 30% when the CO 2  content is about 15%), about 10% H 2 , balance Ar at a pressure of from about 50 to about 200 mbar for about 0.5 to about 5 minutes at a temperature of from about 750 to about 1000° C., depending on the temperature for the subsequent deposition of the alumina layer.   6. Purging by Ar for about 5 min.   7. Repeating steps 3-6 to obtain the an optimum oxidation level.   8. Depositing an alumina layer at a temperature of from about 950 to about 1000° C. and a pressure of from about 50 to about 200 mbar with desired thickness according to known technique or depositing an alumina layer at from 5 about 750 to about 950 using higher deposition pressures (from about 200 to about 500 mbar) together with higher amounts (from about 0.5 to about 1.5%) of catalysing precursors such as H 2 S or SO x , preferably H 2 S. The growth of the alumina layer onto the nucleation layer is started by sequencing the reactant gases in the following order: CO, AlCl 3 , CO 2 . The process temperatures of from about 750 to about 1000° C. can be used since the texture is determined by the nucleation surface.       

     The present invention also relates to a cutting tool insert of a substrate at least partially coated with a coating with a total thickness of from about 15 to about 40 μm, preferably from about 20 to about 25 μm, of one or more refractory layers of which at least one layer is an alpha alumina layer. The α-Al 2 O 3  layer deposited according to the present invention is dense and exhibits a very low defect density. It is composed of columnar grains with a strong (104) texture. The columnar grains have a length/width ratio of from about 2 to about 12, preferably from about 4 to about 8. 
     The texture coefficients (TC) for the α-Al 2 O 3  according to the present invention layer is determined as follows: 
     
       
         
           
             
               TC 
               ⁡ 
               
                 ( 
                 hkl 
                 ) 
               
             
             = 
             
               
                 
                   I 
                   ⁡ 
                   
                     ( 
                     hkl 
                     ) 
                   
                 
                 
                   
                     I 
                     O 
                   
                   ⁡ 
                   
                     ( 
                     hkl 
                     ) 
                   
                 
               
               ⁢ 
               
                 
                   { 
                   
                     
                       1 
                       n 
                     
                     ⁢ 
                     
                       ∑ 
                       
                         
                           I 
                           ⁡ 
                           
                             ( 
                             hkl 
                             ) 
                           
                         
                         
                           
                             I 
                             O 
                           
                           ⁡ 
                           
                             ( 
                             hkl 
                             ) 
                           
                         
                       
                     
                   
                   } 
                 
                 
                   - 
                   1 
                 
               
             
           
         
       
     
     where 
     I(hkl)=intensity of the (hkl) reflection 
     I o (hkl)=standard intensity according to JCPDS card no 46-1212
         n=number of reflections used in the calculation (hkl) reflections used are: (012), (104), (110), (113), (024), (116).   The texture of the alumina layer is defined as follows:   TC(104) greater than about 2.0, preferably greater than about 3. Simultaneously TC(012), TC(110), TC(113), TC(024) should be all less than about 1.0, preferably less than about 0.5. Note that the related (012) and (024) reflections are also low. However, for this growth mode TC(116) is somewhat higher than the other background reflections. TC(116) should be less than about 1.2, preferably less than about 1.       

     The substrate comprises a hard material such as cemented carbide, cermets, ceramics, high speed steel or a super hard material such as cubic boron nitride (CBN) or diamond, preferably cemented carbide or CBN. With CBN is herein meant a cutting tool material containing at least about 40 vol-% CBN. In a preferred embodiment, the substrate is a cemented carbide with a binder phase enriched surface zone. 
     The coating comprises a first layer adjacent the body of CVD Ti(C,N), CVD TiN, CVD TiC, MTCVD Ti(C,N), MTCVD Zr(C,N), MTCVD Ti(B,C,N), CVD HfN or combinations thereof preferably of Ti(C,N) having a thickness of from about 1 to about 20 μm, preferably from about 1 to about 10 μm, and said α-Al 2 O 3  layer adjacent said first layer having a thickness of from about 1 to 40 μm, preferably from about 1 to about 20 μm, most preferably from about 1 to about 10 μm. Preferably, there is an intermediate layer of TiN between the substrate and said first layer with a thickness of less than about 3 μm, preferably from about 0.5 to about 2 μm. 
     In one embodiment, the α-Al 2 O 3  layer is the uppermost layer. 
     In another embodiment, there is a layer of carbide, nitride, carbonitride or carboxynitride of one or more of Ti, Zr and Hf, having a thickness of from about 0.5 to about 3 μm, preferably from about 0.5 to about 1.5 μm, atop the α-Al 2 O 3  layer. Alternatively this layer has a thickness of from about 1 to about 20 μm, preferably from about 2 to about 8 μm. 
     In yet another embodiment, the coating includes a layer of κ-Al 2 O 3  and/or γ-Al 2 O 3  preferably atop the α-Al 2 O 3 . with a thickness of from 0.5 to 10, preferably from 1 to 5 μm. 
     The invention is additionally illustrated in connection with the following examples, which are to be considered as illustrative of the present invention. It should be understood, however, that the invention is not limited to the specific details of the examples. 
     EXAMPLE 1 
     Cemented carbide cutting inserts with a composition of 5.9% Co and balance WC (hardness about 1600 HV) were coated with a layer of MTCVD Ti(C,N). The thickness of the MTCVD layer was about 2 μm. On to this layer two different layers consisting of about 10 μm α-Al 2 O 3  were deposited: 
     Layer a) contained a (104) textured layer and was deposited according to the present invention at 1000° C. The detailed process data is given in Table 1. 
     Layer b) was deposited according to the prior art. 
     Layer c) contained a (104) textured layer and was deposited according to the present invention at 800° C. The detailed process data is given in Table 2. 
     
       
         
               
             
               
               
               
             
               
             
               
               
               
             
               
             
               
               
               
             
               
             
               
               
               
             
               
             
               
               
               
             
               
             
               
               
               
             
               
             
               
               
               
             
               
             
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                 Deposition process for a Layer a) with (104) texture at 
               
               
                 1000° C.: 
               
               
                   
               
             
             
               
                 Step 1: Bonding layer 
               
             
          
           
               
                   
                 Gas mixture 
                 TiCl 4  = 2.8% 
               
               
                   
                   
                 AlCl 3  = 0.8-4.2% 
               
               
                   
                   
                 CO = 5.8% 
               
               
                   
                   
                 CO 2  = 2.2% 
               
               
                   
                   
                 N 2  = 5-6% 
               
               
                   
                   
                 Balance: H 2   
               
               
                   
                 Duration 
                 60 min 
               
               
                   
                 Temperature 
                 1000° C. 
               
               
                   
                 Pressure 
                 100 mbar 
               
             
          
           
               
                 Step 2: Purge 
               
             
          
           
               
                   
                 Gas 
                 Ar = 100% 
               
               
                   
                 Duration 
                 5 min 
               
               
                   
                 Temperature 
                 1000 C. 
               
               
                   
                 Pressure 
                 50 mbar 
               
             
          
           
               
                 Step 3: Pulse 1 
               
             
          
           
               
                   
                 Gas mixture 
                 TiCl 4  = 1.6% 
               
               
                   
                   
                 AlCl 3  = 2.8 
               
               
                   
                   
                 H 2  = Balance 
               
               
                   
                 Duration 
                 2-5 min depending on the 
               
               
                   
                   
                 amount of pulses. 
               
               
                   
                 Temperature 
                 1000 C. 
               
               
                   
                 Pressure 
                 50 mbar 
               
             
          
           
               
                 Step 4: Purge 
               
             
          
           
               
                   
                 Gas 
                 Ar = 100% 
               
               
                   
                 Duration 
                 5 min 
               
               
                   
                 Temperature 
                 1000 C. 
               
               
                   
                 Pressure 
                 50 mbar 
               
             
          
           
               
                 Step 5: Pulse 2 
               
             
          
           
               
                   
                 Gas mixture 
                 CO 2  = 0.05% 
               
               
                   
                   
                 N 2  = 25% 
               
               
                   
                   
                 Balance: H 2   
               
               
                   
                 Duration 
                 0.5-1 min depending on the 
               
               
                   
                   
                 amount of pulses. 
               
               
                   
                 Temperature 
                 1000° C. 
               
               
                   
                 Pressure 
                 100 mbar 
               
             
          
           
               
                 Step 6: Purge 
               
             
          
           
               
                   
                 Gas 
                 Ar = 100% 
               
               
                   
                 Duration 
                 5 min 
               
               
                   
                 Temperature 
                 1000 C. 
               
               
                   
                 Pressure 
                 50 mbar 
               
             
          
           
               
                 Step 7: Nucleation step 
               
             
          
           
               
                   
                 Gas mixture 
                 AlCl 3  = 3.2% 
               
               
                   
                   
                 HCl = 2.0% 
               
               
                   
                   
                 CO 2  = 1.9% 
               
               
                   
                   
                 Balance H 2   
               
               
                   
                 Duration 
                 60 min 
               
               
                   
                 Temperature 
                 1000° C. 
               
               
                   
                 Pressure 
                 210 mbar 
               
             
          
           
               
                 Step 8: Deposition 
               
             
          
           
               
                   
                 Gas mixture 
                 AlCl 3  = 4.2% 
               
               
                   
                   
                 HCl = 1.0% 
               
               
                   
                   
                 CO 2  = 2.1% 
               
               
                   
                   
                 H 2 S = 0.2% 
               
               
                   
                   
                 Balance: H 2   
               
               
                   
                 Duration 
                 520 min 
               
               
                   
                 Temperature 
                 1000° C. 
               
               
                   
                 Pressure 
                 50 mbar 
               
               
                   
                   
               
             
          
         
       
     
     It should be noted that the steps 3-7 can be repeated 5-10 times in sequence in order to obtain grain refinement and the strong desired texture. The amount of pulses can be even higher if the duration of step 6 is reduced. In this example the steps 3-7 were repeated 3 times with durations of 0.6 minutes. 
                                                                                                                                                                               TABLE 2               Deposition process for a Layer c) with (104) texture at       780° C.:                   Step 1: Bonding layer                Gas mixture   TiCl 4  = 2.8%               CH 3 CN = 0.7%               AlCl 3  = increasing               from 0.8 to 4.2%               CO = 5.8%               CO 2  = 2.2%               N 2  = 5%               Balance: H 2             Duration   40 min           Temperature   780° C.           Pressure   100 mbar            Step 2: Purge                Gas   Ar = 100%           Duration   5 min           Temperature   780° C.           Pressure   50 mbar            Step 3: Pulse 1                Gas mixture   TiCl 4  = 1.6%               AlCl 3  = 2.8               H 2  = Balance           Duration   5 min.           Temperature   780° C.           Pressure   50 mbar            Step 4: Purge                Gas   Ar = 100%           Duration   5 min           Temperature   780° C.           Pressure   50 mbar            Step 5: Pulse 2                Gas mixture   CO 2  = 0.05%               N 2  = 25%               H 2  = 10%               Balance: Ar           Duration   2 min           Temperature   780° C.           Pressure   100 mbar            Step 6: Purge                Gas   Ar = 100%           Duration   5 min           Temperature   780° C.           Pressure   50 mbar            Step 7: Nucleation step                Gas mixture   AlCl 3  = 3.2%               HCl = 2.0%               CO 2  = 1.9%               Balance H 2             Duration   60 min           Temperature   780° C.           Pressure   50 mbar            Step 8: Deposition                Gas mixture   AlCl 3  = 4.1%               HCl = 1.0%               CO 2  = 2.3%               H 2 S = 0.9%               Balance: H 2             Duration   600 min           Temperature   780° C.           Pressure   350 mbar                        
Steps 3-6 were repeated three times.
 
     EXAMPLE 2 
     Layers a, b and c were studied using X-ray diffraction. The texture coefficients were determined are presented in Table 3. As clear from Table 3 the layer according to the present invention exhibits a strong (104) texture when deposited either at 1000° C. or 780° C. Typically, for this growth mode the (116) reflection is somewhat more profound than the other background reflections. 
     
       
         
               
               
               
               
             
           
               
                 TABLE 3 
               
               
                   
               
               
                 Hkl 
                 Invention, layer a 
                 Prior art, layer b, 
                 Invention, layer c 
               
               
                   
               
             
             
               
                 012 
                 0.24 
                 0.97 
                 0.49 
               
               
                 104 
                 4.30 
                 1.14 
                 3.13 
               
               
                 110 
                 0.06 
                 0.95 
                 0.49 
               
               
                 113 
                 0.19 
                 0.99 
                 0.41 
               
               
                 024 
                 0.27 
                 0.86 
                 0.49 
               
               
                 116 
                 0.94 
                 1.09 
                 0.99 
               
               
                   
               
             
          
         
       
     
     EXAMPLE 3 
     Layers a) and b) were studied using Scanning Electron Microscopy. The cross section images of the layers are shown in  FIGS. 1 and 2 , respectively. The differences in microstructure and morphology are clear. 
     EXAMPLE 4 
     The layers a) and b) from the Example 1 were tested with respect to edge chipping in longitudinal turning of cast iron. 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Work piece: 
                 Cylindrical bar 
               
               
                   
                 Material: 
                 SS0130 
               
               
                   
                 Insert type: 
                 SNUN 
               
               
                   
                 Cutting speed: 
                 400 m/min 
               
               
                   
                 Feed: 
                 0.4 mm/rev 
               
               
                   
                 Depth of cut: 
                 2.5 mm 
               
               
                   
                 Remarks: 
                 dry turning 
               
               
                   
                   
               
             
          
         
       
     
     The inserts were inspected after 2 and 4 minutes of cutting, As clear from Table 4 the edge toughness of the prior art product was considerably enhanced when the layer was produced according to the present invention. 
     
       
         
               
               
               
             
               
               
               
             
           
               
                   
                 TABLE 4 
               
               
                   
                   
               
               
                   
                 Flaking of the edge 
                 Flaking of the edge 
               
               
                   
                 line (%) after 2 minutes 
                 line (%) After 6 minutes 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                 Layer a (Invention) 
                 0 
                 6 
               
               
                 Layer b 
                 12 
                 22 
               
               
                   
               
             
          
         
       
     
     EXAMPLE 5 
     The layer produced according to the present invention was compared with a market leader, referred here as Competitor X. This coating is composed of MTCVD Ti(C,N) and α-Al 2 O 3 . XRD was used to determine the texture coefficients for these competitor coatings. Two inserts from Competitor X were randomly chosen for XRD. Table 5 shows the obtained TCs for the Competitor X. The coatings from Competitor X exhibit a random texture and can be compared with the present invention, Table 1. 
                                           TABLE 5               Hkl   TC(hkl)                                012   0.71   0.57       104   0.92   0.86       110   1.69   1.92       113   0.48   0.40       024   1.16   1.14       116   1.04   1.11                    
The X-rayed inserts from the competitor X were compared with inserts produced according to the present invention, Layer a).
 
     Two inserts produced according to the present invention were compared with the two Competitor X inserts with respect to flank wear resistance in face turning of ball bearing material: 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Work piece: 
                 Cylindrical tubes (Ball bearings) 
               
               
                   
                 Material: 
                 SS2258 
               
               
                   
                 Insert type: 
                 WNMG080416 
               
               
                   
                 Cutting speed: 
                 500 m/min 
               
               
                   
                 Feed: 
                 0.5 mm/rev 
               
               
                   
                 Depth of cut: 
                 1.0 mm 
               
               
                   
                 Remarks: 
                 Dry turning 
               
               
                   
                 Tool life criterion: 
                 Flank wear &gt;0.3 mm, three edges of each 
               
               
                   
                   
                 variant were tested. 
               
               
                   
                   
               
             
          
         
       
     
     
       
         
               
               
               
             
           
               
                   
                   
               
               
                   
                 Results: 
                 Tool life (min) 
               
               
                   
                   
               
             
             
               
                   
                 Layer a 
                 25.0 (invention) 
               
               
                   
                 Layer a 
                 23.5 (invention) 
               
               
                   
                 Competitor 1 
                 14.5 (prior art) 
               
               
                   
                 Competitor 2 
                 15.5 (prior art) 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 6 
     Layer a), b) and c) deposited on Co-enriched substrates were tested with respect to toughness in longitudinal turning with interrupted cuts. 
     
       
         
               
               
             
           
               
                   
               
             
             
               
                 Work piece: 
                 Cylindrical slotted bar 
               
               
                 Material: 
                 SS1672 
               
               
                 Insert type: 
                 CNMG120408-M3 
               
               
                 Cutting speed: 
                 140 m/min 
               
               
                 Feed: 
                 0.1, 0.125, 0.16, 0.20, 0.25, 0.315, 0.4, 
               
               
                   
                 0.5, 0.63, 0.8 mm/rev gradually increased after 10 mm 
               
               
                   
                 length of cut 
               
               
                 Depth of cut: 
                 2.5 mm 
               
               
                 Remarks: 
                 dry turning 
               
               
                 Tool life criteria: 
                 Gradually increased feed until edge 
               
               
                   
                 breakage. 10 edges of each variant were tested. 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
             
               
               
               
             
           
               
                   
                 TABLE 6 
               
               
                   
                   
               
               
                   
                 Mean feed at breakage (mm/rev) 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Layer a (invention) 
                 0.24 
               
               
                   
                 Layer b (prior art) 
                 0.12 
               
               
                   
                 Layer c (invention) 
                 0.32 
               
               
                   
                   
               
             
          
         
       
     
     The test results show (Table 6) that layers according to the present invention exhibited clearly better toughness behaviour than the prior-art (layer b). 
     EXAMPLE 7 
     Cubic boron nitride (CBN) insert containing about 90% of polycrystalline CBN (PCBN) were coated according to the present invention and according to prior art layer discussed in Example 1. The coated CBN was compared with uncoated CBN insert in cutting of steel containing ferrite. It is known that B has a high affinity to ferrite and diffusion wear occurs at high cutting speeds. As shown in Table 7 the layer according to the present invention is superior to the prior art. 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Work piece: 
                 Cylindrical bar 
               
               
                   
                 Material: 
                 SS0130 
               
               
                   
                 Insert type: 
                 SNUN 
               
               
                   
                 Cutting speed: 
                 750 m/min 
               
               
                   
                 Feed: 
                 0.4 mm/rev 
               
               
                   
                 Depth of cut: 
                 2.5 mm 
               
               
                   
                 Remarks: 
                 dry turning 
               
               
                   
                   
               
             
          
         
       
     
     
       
         
               
               
             
               
               
               
             
           
               
                   
                 TABLE 7 
               
               
                   
                   
               
               
                   
                 Life time (min) 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Coated CBN (Invention) 
                 26 
               
               
                   
                 Coated according to prior art 
                 11 
               
               
                   
                 Uncoated CBN 
                 9 
               
               
                   
                   
               
             
          
         
       
     
     Although the present invention has been described in connection with preferred embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without department from the spirit and scope of the invention as defined in the appended claims.