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CN103201410A - 包括多层涂层的切削刀具 - Google Patents

包括多层涂层的切削刀具 Download PDF

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CN103201410A
CN103201410A CN2011800389902A CN201180038990A CN103201410A CN 103201410 A CN103201410 A CN 103201410A CN 2011800389902 A CN2011800389902 A CN 2011800389902A CN 201180038990 A CN201180038990 A CN 201180038990A CN 103201410 A CN103201410 A CN 103201410A
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nitride
cutting tool
aluminum
tool according
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CN103201410B (zh
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法伊特·席尔
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Walter AG
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Abstract

本发明涉及一种切削刀具，其包括主部分和涂敷于该主部分上的多层涂层。由硬质材料制成的第一层A涂敷在所述主部分上，所述硬质材料选自氮化钛铝(TiAlN)、氮化钛铝硅(TiAlSiN)、氮化铬(CrN)、氮化铝铬(AlCrN)、氮化铝铬硅(AlCrSiN)和氮化锆(ZrN)，并且，由氮化硅(Si3N4)制成的第二层B直接涂敷于所述第一层A上。

Description

包括多层涂层的切削刀具
本发明涉及一种切削刀具，该切削刀具包括主体和涂敷于该主体的多层涂层。
背景技术
切削刀具包括主体和单层或多层硬质材料涂层，该主体例如由硬质金属、陶瓷、钢或高速钢制成，该硬质材料涂层涂敷于所述主体以延长寿命或者还提高切削性能。使用CVD(化学气相沉积)工艺和/或PVD(物理气相沉积)工艺来涂敷该硬质材料涂层。
WO 96/23911描述了一种切削刀具，该切削刀具包括具有多个单层的多层耐磨涂层，其中，包括硬质金属材料的单层被直接涂敷于主体，进一步地，在该主体上布置多个单层，使得这些单层形成了包括三种不同的相应单层的、周期性重复的复合体(composite)，该复合体均包括两个不同的金属硬质材料层和一个共价硬质材料层。在被描述为优选实施例的一个实施例中，该三层的复合体包括两个单层(氮化钛层和碳化钛层)以及具有共价硬质材料碳化硼的一个单层。该文献中描述了：耐磨涂层包括至少三个共价硬质材料层部分，因此包括至少9个单层。优选地，布置在主体上的第一单层是氮化钛层或碳化钛层，这是因为氮化钛和碳化钛据说能够很好地附着于钢或硬质金属的主体上。除了特别优选的碳化硼以外，碳化硅、氮化硅、氮化硼、塞隆(硅和氮氧化铝的混合晶体)、碳和其它材料也被指定用于共价硬质材料的单层。然而，已经发现，所描述的、包括硬质金属材料、氮化钛和碳化钛的单层在防止磨损方面并不满足如今的要求。尽管公认碳化钛很硬，但对于耐磨层来说却太脆。氮化钛比碳化钛软且没有碳化钛脆。碳化钛和氮化钛的耐温性均不足以在涉及高温负载的场合使用。当对金属进行加工时，切屑和切削料(cuttings)中的散热也不充分。
发明目的
本发明目的是提供切削刀具，该切削刀具具有主体和多层涂层，与现有技术相比，该多层涂层提高了在主体上的粘附性，具有更好的高温属性，并具有相当或更高的硬度值和提高的耐磨性。
发明内容
通过如下的切削刀具来实现上述目的，该切削刀具包括主体和涂敷于该主体上的多层涂层，其中，涂敷于该主体上的是硬质材料的第一层A，该硬质材料选自氮化钛铝(TiAlN)、氮化钛铝硅(TiAlSiN)、氮化铬(CrN)、氮化铝铬(AlCrN)、氮化铝铬硅(AlCrSiN)和氮化锆(ZrN)，并且，氮化硅(Si3N4)的第二层B直接涂敷于所述第一层A上。
与现有技术中已知的例如TiC或TiN等的金属硬质材料层相比，第一氮化物层A具有明显提高的耐温性，同时还具有与TiC的硬度相当但没有TiC脆的高硬度。氮化硅(Si3N4)的第二层很硬且耐磨，并且与第一氮化物层A一起非常有效地防止了经由耐磨涂层到主体中的热传递，因此，在用该切削刀具进行的金属加工中，促进了向切屑和切削料中的散热。与经常用作硬质耐磨层的氧化铝类似，氮化硅也有效防止了热传递。另外，氮化硅(Si3N4)的第二层B甚至在高温下也具有非常高的抗氧化性。
在本发明的特别优选的实施例中，硬质材料的第一层A直接涂敷于所述主体上。这提供了氮化硅和所述主体之间的特别良好的粘附性，尤其是第一层A含有TiAlN的情况下。
在本发明的另一优选实施例中，至少一个另外的、周期性重复的层A和层B序列被涂敷到第二层B上，其中，所述周期性重复的层A和层B序列中的层A也选自氮化钛铝(TiAlN)、氮化钛铝硅(TiAlSiN)、氮化铬(CrN)、氮化铝铬(AlCrN)、氮化铝铬硅(AlCrSiN)和氮化锆(ZrN)，但所述周期性重复的层A和层B序列中的层A可以不同于第一层A的硬质材料。优选地，所有的层A均为氮化钛铝(TiAlN)，并且，所有的层B相应地为氮化硅(Si3N4)。
在本发明的另一优选实施例中，硬质材料层B的氮化硅(Si3N4)为非晶态的。非晶态的氮化硅具有惊人地良好的耐磨性和良好的耐温性，同时还具有高水平的硬度。
硬质层B的氮化硅(Si3N4)可以分别含有最高达20原子百分比、优选最高达5原子百分比的常规或非常规的杂质或掺杂元素。优选地，这些常规或非常规的杂质或掺杂元素选自氧、碳、硼、镓和砷。
在本发明特别优选的实施例中，第一层A的硬质材料为氮化钛铝(TiAlN)。已经证明，氮化钛铝在与氮化硅(Si3N4)的第二层B结合时是特别有利的。TiAlN与TiAlSiN类似地具有面心立方晶格(cubicface-centered crystal lattice)，按重量百分比计，TiAlN层中可以含有最高达5％的TiAlSiN。
在本发明的另一实施例中，涂敷在层A和层B上或者涂敷在周期性重复的层A和层B复合体上的是至少一个另外的硬质材料层或金属层，该硬质材料层或金属层选自氧化铝、氧化铝铬、氧化铬、氮化锆、氮化钛和金属铝，其中，所有前述的硬质材料均能可选地掺杂有一种或多种其他元素。
在本发明的变型例中，含有氧化铝的至少一个另外的硬质材料层涂敷在层A和B上，并且，涂敷在该含有氧化铝的至少一个另外的硬质材料层上的是氮化锆、氮化钛或金属铝的另一层。
可以涂敷在层A和B上的所述另外的层是基本公知的。例如，氧化铝是非常硬且具有良好耐磨性的层，氧化铝铬和氧化铬也同样如此。与氮化锆相比，氮化钛和金属铝通常用于给切削刀具上色，并以最外层的形式作为使用切削刀具时的指示层。
理想地，根据本发明的多层涂层的、总的层厚度的范围是2至10μm，优选是3至6μm。理想地，优选直接涂敷于所述主体上的第一层A的层厚度的范围是0.5至4μm，优选是1至3μm。相比之下理想地，可选地存在的另外的层A的层厚度的范围是0.2至2μm，优选是0.3至1μm。理想地，层B的层厚度的范围是0.2至5μm，优选是0.3至3μm，尤其优选的范围是0.5至1μm。在层厚度过大的情况下，由于层内的机械应力过高，通常存在开裂的风险。在层厚度过小的情况下，存在如下危险：各个单层并不发挥或不足以发挥希望该单层所具有的功能。
优选地，根据本发明的涂层中的层A和B是通过PVD工艺而涂敷于所述主体上的层，其中，尤其优选通过电弧气相沉积(arc PVD)来涂敷层A，且尤其优选通过磁控溅射、尤其是双磁控溅射或HIPIMS(高能脉冲磁控溅射)来涂敷层B。
根据本发明的切削刀具的主体优选由硬质金属、陶瓷、钢或高速钢(HSS)制成。
本发明的新颖涂层提供了大范围的可能选项，以提高和/或改变切削刀具的耐磨性、使用寿命和切削性能。切削刀具上的涂层的耐磨性、稳定性和切削性能取决于各种因素，例如切削刀具主体的材料，该涂层中的层的序列、性质及构成，各个层的厚度、以及尤其是用该切削刀具进行的切削操作的性质。取决于待加工工件的性质、相应的加工工艺以及在加工期间的其他条件(例如产生高温或使用了腐蚀性冷却流体)，对于同一切削刀具可以提供不同水平的耐磨性。另外，各种磨损之间也存在差别，这种差别可以取决于相应的加工操作而在或大或小的程度上影响刀具的使用时限，即该刀具的使用寿命。因此，总是考虑到在与现有技术相当的条件下应提高并评估该刀具的哪些性能，来考虑切削刀具的进一步开发和改进。
具有主体和根据本发明的多层涂层的、根据本发明的切削刀具中的实质性改进是：相对于现有技术提高的该涂层在所述主体上的粘附性，并且该涂层具有更好的高温属性、更高的硬度值和提高的耐磨性。
通过根据本发明的涂层而观察到的另一惊人效果是：减小了总涂层的导热率。在使用这种切削刀具对金属和复合材料进行切削时，所实现的、涂层导热率的这种惊人减小具有非常积极的效果。这种减小的导热率引起所述主体的材料(尤其是硬质金属)的、提高的耐热冲击性和由此提高的抗梳裂强度(comb cracking strength)。
不言而喻，此处针对根据本发明特定实施例而描述的所有单独特征均可以在技术意义和可能的范围内与根据本发明实施例的所有其它描述的特征相组合，并且，这种组合应当认为在本文中公开。这里，为了具有更好的可读性，无需将所有可能的组合都单独列举出来。
借助于以下实例来描述本发明的其他优点、特征及实施例。
具体实施方式
在PVD涂敷设备(Flexicoat；Hauzer Techno Coating)中，硬质金属主体设有多层PVD涂层。该主体的几何规格为SEHW120408或ADMT160608-F56(根据DIN-ISO 1832)。在沉积这些层之前，该设备被抽真空至1×10-5mbar，并且通过在170V的偏置电压下以氩离子刻蚀来清洗硬质金属表面。
实例1
层A：TiAlN
PVD工艺：电弧气相沉积(Arc-PVD)
靶：Ti/Al(33/67的原子百分数)，圆形的源(63mm的直径)
沉积：温度：500℃；蒸发器电流：65安培；
3.2Pa氮气压力，50伏衬底偏置电压
层B：Si3N4
PVD工艺：双磁控溅射
靶：矩形的硅源(80cm×20cm)
沉积：温度：500℃；6W/cm2；200sccm的氮气；
0.5Pa氩气压力；90伏衬底偏置电压
结构    X-射线下，非晶态
成键特征：根据XPS分析为共价的
层序列：主体/2.5μm的TiAlN/0.6μm的Si3N4
比较例1
以实例1的其他沉积参数来沉积3.3μm厚的TiAlN层，但不再沉积氮化硅层B。
在对含有42CrMo4钢(强度：950MPa)的工件进行的铣削测试中，将实例1和比较例1的切削刀具进行比较。在没有冷却润滑剂的情况下，以Vc＝235m/min的切削速度和f2＝0.2mm的每齿进刀量来进行顺铣(downcut milling)。在4800mm的铣削行程之后，测量其后刀面(reliefsurface)上的磨损，作为平均磨损痕迹宽度VBmm(在主切削刃处)。
发现了如下的磨损痕迹宽度VB：
磨损痕迹宽度VB
实例1： 0.06mm
比较例1： 0.10mm
实例2
以与实例1中相同的PVD工艺和相同的参数来沉积TiAlN层和氮化硅层B。
层序列：主体/2.5μm的TiAlN/0.6μm的Si3N4/0.3μm的TiAlN/0.1μm的Si3N4/0.3μm的TiAlN/0.1μm的Si3N4。
比较例2
与比较例1类似，但比较例2中沉积了4.0μm厚的TiAlN层。
在与实例1中类似、以Vc＝283m/min的切削速度和f2＝0.3mm的每齿进刀量进行的铣削试验中，发现了如下的磨损痕迹宽度VB：
磨损痕迹宽度VB
实例2： 0.10mm
比较例2： 0.30mm

Claims (12)

1.一种切削刀具，包括主体和涂敷于所述主体上的多层涂层，
其中，涂敷于所述主体上的是硬质材料的第一层A，所述硬质材料选自氮化钛铝(TiAlN)、氮化钛铝硅(TiAlSiN)、氮化铬(CrN)、氮化铝铬(AlCrN)、氮化铝铬硅(AlCrSiN)和氮化锆(ZrN)，并且
氮化硅(Si3N4)的第二层B直接涂敷于所述第一层A上。
2.根据前述权利要求中的任一项所述的切削刀具，其特征在于：
至少一个另外的、周期性重复的层A和层B序列被涂敷在所述第二层B上，其中，所述周期性重复的层A和层B序列中的层A也选自氮化钛铝(TiAlN)、氮化钛铝硅(TiAlSiN)、氮化铬(CrN)、氮化铝铬(AlCrN)、氮化铝铬硅(AlCrSiN)和氮化锆(ZrN)，但所述周期性重复的层A和层B序列中的层A能够不同于所述第一层A的硬质材料。
3.根据前述权利要求中的任一项所述的切削刀具，其特征在于：所述硬质层B的氮化硅(Si3N4)为非晶态的。
4.根据前述权利要求中的任一项所述的切削刀具，其特征在于：所述硬质层B的氮化硅(Si3N4)分别含有最高达20原子百分比、优选最高达5原子百分比的常规或非常规的杂质或掺杂元素，优选地，这些常规或非常规的杂质或掺杂元素选自氧、碳、硼、镓和砷。
5.根据前述权利要求中的任一项所述的切削刀具，其特征在于：所述第一层A的硬质材料是氮化钛铝(TiAlN)。
6.根据前述权利要求中的任一项所述的切削刀具，其特征在于：含有硬质材料的所述第一层A直接涂敷于所述主体上，和/或至少一个另外的硬质材料层或金属层涂敷在所述层A和B上，所述至少一个另外的硬质材料层或金属层选自氧化铝、氧化铝铬、氧化铬、氮化锆、氮化钛和金属铝，其中，所有前述的硬质材料均能可选地掺杂有一种或多种其他元素。
7.根据前述权利要求中的任一项所述的切削刀具，其特征在于：
含有氧化铝的至少一个另外的硬质材料层涂敷在所述层A和B上，并且，涂敷在该含有氧化铝的至少一个另外的硬质材料层上的是氮化锆、氮化钛或金属铝的另一个层。
8.根据前述权利要求中的任一项所述的切削刀具，其特征在于：所述多层涂层的总的层厚度的范围是2至10μm，优选是3至6μm。
9.根据前述权利要求中的任一项所述的切削刀具，其特征在于：直接涂敷于所述主体上的所述第一层A的层厚度的范围是0.5至4μm，优选是1至3μm，并且，可选地存在的、另外的层A的层厚度的范围是0.2至2μm，优选是0.3至1μm。
10.根据前述权利要求中的任一项所述的切削刀具，其特征在于：所述层B的层厚度的范围是0.2至5μm，优选是0.3至3μm，尤其优选的范围是0.5至1μm。
11.根据前述权利要求中的任一项所述的切削刀具，其特征在于：
所述层A和B是通过PVD工艺而涂敷于所述主体上的层，其中，优选通过电弧气相沉积(arc PVD)来涂敷所述层A，和/或通过磁控溅射、优选通过双磁控溅射或HIPIMS来涂敷所述层B。
12.根据前述权利要求中的任一项所述的切削刀具，其特征在于：所述主体由硬质金属、陶瓷、钢或高速钢(HSS)制成。
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US20130216804A1 (en) 2013-08-22
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EP2601330B1 (de) 2017-10-04
DE102010039035A1 (de) 2012-02-09
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