INDUSTRIAL PVD PROCESSES FOR THE MANUFACTURING OF A COATED CUTTING TOOL

Description

[0001] The present invention relates to a method for producing a coated cutting tool having a coating comprising aluminum oxide with a significant amount of alpha phase content. The present invention also relates to a coated cutting tool.Introduction

[0002] There is a continuous desire to improve cutting tools for metal machining so that they last longer, withstand higher cutting speeds and / or other increasingly demanding cutting operations. Commonly, a cutting tool for metal machining comprises a hard substrate material such as cemented carbide which has a thin hard coating usually deposited by either chemical vapour deposition (CVD) or physical vapour deposition (PVD).

[0003] Aluminium oxide (Al 2 O 3 ) coatings are being used in coatings for cutting tools. The deposition of hard Al 2 O 3 coatings in the industrial-scale PVD coaters is state of the art, but then only for gamma (γ) -Al 2 O 3 . The drawback of metastable Al 2 O 3 phases like gamma (γ) or kappa (κ) is phase transformation into the thermodynamically stable alpha (α) -Al 2 O 3 (corundum, R-3c) phase in a typical temperature range between 900°C and 1100°C. This limits the usage of metastable Al 2 O 3 coatings in metal cutting applications to maximum temperatures below 900°C. At higher temperatures, the phase transformation takes place and the hardness, stress and volume of the metastable Al 2 O 3 coatings change rapidly due to the heat evolved during metal cutting, resulting in cracks and flaking, and these coatings can't therefore be used in metal cutting applications. On the other hand, the usage of α-Al 2 O 3 coatings in an as-deposited state, which is state of the art in CVD, is beneficial in high temperature cutting applications like e.g. turning.

[0004] The deposition of α-Al 2 O 3 by PVD shows several advantages over CVD deposition methods. The α-Al 2 O 3 deposition by CVD requires high temperatures in the range between 900°C to 1100°C and the coatings are having a tensile stress profile while lower temperatures are used in PVD processes. Furthermore, as-deposited PVD coatings typically have a residual stress being compressive, which is beneficial for providing high toughness which is necessary for milling applications, while CVD coatings typically have a residual stress being tensile.

[0005] A cutting tool with an Al 2 O 3 coating of α-phase, or at least having a high content of α-phase, can thus be used at high temperature cutting applications, such as turning, while there is less beneficial to use Al 2 O 3 coatings of γ- or κ-phase.

[0006] In order to produce a sufficient amount of coated cutting tools to be offered on the commercial market one has to be able to charge a PVD reactor with many uncoated blanks or substrates. Furthermore, in the case of commercial cutting tool inserts having rake and flank faces they should generally be coated on the whole insert, i.e., the coating should be deposited as evenly as possible on all sides of an insert.

[0007] The use of rotating carousels where uncoated blanks are mounted on for example pins provides for the production of a large number of coated inserts with an evenly distribution of a coating around the inserts. One mode of deposition is two-fold (2f) rotation where there is a first axis of rotation in the center of the whole carousel (table) and then a second axis of rotation by a number of rotating spindles which in its turn have (non-rotating) pins on which inserts are mounted. Another mode of deposition is three-fold (3f) rotation where there is a first axis of rotation in the center of the whole carousel (table) and then a second axis of rotation by a number of rotating spindles which in its turn have rotating pins on which inserts are mounted forming a third axis of rotation.

[0008] One consequence of deposition in a commercial 2f- or 3f- rotating mode is that the deposition of a coating will be repeatedly interrupted due to the rotation of the inserts. The rotation leads to that an area of an insert is either facing the plasma, or not facing the plasma, or being in some position partly facing the plasma. Furthermore, the distance to a target is varying during deposition as a result of the 2f- or 3f rotation. The above mentioned issues have prevented a commercial production of cutting tools with PVD alpha-aluminium oxide coatings.

[0009] Yamada-Takamura et al, Surface and Coatings Technology, 142-144 (2001) 260-264, discloses deposition of films containing α-Al 2 O 3 by filtered arc deposition. However, the film starts with amorphous Al 2 O 3 and nanocrystalline γ-Al 2 O 3 followed by nucleation and subsequent growth of α-Al 2 O 3 . Furthermore, the arc-deposited film will contain a lot of droplets.

[0010] EP151707A1 discloses the formation of an α-Al 2 O 3 coating where the temperature has to be raised to at least 800°C.

[0011] US2009 / 0214894A1 discloses formation of a coating comprising α-Al 2 O 3 by first forming an oxide layer of corundum structure by oxidising a TiAlN, TiN or TiCN layer at a temperature of about 650-800°C and then depositing a layer comprising α-Al 2 O 3 , also at 650-800°C, by reactive sputtering.

[0012] However, when depositing a coating onto a cemented carbide substrate at high temperatures, such as 650°C, or higher, the substrate loses toughness which is a draw-back when designing a coated cutting tool. Furthermore, the use of template layers like chromium oxide or titanium oxide as templates for growing α-Al 2 O 3 has substantial drawbacks since such template layers are mechanically weak and deteriorate the overall wear resistance of the whole coating during metal cutting.

[0013] US 8,540,786 B2 discloses a coating comprising α-Al 2 O 3 oxide deposited by HIPIMS (High Power Impulse Magnetron Sputtering). In this disclosure, the substrate is constantly facing the magnetron sputtering glow discharge. Thus, no 2f- or 3f- rotation is used. No disclosure of any α-Al 2 O 3 on both a rake and a flank face is disclosed.

[0014] EP0744473 A1 discloses a coated cutting tool with an alpha-alumina coating covering the flank and the rake face of the tool. US2010 / 183900 A1 also discloses a a coated cutting tool and a method wherein HilMPS methods are used to produce a coated cutting tool with enlarged service life.

[0015] It would therefore be beneficial in many metal cutting applications to use a cutting tool having a PVD α-Al 2 O 3 containing coating and therefore further desired to provide a method for the efficient deposition of α-Al 2 O 3 containing coatings by industrial-scale PVD at low substrate temperatures, with a high deposition rate, the α-Al 2 O 3 containing coatings having high hardness, high Young's modulus, high crystallinity, residual stress being compressive, having high phase fractions of α-Al 2 O 3 , and being substantially droplet-free.

[0016] The object of the present invention is therefore to provide a method of producing, in industrial scale, a cutting tool having a coating comprising a PVD α-Al 2 O 3 .The invention

[0017] It has now been provided a method for producing a coated cutting tool which satisfies the above-mentioned objective. The method comprises HIPIMS deposition of α-phase containing Al 2 O 3 coatings on two-fold (2f) and three-fold (3f) rotated substrates in industrial-scale PVD coaters for metal cutting industry with a high deposition rate and substrate temperatures below 600°C.

[0018] Thus, it is hereby provided a method for producing a coated cutting tool having at least one rake face and at least one flank face, the cutting tool comprising a substrate of cemented carbide, cermet, cBN, or ceramic and a coating, the method comprises depositing on every flank face and every rake face of the cutting tool an Al 2 O 3 layer by a HIPIMS process, in the process the specific target peak pulse power density is ≥ 350 W / cm 2< , the specific average target power density is ≥ 6 W / cm 2< , the pulse time is 20-150 µs, the pulse frequency is ≥ 100 Hz, the peak pulse current is ≥ 400 A, the method comprising the following steps: charging a PVD reactor chamber, containing at least one Al target and a rotatable substrate holder, with cutting tool blanks, depositing an Al 2 O 3 layer in the HIPIMS process during two-fold or three-fold rotation of the substrates, at a substrate temperature < 600°C, the deposited Al2O3 layer comprises α-Al2O3.

[0019] The substrate temperature during the deposition in the HIPIMS process is ≥ 350°C but < 600°C, preferably ≥ 400°C but ≤ 580°C, most preferably ≥ 450°C but ≤ 560°C.

[0020] In the HIPIMS process the pulse time is suitably from 30 to 100 µs, preferably from 40 to 70 µs.

[0021] In the HIPIMS process the peak pulse cathode power is ≥ 500 kW, preferably ≥ 1 MW.

[0022] In the HIPIMS process the peak pulse current is preferably ≥ 600 A.

[0023] In the HIPIMS process the value of negative peak pulse voltage is ≥ 1200 V, preferably ≥ 1800 V.

[0024] In the HIPIMS process the pulse frequency is suitably ≥ 300 Hz, preferably ≥ 500 Hz.

[0025] In the HIPIMS process the oxygen partial pressure is ≥ 1x10 -4< mbar, preferably ≥ 3x10 -4< mbar.

[0026] In the HIPIMS process the total pressure is from 0.25 to 3 Pa, preferably from 0.5 to 1.5 Pa. The PVD reactor chamber gas comprises a noble gas element such as Ar which during operation of the HIPIMS process is ionised. If the total pressure is too low the noble gas element is more difficult to ionise and no plasma forms. If the total pressure is too high the noble gas element ions may be so many in the plasma that the average free path is too small hindering the transport of metal ions from the target to the substrate.

[0027] In the HIPIMS process the target size is from 500 to 3000 cm 2< , preferably from 1000 to 2000 cm 2< .

[0028] In the HIPIMS process the average cathode power is suitably ≥ 10 kW, preferably ≥ 15 kW.

[0029] In the HIPIMS process there is either a pulsed bias, or DC bias, voltage applied of from 150 to 300 V, preferably from 175 to 275 V, negative bias.

[0030] In the HIPIMS process the specific average target power density is suitably ≥ 8 W / cm 2< , preferably ≥ 10 W / cm 2< .

[0031] In the HIPIMS process the specific target peak pulse current density is suitably ≥ 0.25 A / cm 2< , preferably ≥ 0.35 A / cm 2< .

[0032] In the HIPIMS process the specific target peak pulse power density is suitably ≥ 650 W / cm 2< .

[0033] In the HIPIMS process the peak bias current is ≥ 100 A and ≤ 800 A, preferably ≥ 200 A and ≤ 400 A.

[0034] In the HIPIMS process the specific bias current density is 5 - 80 mA / cm 2< , preferably 10 - 40 mA / cm 2< .

[0035] In one embodiment, two-fold (2f) rotated substrates is used in the HIPIMS process.

[0036] In one embodiment, three-fold (3f) rotated substrates is used in the HIPIMS process.

[0037] The substrate holder can be a rotatable table (i) which comprises rotatable spindles (ii) which in its turn each comprises a number or rotatable pins (iii). In two-fold (2f) rotation (i) and (ii) rotates while in three-fold (3f) rotation all of (i), (ii) and (iii) rotate.

[0038] The PVD reaction chamber suitably has a chamber volume of ≥ 800 l, preferably ≥ 1000 l.

[0039] In one embodiment, not a part of the present invention, the deposited aluminium oxide layer is an α-Al 2 O 3 layer.

[0040] Two-fold (2f) and three-fold (3f) rotation of substrates lead to an interrupted deposition process due to the rotation of the substrates in the flow of elements in the plasma. Thus, the plasma density subjected to the substrates will vary to a great extent, from high levels down to very low levels. Despite this, significant amounts of α-phase of Al 2 O 3 is deposited.

[0041] As a result of the method described herein an Al 2 O 3 layer is provided in which an a-phase fraction on both a flank and rake face of 2f-, or even 3f-, rotated substrates is detected. It is especially noticeable that the production-like 3f- rotated substrates showed clear α-Al 2 O 3 phase containing XRD signals on their flank and rake faces.

[0042] The method herein disclosed provides the following benefits: no usage of nucleation layer is needed, a low deposition temperature can be used so that the deterioration of substrate toughness is minimised, a full scale production equipment can be used, droplet-free coatings are provided, the deposition process provides a constant or increased α-Al 2 O 3 phase fraction in the coating over time, hard α-Al 2 O 3 containing coatings are provided with hardness ≥ 2000 HV.

[0043] In one embodiment the Al 2 O 3 layer is deposited directly onto the substrate. This means that in this embodiment no other previously deposited layer is present between the Al 2 O 3 layer and the substrate.

[0044] In a 2theta XRD analysis of the deposited Al 2 O 3 layer the diffractogram shows at least clear peaks of α-Al 2 O 3 (113) and α-Al 2 O 3 (024). These peaks are, according to PDF no. 42-1468 of the ICDD database, positioned at 43.36 and 52.56 degrees 2theta respectively. When identifying diffraction peaks from an actual layer the peak positions in a diffractogram are often seen slightly shifted from PDF data due to, for example, internal stresses within the layer and equipment effects.

[0045] Thus, from XRD analysis one clearly sees that the deposited Al 2 O 3 layer shows peaks from at least α-Al 2 O 3 (113) and α-Al 2 O 3 (024) in XRD analysis.

[0046] The thickness of the deposited Al 2 O 3 layer is suitably from 0.1 to 20 µm, preferably from 0.5 to 10 µm.

[0047] In one embodiment the deposited Al 2 O 3 layer contains a mixture of α-Al 2 O 3 and γ-Al 2 O 3 .

[0048] In one embodiment a minimum of two or more reflections of α-Al 2 O 3 are detectable in XRD analysis.

[0049] The deposited Al 2 O 3 layer shows a relation between α-Al 2 O 3 and γ-Al 2 O 3 as follows: In GIXRD (gracing incidence x-ray diffraction) analysis at 0.5° incidence angle the ratio l(α-Al 2 O 3 (113)) to l(γ-Al 2 O 3 (400)) is ≥ 0.5, preferably ≥ 1, most preferably ≥ 2, on at least one of the rake face or flank face of the cutting tool. In GIXRD (gracing incidence x-ray diffraction) analysis at 0.5° incidence angle the ratio l(α-Al 2 O 3 (024)) to l(γ-Al 2 O 3 (400)) is ≥ 0.2, preferably ≥ 0.5, most preferably ≥ 1, on at least one of the rake face or flank face of the cutting tool. In GIXRD (gracing incidence x-ray diffraction) analysis at 0.5° incidence angle the ratio l(α-Al 2 O 3 (116)) to l(γ-Al 2 O 3 (400)) is ≥ 0.1, preferably ≥ 0.2, most preferably ≥ 0.5, on at least one of the rake face or flank face of the cutting tool.

[0050] The deposited Al 2 O 3 layer is suitably substantially droplet-free.

[0051] The deposited Al 2 O 3 layer suitably has a Vickers hardness of ≥ 2000 HV, preferably from 2200 to 3000 HV, most preferably from 2600 to 3000 HV.

[0052] The deposited Al 2 O 3 layer suitably has a reduced Young's modulus of ≥ 320 GPa, preferably from 330 to 420 GPa.

[0053] The coated cutting tool is a cutting tool for metal machining.

[0054] The coated cutting tool is in the form of an insert, a drill or an end mill.

[0055] The α-Al 2 O 3 is present in the deposited Al 2 O 3 layer on every rake face and every flank face of the cutting tool.

[0056] The present invention further relates to a coated cutting tool having at least one rake face and at least one flank face, comprising a substrate of cemented carbide, cermet, cBN, or ceramic and ceramic, and a coating comprising an Al 2 O 3 layer deposited according to the method as herein disclosed.

[0057] The α-Al 2 O 3 is present in the deposited Al 2 O 3 layer on every rake face and flank face of the cutting tool.

[0058] The thickness of the Al 2 O 3 layer is suitably from 0.1 to 20 µm, preferably from 0.5 to 10 µm.

[0059] The deposited Al 2 O 3 layer contains a mixture of α-Al 2 O 3 and γ-Al 2 O 3 .

[0060] The Al 2 O 3 layer shows a relation between alpha-aluminium oxide and gamma-aluminium oxide as follows: In GIXRD (gracing incidence x-ray diffraction) analysis at 0.5° incidence angle the ratio l(α-Al 2 O 3 (113)) to l(γ-Al 2 O 3 (400)) in an XRD 2theta diffractogram is ≥ 0.5, preferably ≥ 1, most preferably ≥ 2, on at least one of the rake face or flank face of the cutting tool. In GIXRD (gracing incidence x-ray diffraction) analysis at 0.5° incidence angle the ratio l(α-Al 2 O 3 (024)) to l(γ-Al 2 O 3 (400)) in an XRD 2theta diffractogram is ≥ 0.2, preferably ≥ 0.5, most preferably ≥ 1, on at least one of the rake face or flank face of the cutting tool. In GIXRD (gracing incidence x-ray diffraction) analysis at 0.5° incidence angle the ratio l(α-Al 2 O 3 (116)) to l(γ-Al 2 O 3 (400)) in an XRD 2theta diffractogram is ≥ 0.1, preferably ≥ 0.2, most preferably ≥ 0.5, on at least one of the rake face or flank face of the cutting tool.

[0061] The Al 2 O 3 layer suitably has a Vickers hardness of ≥ 2000 HV, preferably from 2200 to 3000 HV, most preferably from 2600 to 3000 HV.

[0062] The Al 2 O 3 layer suitably has a reduced Young's modulus of ≥ 320 GPa, preferably from 330 to 420 GPa.

[0063] The coated cutting tool is a cutting tool for metal machining.

[0064] The coated cutting tool is in the form of an insert, a drill or an end mill.Brief description of the drawings

[0065] Fig. 1 shows GIXRD measurements on an inventive coating with an incident angle of 1° of a 2f rotated rake face. Fig. 2 shows GIXRD measurements on an inventive coating with an incident angle of 1° of a 2f rotated rake face Fig. 3 shows GIXRD measurements on an inventive coating with an incident angle of 0.2° of a 2f rotated rake face Fig. 4 shows GIXRD measurements on an inventive coating with an incident angle of 0.5° of a 3f rotated flank face MethodsXRD-phase analysis:

[0066] The X-ray diffraction patterns concerning the phase analysis were acquired by Grazing incidence mode (GIXRD) on a diffractometer from Panalytical (Empyrean). CuKalpha-radiation with line focus was used for the analysis (high tension 40 kV, current 40 mA). The incident beam was defined by a 2 mm mask and a 1 / 8° divergence slit in addition with a X-ray mirror producing a parallel X-ray beam. The sideways divergence was controlled by a Soller slit (0,04°). For the diffracted beam path a 0,18° parallel plate collimator in conjunction with a proportional counter (0D-detector) was used. The measurement was done in grazing incidence mode (Omega = 1°). The 2Theta range was about 28-45° with a step size of 0,03° and a counting time of 10 s. For the XRD-line-profile analysis a reference measurement (with LaB6-powder) was done with the same parameters as listed above to correct for the instrumental broadening.Vickers hardness:

[0067] The Vickers hardness was measured by means of nano indentation (load-depth graph) using a Picodentor HM500 of Helmut Fischer GmbH, Sindelfingen, Germany. For the measurement and calculation the Oliver and Pharr evaluation algorithm was applied, wherein a diamond test body according to Vickers was pressed into the layer and the force-path curve was recorded during the measurement. The maximum load used was 15 mN (HV 0.0015), the time period for load increase and load decrease was 20 seconds each and the holding time (creep time) was 10 seconds. From this curve hardness was calculated. Hardness values and values for the reduced Young's modulus, indicated in the examples were each measured on the flank face of the coated tool.Reduced Young's modulus

[0068] The reduced Young's modulus (reduced modulus of elasticity) was determined by means of nano-indentation (load-depth graph) as described for determining the Vickers hardness.Thickness:

[0069] The thickness of the coating layers was determined by calotte grinding. Thereby a steel ball was used having a diameter of 30 mm for grinding the dome shaped recess and further the ring diameters were measured, and the layer thicknesses were calculated therefrom. Measurements of the layer thickness on the rake face (RF) of the cutting tool were carried out at a distance of 2000 µm from the corner, and measurements on the flank face (FF) were carried out in the middle of the flank face.Examples:Example 1 (invention):

[0070] On a WC-Co based cemented carbide substrate, having a Co content of 8 wt% and balance WC, an aluminium oxide coating was deposited in a Hauzer HTC1000 equipment under the following process conditions: Al target with size 830 mm x 170 mm, TruPlasma Highpulse 4002 generator of Trumpf Huettinger Sp. z o. o., HIPIMS block shape mode, average cathode power 15 kW, total gas pressure approx. 1 Pa, 1260 sccm Ar gasflow, approx. 95 sccm O 2 gasflow, DC bias voltage 250 V, negative bias bias current 14.5 A at the end of process, substrate temperature 550°C, HIPIMS pulse time approx. 45 µs, HIPIMS DC charging voltage 2000 V (negative voltage), power supply peak voltage during pulse approx. 1650 V (negative voltage), power supply peak current during pulse approx. 680 A, HIPIMS pulse frequency approx. 680Hz, peak pulse cathode power approx. 1150 kW, coil current approx. 4.0 A, oxygen partial pressure approx. 5.1x10 -4< mbar, process time 180 minutes

[0071] In 2f rotating mode an aluminium oxide coating having a thickness of 0.75 µm on the rake face and in 3f rotating mode an aluminium oxide coating having a thickness of 0.81 µm on the flank face was made.

[0072] The hardness was 2887 HV and the red. Young's modulus was 384 GPa.Examples 2-7:

[0073] Further Examples 2-7, using the same equipment as in Example 1, providing aluminium oxide coatings according to the invention were made where the process conditions had been varied according to Tables 1-4. Both 2f rotating and 3f rotating samples were produced. Table 1. Process conditionsExample no. O2 in sccm at begin O2 in sccm after 30 min O2 partial pressure in mbar Ar in sccm Temperature in °C 1100955.1x10^-412605502100955.0x10^-412605503100903.3x10^-41260550495953.5x10^-412605505100903.4x10^-412605506100953.8x10^-41260550795953.4x10^-41260550 Table 2. Process conditions cont. Example no. Pressure in Pa Coil in A DC bias voltage in V Bias in A at begin Bias in A at end Pulse length in µs 11.04.0-25024.014.54521.04.0-25027.016.04531.04.0-25024.014.54541.04.0-25022.00.14851.04.0-25020.612.34561.03.6-30019.13.84571.04.0-25020.013.045 Table 3. Process conditions cont. Example no. Voltage* in V Current in A Power in kW Frequency in Hz DC voltage** in V DC current in A 1-165068015680-20008.02-165562715742-20008.03-164070015670-20008.54-167065015650-20008.55-161576815617-20008.46-160085015566-20008.77-142062015850-17509.6 * used in the pulse ** charged voltage Table 4. Process conditions cont. Example no. Duty in % Time in min. U PeakMax in V I PeakMax in A P PeakMax in kW 13.0180-2000680115023.3120-1990626100033.0180-2005720115043.2150-2000650108052.8270-2000768124162.6250-1995860140073.9140-1670605840

[0074] Aluminium oxide coatings with thicknesses, hardnesses and red. Young's modulus according to Table 5 resulted from the depositions. Table 5.Example no. Thickness 2f rake in µm Hardness 2f rake in HV Red. Young's modulus 2f in GPa Thickness 3f flank in µm Hardness 3f flank in HV red. Young's modulus 3f flank in GPa 10.7528873840.81234637320.3024434120.45244241230.7528574010.66264041940.6026913860.62222039251.2026413511.16246535560.7525193590.85265037070.6524963700.462340387 Grazing incidence XRD (GIXRD) measurements:

[0075] GIXRD measurements in the 2theta range 35 to 60° of inventive examples no. 1-7 were made under an angle of 0.5° of a 3f rotated flank. The XRD diffractograms all show clearly α-Al 2 O 3 (113), (024) and (116) peaks (43.363°, 52.559° and 57.504°, respectively, in PDF no. 42-1468 of the ICDD database). All diffractograms were found to show peaks of α-Al 2 O 3 (113), (024) and (116).

[0076] Inventive example No. 1 was investigated further.

[0077] A GIXRD measurement in the 2theta range 20 to 60°, and a fine scan GIXRD measurement in the 2theta range 49 to 61°, were made on inventive example no. 1 with an incident angle of 1° of a 2f rotated rake face are shown in Figure 1 and Figure 2. Solid lines mark positions for α-Al 2 O 3 and dashed lines mark positions for γ-Al 2 O 3 , according to PDF no. 42-1468 and PDF no. 10-425 of the ICDD database. The XRD diffractogram in Figure 1 shows clearly a γ-Al 2 O 3 (400) peak (45.863° in PDF no. 10-425 of the ICDD database). Furthermore one sees weak α-Al 2 O 3 (024) and (116) peaks (52.559° and 57.504°, respectively, in PDF no. 42-1468 of the ICDD database). Figure 2 shows an enlarged part of the 2theta range and here the α-Al 2 O 3 (024) and (116) peaks are clearly seen.

[0078] A GIXRD measurement in the 2theta range 20 to 70° of inventive example no. 1 was made under an angle of 0.2° of a 2f rotated rake face and is shown in Figure 3. Solid lines mark positions for α-Al 2 O 3 according to PDF no. 42-1468 of the ICDD database. γ-Al 2 O 3 peaks are also seen at positions according to PDF no. 10-425 but are not marked in the diffractogram. The smaller angle used in this GIXRD measurement gives a somewhat even more distinct caption of the γ-Al 2 O 3 (400) peak (45.863°) but here the 2theta range has been extended so that also the γ-Al 2 O 3 (440) peak is clearly seen (67.034° in PDF no. 10-425 of the ICDD database).

[0079] The conclusion of GIXRD of a 2f-rotated rake face of inventive example no.1 from Figures 1-3 is that the aluminium oxide layer contains α-Al 2 O 3 in a mixture with γ-Al 2 O 3 and the γ-phase dominates.

[0080] A GIXRD measurement in the 2theta range 35 to 62° of inventive example no. 1 was made under an angle of 0.5° of a 3f rotated flank and is shown in Figure 4. Solid lines mark positions for α-Al 2 O 3 and dashed lines mark positions for γ-Al 2 O 3 , according to PDF no. 42-1468 and PDF no. 10-425 of the ICDD database. The XRD diffractogram shows clearly a γ-Al 2 O 3 (400) peak (45.863°) and also a weak γ-Al 2 O 3 (222) peak (39.492° in PDF no. 10-425 of the ICDD database). Furthermore one sees strong α-Al 2 O 3 (113) and (024) peaks (43.363° and 52.559°, respectively, in PDF no. 42-1468 of the ICDD database).

[0081] The conclusion of GIXRD of a 3f-rotated flank face of inventive example no.1 from Figure 4 is that the aluminium oxide layer contains a high amount of α-Al 2 O 3 in a mixture with γ-Al 2 O 3 .

[0082] From Figure 4 it is also concluded that in the GIXRD measurements of inventive example 1 under an angle of 0.5° of a 3f rotated flank face show that the ratio l(α-Al 2 O 3 (113)) to l(γ-Al 2 O 3 (400)) is about 1.4, the ratio l(α-Al 2 O 3 (024)) to l(γ-Al 2 O 3 (400)) is about 0.6 and the ratio l(α-Al 2 O 3 (116)) to l(γ-Al 2 O 3 (400)) is about 0.3.Example 9 (comparison):

[0083] On a WC-Co based cemented carbide substrate, having a Co content of 8 wt% and balance WC, an aluminium oxide coating was deposited in a Hauzer HTC1000 equipment using dual magnetron sputtering (DMS) 20 kW. The further process conditions were: Al target with size 830 mm x 170 mm, approx. 0.47 Pa Ar, target voltage control mode 480 V, DMS coil current 6.5 A, bias current 28.6 A

[0084] In 2f and 3f rotating mode an aluminium oxide coating having a thickness of approx. 1,2 µm was made. The hardness was 2792 HV and the red. Young's modulus was 340 GPa.

[0085] Only γ-Al 2 O 3 peaks in XRD analysis were seen.

Claims

1. A method for producing a coated cutting tool having at least one rake face and at least one flank face, the cutting tool comprising a substrate of cemented carbide, cermet, cBN, or ceramic and a coating, the coated cutting tool is in the form of an insert, a drill or an endmill comprising an Al2O3 layer, the Al2O3 layer comprises α-Al2O3, wherein α-Al2O3 is present in the Al2O3 layer on every rake face and flank face of the cutting tool, wherein the Al2O3 layer in GIXRD (gracing incidence x-ray diffraction) analysis at 0.5° incidence angle in an 2theta diffractogram, using CuKalpha-radiation, on at least one of the rake face or flank face of the cutting tool, shows: a ratio l(α-Al2O3 (113)) to l(γ-Al2O3 (400)) in an XRD 2theta diffractogram being ≥ 0.5, preferably ≥ 1, most preferably ≥ 2, and / or a ratio l(α-Al2O3 (024)) to l(γ-Al2O3 (400)) in an XRD 2theta diffractogram being ≥ 0.2, preferably ≥ 0.5, most preferably ≥ 1, and / or a ratio l(α-Al2O3 (116)) to l(γ-Al2O3 (400)) in an XRD 2theta diffractogram being ≥ 0.1, preferably ≥ 0.2, most preferably ≥ 0.5, in the GIXRD analysis peaks of α-Al2O3 (113), α-Al2O3 (024) and α-Al2O3 (116) in the diffractogram are, according to PDF no. 42-1468 of the ICDD database, positioned at 43.363 degrees, 52.559 degrees and 57.504 degrees 2theta, respectively, and a peak of γ-Al2O3 (400) in the diffractogram is, according to PDF no. 10-425 of the ICDD database, positioned at 45.863 degrees 2theta, the method comprises depositing on every flank face and every rake face of the cutting tool an Al2O3 layer by a HIPIMS process, in the process the peak pulse cathode power is ≥ 500 kW, the value of negative peak pulse voltage is ≥ 1200 V, the specific target peak pulse power density is ≥ 350 W / cm2, the specific average target power density is ≥ 6 W / cm2, the pulse time is 20-150 µs, the pulse frequency is ≥ 100 Hz, the peak pulse current is ≥ 400 A, there is either a pulsed bias, or DC bias, voltage applied of from 150 to 300 V, negative bias, the peak bias current is ≥ 100 A and ≤ 800 A, the specific bias current density is 5 - 80 mA / cm2, the oxygen partial pressure is ≥ 1x10-4 mbar, the total pressure is from 0.25 to 3 Pa, the method comprising the following steps: - charging a PVD reactor chamber, containing at least one Al target and a rotatable substrate holder, with cutting tool blanks, the target size is from 500 to 3000 cm2, - depositing an Al2O3 layer in the HIPIMS process during two-fold or three-fold rotation of the substrates, at a substrate temperature ≥ 350°C but < 600°C, the deposited Al2O3 layer comprises α-Al2O3.

2. A method according to claim 1, wherein the substrate temperature during the deposition in the HIPIMS process is ≥ 400°C but ≤ 580°C.

3. A method according to any one of claims 1-2, wherein in the HIPIMS process the pulse time is from 30 to 100 µs.

4. A method according to any one of1 claims 1-3, wherein in the HIPIMS process the peak pulse cathode power is ≥ 1 MW.

5. A method according to any one of claims 1-4, wherein in the HIPIMS process the specific target peak pulse current density is ≥ 0.25 A / cm2.

6. A method according to any one of claims 1-5, wherein in the HIPIMS process the specific target peak pulse power density is ≥ 650 W / cm2.

7. A method according to any one of claims 1-6, wherein in the HIPIMS process the specific bias current density is 10 - 40 mA / cm2.

8. A method according to any one of claims 1-7, wherein the deposited Al2O3 layer contains a mixture of α-Al2O3 and γ-Al2O3.

9. A coated cutting tool in the form of an insert, a drill or an endmill having at least one rake face and at least one flank face, comprising an Al2O3 layer deposited according to the method according to any one of claims 1-8, the deposited Al2O3 layer comprises α-Al2O3, wherein α-Al2O3 is present in the deposited Al2O3 layer on every rake face and flank face of the cutting tool, wherein the Al2O3 layer in GIXRD (gracing incidence x-ray diffraction) analysis at 0.5° incidence angle in an 2theta diffractomgram, using CuKalpha-radiation, on at least one of the rake face or flank face of a cutting tool, shows: a ratio I(α-Al2O3 (113)) to l(γ-Al2O3 (400)) in an XRD 2theta diffractogram being ≥ 0.5, preferably ≥ 1, most preferably ≥ 2, and / or a ratio l(α-Al2O3 (024)) to I(γ-Al2O3 (400)) in an XRD 2theta diffractogram being ≥ 0.2, preferably ≥ 0.5, most preferably ≥ 1, and / or a ratio l(α-Al2O3 (116)) to l(γ-Al2O3 (400)) in an XRD 2theta diffractogram being ≥ 0.1, preferably ≥ 0.2, most preferably ≥ 0.5, in the GIXRD analysis peaks of α-Al2O3 (113), α-Al2O3 (024) and α-Al2O3 (116) in the diffractogram are, according to PDF no. 42-1468 of the ICDD database, positioned at 43.363 degrees, 52.559 degrees and 57.504 degrees 2theta, respectively, and a peak of γ-Al2O3 (400) in the diffractogram is, according to PDF no. 10-425 of the ICDD database, positioned at 45.863 degrees 2theta.

10. A coated cutting tool according to claim 9, wherein the Al2O3 layer has a Vickers hardness of ≥ 2000 HV.

11. A coated cutting tool according to any one of claims 9-10, wherein the Al2O3 layer has a reduced Young's modulus of ≥ 320 GPa.