AlTi Multilayer Coating Structure for Wear and Joinability
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Solution Overview
Problem
Existing coated tools for cutting processes face a challenge in balancing wear resistance and joinability, as increasing the thickness of one phase to enhance wear resistance compromises joinability, and vice versa.
Innovation Solution
A coated tool with a coating layer configuration where first AlTi layers and second AlTi layers are alternately laminated, with varying thicknesses such that the ratio of the second AlTi layer to the first AlTi layer is higher away from the base member for improved wear resistance, and the ratio of the first AlTi layer to the second AlTi layer is higher closer to the base member for enhanced joinability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the first phase (Ti1-x1Alx1N) is increased to enhance wear resistance, then wear resistance is improved, but joinability between the base member and the coating layer is lowered
Solution Approach 1:
The patent applies local quality by creating a coating layer where the thickness of the first AlTi layer varies at different locations. Specifically, the first AlTi layer has a greater thickness closer to the base member and a smaller thickness farther from the base member. This gradient thickness distribution allows the region closer to the base member to provide strong joinability, while the overall coating structure maintains wear resistance, thus resolving the contradiction between wear resistance and joinability.
2Reliability
If the thickness of the second phase (Alx2Ti1-x2N) is increased to enhance joinability, then joinability is improved, but wear resistance of the coating layer is lowered
Solution Approach 1:
The patent applies local quality by creating a coating layer where the thickness of the second AlTi layer varies at different locations. Specifically, the second AlTi layer has a smaller thickness closer to the base member and a greater thickness farther from the base member. This gradient thickness distribution allows the region farther from the base member to provide wear resistance, while the overall coating structure maintains joinability, thus resolving the contradiction between wear resistance and joinability.
Data Source
AI summary
A coated tool may include a base member and a coating layer. The coating layer may include a plurality of first AlTi layers indicated by Al1-x1Tix1 and a plurality of second AlTi layers indicated by Al1-x2Tix2. The coating layer may have alternating first AlTi layers and second AlTi layers, i.e. one upon another in a direction away from the base member, and x1 may be larger than x2. The plurality of first AlTi layers may include a first region having two or more adjacent first AlTi layers, where a first AlTi layer of the two or more adjacent first AlTi layers is located farther away from the base member and is smaller in thickness than a first AlTi layer of the two or more adjacent first AlTi layers located closer to the base member.