Chlorine-Graded TiCN Al2O3 Coating for Wear-Resistant Cutting Tools
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Solution Overview
Problem
Existing coated tools and cutting tools face challenges in achieving high wear and fracture resistance, particularly at low speeds below 150 m/min, and are costly due to the need for ion implantation processes that result in uneven chlorine distribution across the coating layers.
Innovation Solution
A coated tool configuration with a base and a coating layer comprising a first TiCN layer, a second Al2O3 layer, and a third TiN or TiCN layer, where the chlorine content in the first and third layers is higher than in the second layer, enhancing both wear and fracture resistance across a range of machining speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ion implantation is used to achieve high wear resistance, then wear resistance is improved, but device complexity and manufacturing cost increase due to requiring specialized apparatus and processes
Solution Approach 1:
The patent extracts the essential function of ion implantation (introducing chlorine into the coating layer) and achieves it through a simpler CVD process parameter optimization approach, eliminating the need for complex ion implantation apparatus while maintaining wear resistance improvement
Solution Approach 2:
The patent changes the deposition parameters during CVD coating formation to achieve appropriate chlorine content distribution in the coating layer, replacing the need for post-deposition ion implantation processing with controlled parameter adjustments during the coating deposition itself
2Reliability
If ion implantation is used to achieve high wear resistance, then wear resistance is improved, but manufacturing cost increases due to additional processing steps
Solution Approach 1:
The patent merges the coating deposition process with the chlorine introduction function by optimizing CVD parameters, combining what were previously separate processes (coating deposition and ion implantation) into a single integrated coating process, thereby reducing manufacturing cost
Solution Approach 2:
The patent removes the costly ion implantation processing step from the manufacturing sequence while achieving the same functional outcome (appropriate chlorine content for wear resistance) through simplified CVD parameter control
3Reliability
If ion implantation is used to achieve high wear resistance, then wear resistance at high speed is improved, but wear resistance deteriorates at speeds lower than 150 m/min
Solution Approach 1:
The patent creates local quality variations within the coating layer by controlling chlorine content distribution through deposition parameters, achieving optimal wear resistance characteristics that adapt to different machining speed conditions without requiring high-speed specific optimization
Solution Approach 2:
The patent adjusts deposition parameters to achieve appropriate chlorine content and distribution in the coating layer, creating a coating structure that provides balanced wear resistance performance across both high-speed and low-speed machining conditions
4Reliability
If chlorine concentration is high at the surface during ion implantation, then surface wear resistance is improved, but fracture resistance deteriorates due to low chlorine content at the base
Solution Approach 1:
The patent applies local quality principle by creating a chlorine content gradient within the coating layer through controlled deposition, where chlorine content varies at different depths to simultaneously provide surface wear resistance and base fracture resistance
Solution Approach 2:
The patent creates a composite coating structure with varying chlorine content distribution, combining regions with different chlorine concentrations to achieve both surface wear resistance (higher chlorine) and base fracture resistance (lower chlorine), effectively creating a functionally graded material
Data Source
AI summary
A coated tool includes a base and a coating layer. The coating layer includes a first layer including TiCN, a second layer including Al2O3, and a third layer including at least one of TiN and TiCN. Cl content included in the first, second and third layers is first, second and third Cl content. Each of the first Cl content and the third Cl content is larger than the second Cl content. The first Cl content is more than 0.2 atomic % and not more than 2 atomic %. The third Cl content is more than 0.2 atomic % and not more than 2 atomic %. A cutting tool of the present disclosure includes a holder which has a length from a first end to a second end and includes a pocket on a side of the first end; and the coated tool located in the pocket.