Alternating Coated Tool Layers for Wear and Fracture Resistance

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Solution Overview

Problem

There is a need to enhance the wear resistance and fracture resistance of coating layers in coated tools, as existing technologies do not adequately address these requirements.

Innovation Solution

A coated tool with a base member and a coating layer featuring an alternating layer structure, where the first layers contain (TibNbdMe)CxN1-x and the second layers contain M′N, with specific composition ranges and thicknesses, providing high hardness, oxidation resistance, and toughness, and are laminated alternately to achieve improved wear and fracture resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single-layer coating or simple multi-layer coating is used, then the manufacturing process is simple, but the wear resistance and fracture resistance are insufficient

Engineering Contradiction:

Improvewear resistance and fracture resistanceVSAvoidcoating layer structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The coating layer is segmented into multiple alternating layers with different compositions and properties. The coating includes a first alternating layer with (Ti,Nb)AlN and (Ti,Nb)SiN phases, and a second alternating layer with TiAlN and TiSiN phases, creating a multi-layered structure that provides both wear resistance and fracture resistance through the complementary properties of each layer

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The coating layer uses composite materials with specific phase compositions. Each alternating layer contains a composite structure of nitride phases ((Ti,Nb)AlN and (Ti,Nb)SiN in the first layer, TiAlN and TiSiN in the second layer) with controlled ratios, creating a composite coating that combines the advantages of different materials to achieve both hardness and toughness

Inventive Principle:

Principle #40Composite materials

2Reliability

If harder coating materials are used to improve wear resistance, then wear resistance increases, but fracture resistance decreases

Engineering Contradiction:

Improvewear resistanceVSAvoidfracture resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

Different regions of the coating layer have different local qualities tailored to specific functions. The first alternating layer with (Ti,Nb)AlN and (Ti,Nb)SiN phases provides a balance of properties, while the second alternating layer with TiAlN and TiSiN phases provides complementary properties. This local differentiation allows the coating to exhibit both high wear resistance and high fracture resistance overall

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The coating layer utilizes parameter changes in material composition and phase ratios. By controlling the Al/Si ratio between 0.3-0.7 and the Nb content between 1-10 atom%, the coating achieves optimal balance between hardness (for wear resistance) and toughness (for fracture resistance). The alternating layer structure further modulates these parameters to achieve both properties simultaneously

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11224920B2Coated tool

Publication Date: 2022.01.18 KYOCERA CORP

AI summary

A coated tool may include a base member and a coating layer located on the base member. The coating layer may include an alternating layer having first layers and second layers. The first layers may contain (TibNbdMe)CxN1-x (where M is one or more kinds selected from metals of Groups 4, 5 and 6 in the periodic table except for Ti and Nb, and Al, 0.2≤b≤0.8, 0.01≤d≤0.2, 0≤e≤0.7, b+d+e=1 and 0<x<1). The second layers may contain M′N (where M′ is metal of Groups 4, 5 and 6 in the periodic table except for Nb).