Multilayer Cubic Coating for Impact-Resistant Cutting Tools
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Solution Overview
Problem
Existing coated tools lack sufficient impact resistance, which limits their effectiveness in cutting processes.
Innovation Solution
A coated tool with a base body made of cemented carbide or cermet, featuring a coating layer composed of cubic crystals from Groups 4a, 5a, and 6a elements, Al, and Si, along with C and N, optimized for high adhesion and durability through an intermediate layer and a striped structure of AlCrSiN and TiSiN layers, enhancing crystal orientability and reducing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coating layer is applied to improve wear resistance, then wear resistance is improved, but impact resistance deteriorates
Solution Approach 1:
The patent changes the crystal orientation parameters of the coating layer by controlling the deposition process to achieve a specific texture where the (200) plane is predominant. This parameter change in crystal structure maintains the hardness and wear resistance while improving impact resistance through the specific orientation arrangement that allows better stress distribution
Solution Approach 2:
The patent creates a composite coating structure with multiple layers having different compositions and crystal orientations. The coating includes layers with varying ratios of metal elements (Ti, Al, Si, Cr) and nitrogen, forming a multi-phase composite material that combines the wear resistance of hard phases with the toughness of metallic bonds, thereby achieving both wear resistance and impact resistance
2Duration of action of stationary object
If a coating layer is applied to improve durability, then durability is improved, but adhesion to base body deteriorates
Solution Approach 1:
The patent optimizes the compositional parameters of the coating layers, specifically controlling the atomic ratios of metal elements (Ti: 30-70 at%, Al: 5-40 at%, Si: 5-40 at%, Cr: 0-20 at%) and nitrogen content. These parameter changes create a coating with enhanced adhesion properties while maintaining durability, by balancing the hardness and bonding characteristics through precise compositional control
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The tool exhibits improved impact resistance and durability, capable of withstanding impacts from various directions without chipping or damage, as demonstrated by increased resistance to impacts during cutting tests.
Implementation Method 1
The coating layer contains a cubic crystal composed of at least one element selected from Groups 4a, 5a and 6a elements in the periodic table, Al and Si, and at least one element selected from C and N
Implementation Method 2
The coating layer has a maximum value of X-ray intensity (I1max) in a measurement range of an α-axis angle of 0° or greater and 90° or less on an X-ray intensity distribution of an α-axis of a positive pole figure related to a (111) plane of the cubic crystal
Data Source
AI summary
A coated tool according to an aspect of the present disclosure includes a base body, and a coating layer of at least one layer located on the base body. The coating layer contains a cubic crystal composed of at least one element selected from Groups 4a, 5a and 6a elements in the periodic table, Al and Si, and at least one element selected from C and N. The coating layer has a maximum value (I1max) of an X-ray intensity in a measurement range of 0° or greater and 90° or less on an X-ray intensity distribution of an α-axis of a positive pole figure related to a (111) plane of the cubic crystal, and an angle region (θ1F) having an X-ray intensity of 85% or more of I1max occupies 90% or more in a region of 30° or greater and 90° or less.