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US5328761A
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Diamond-coated hard material, throwaway insert and a process for the production thereof
Assignee: Sumitomo Electric Industries Ltd
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Filing: 1991-10-04
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Granted: 1994-07-12
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Expires: 2011-10-04
Abstract
Abstract PCT No. PCT/JP91/01359 Sec. 371 Date Jul. 14, 1992 Sec. 102(e) Date Jul. 14, 1992 PCT Filed Oct. 4, 1991 PCT Pub. No. WO92/05904 PCT Pub. Date Apr. 16, 1992.An object of the present invention is to provide a diamond-coated hard material having a high bonding strength to a substrate and a diamond-coated throwaway insert capable of cutting various light alloys such as Al-Si alloys at a high cutting rate for a long time. This object can effectively be attained by a diamond-coated hard material comprising a sintered body consisting of Si3N4 as a predominant component, at least a part of the sintered body having a sintered surface at least a part of which is coated with diamond and a diamond-coated throwaway insert having a diamond- or diamond-like carbon-coated layer with a thickness of 0.1 to 200 mu m, deposited from gaseous phase, on the surface of a substrate consisting of Si3N4, as a predominant component, in which the surface state of the substrate is maintained as sintered and a part or whole of the sintered surface is coated with the diamond- or diamond-like carbon-coated layer.
Inventors
- 👤 Naoya Omori
- 👤 Toshio Nomura
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 20:03
CPC Classifications
C; C04; C04B; C04B41/00; C04B41/009; B; B23; B23B; B23B27/00; B23B27/14; B23B27/141; B23B27/148; B23B51/00; B23B51/0002; B23B51/0003; B23B51/00035; B23B51/02; C04B41/45; C04B41/50; C04B41/5001; C04B41/5002; C04B41/80; C04B41/81; C04B41/85; C23; C23C; C23C16/00; C23C16/02; C23C16/0227; C23C16/0272; C23C16/22; C23C16/26; C23C16/27; C23C16/271; C23C16/274; B23B2200/00; B23B2200/08; B23B2200/081; B23B2251/00; B23B2251/02; B23B2251/48; B23B2251/50; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24355; Y10T428/24479; Y10T428/26; Y10T428/263; Y10T428/264; Y10T428/265; Y10T428/30
Claims Analysis
Total Claims: 21
Claim 1
Independent Claim
40 words
A diamond-coated hard material comprising a sintered body consisting of Si 3 N 4 as a predominant component, at least a part of the sintered body having a sintered surface at least a part of which is coated with diamond.
Claim 2
Dependent Claim
40 words
A diamond-coated hard material comprising a sintered body consisting of Si 3 N 4 as a predominant component, at least a part of the sintered body having a sintered surface at least a part of which is coated with diamond.
Claim 3
Dependent Claim
107 words
A diamond-coated hard material having a diamond-coated layer formed on the surface of a hard material consisting of Si 3 N 4 as a predominant component, in which: (1) microscopic roughness is present on the surface of the substrate, (2) at least one protrusive part is present in the standard length of 10 μm in a diamond-coated layer and substrate interface, (3) the ratio of sum A of the lengths of dent parts to sum B of the lengths of the protrusive parts is in the range of 0.05≦A/B≦20 in the standard length in the interface, and (4) the protrusive parts are intruded into the diamond-coated layer.
Claim 4
Dependent Claim
107 words
A diamond-coated hard material having a diamond-coated layer formed on the surface of a hard material consisting of Si 3 N 4 as a predominant component, in which: (1) microscopic roughness is present on the surface of the substrate, (2) at least one protrusive part is present in the standard length of 10 μm in a diamond-coated layer and substrate interface, (3) the ratio of sum A of the lengths of dent parts to sum B of the lengths of the protrusive parts is in the range of 0.05≦A/B≦20 in the standard length in the interface, and (4) the protrusive parts are intruded into the diamond-coated layer.
Claim 5
Dependent Claim
76 words
A diamond-coated hard material having a diamond- and/or diamond-like carbon-coated layer formed on the surface of a hard material consisting of Si 3 N 4 as a predominant component, in which: (1) microscopic roughness is present on the surface of the substrate and (2) the protrusive parts are defined by a surface roughness represented by an Rmax of 1.5 to 30 μm in the standard length of 50 μm in the diamond-coated layer and substrate interface.
Claim 6
Dependent Claim
76 words
A diamond-coated hard material having a diamond- and/or diamond-like carbon-coated layer formed on the surface of a hard material consisting of Si 3 N 4 as a predominant component, in which: (1) microscopic roughness is present on the surface of the substrate and (2) the protrusive parts are defined by a surface roughness represented by an Rmax of 1.5 to 30 μm in the standard length of 50 μm in the diamond-coated layer and substrate interface.
Claim 7
Dependent Claim
29 words
The diamond- or diamond-like carbon-coated hard material as claimed in claim 2 or 3, wherein the protrusive parts are intruded into the diamond-coated layer by at least 0.2 μm.
Claim 8
Dependent Claim
32 words
The diamond- or diamond-like carbon-coated hard material as claimed in any of claims 2 to 4, wherein the protrusive parts are composed of silicon nitride crystals and/or silicon nitride-containing crystals and/or sialon.
Claim 9
Dependent Claim
69 words
A diamond-coated throwaway insert having a diamond- or diamond-like carbon-coated layer with a thickness of 0.1 to 200 μm, deposited from gaseous phase, on the surface of a substrate consisting of Si 3 N 4 as a predominant component, in which the surface state of the substrate is maintained as sintered and a part or whole of the sintered surface is coated with the diamond- or diamond-like carbon-coated layer.
Claim 10
Dependent Claim
69 words
A diamond-coated throwaway insert having a diamond- or diamond-like carbon-coated layer with a thickness of 0.1 to 200 μm, deposited from gaseous phase, on the surface of a substrate consisting of Si 3 N 4 as a predominant component, in which the surface state of the substrate is maintained as sintered and a part or whole of the sintered surface is coated with the diamond- or diamond-like carbon-coated layer.
Claim 11
Dependent Claim
69 words
The diamond-coated throwaway insert as claimed in claim 6, in which at least a part or whole of each of the rake face and flank face of the insert is coated with the diamond- or diamond-like carbon-coated layer in such a manner that only the upper and lower surfaces of the sintered throwaway insert substrate or the rake face is ground and the flank face is maintained as sintered.
Claim 12
Dependent Claim
75 words
The diamond-coated throwaway insert as claimed in claim 6, in which a part or whole of each of the edge-treated surface, the rake face and flank face of the insert is coated with the diamond- or diamond-like carbon-coated layer in such a manner that the sintered throwaway insert substrate is subjected to an edge treatment, only the upper and lower surfaces or the rake face is ground and the flank face is maintained as sintered.
Claim 13
Dependent Claim
72 words
The diamond-coated throwaway insert as claimed in claim 6, in which a part or whole of each of the edge-treated surface, the rake face and flank face of the insert is coated with the diamond- or diamond-like carbon-coated layer in such a manner that the sintered throwaway insert substrate is subjected to an edge treatment, the upper and lower surfaces or the rake face and the flank face are maintained as sintered.
Claim 14
Dependent Claim
77 words
The diamond-coated throwaway insert as claimed in claim 6, in which a part or whole of the sintered throwaway insert substrate is ground and optionally subjected to an edge treatment, and is then subjected to a heat treatment to maintain the whole surface of the insert as heat-treated, and a part or whole of each of the edge-treated surface, the rake face and flank face of the insert is coated with the diamond- or diamond-like carbon-coated layer.
Claim 15
Dependent Claim
87 words
The diamond-coated throwaway insert as claimed in claim 6, in which a part or whole of the sintered throwaway insert substrate is ground and optionally subjected to an edge treatment, and is again subjected to a heat treatment to maintain the whole surface of the insert as heat-treated, and after grinding a partial or whole surface of the insert, a part or whole of each of the edge-treated surface, the rake face and flank face of the insert is coated with the diamond- or diamond-like carbon-coated layer.
Claim 16
Dependent Claim
41 words
The diamond-coated hard material or diamond-coated throwaway insert as claimed in anyone of claims 1 to 11, wherein a freely grown columnar or hexagonal pillar crystal structure of Si 3 N 4 is present on the surface of the insert substrate.
Claim 17
Dependent Claim
33 words
The diamond-coated hard material or diamond-coated throwaway insert as claimed in claim 12, wherein the Si 3 N 4 columnar or hexagonal pillar crystal has a mean major axis/minor axis ratio of 1.5.
Claim 18
Dependent Claim
39 words
The diamond-coated hard material or diamond-coated throwaway insert as claimed in claim 12, wherein at least a part of the Si 3 N 4 columnar or hexagonal pillar crystal has a mean major axis of at least 2 μm.
Claim 19
Dependent Claim
118 words
A process for the production of a diamond-coated throwaway insert, which comprises sintering a mixed powder to be a substrate, comprising Si 3 N 4 powder containing at least 50 % of a Si 3 N 4 , as a predominant component, and 1 to 50 wt % of at least one sintering assistant selected from the group consisting of Al 2 O 3 , Y 2 O 3 MgO AlN and SiO 2 at a temperature of 1,600° to 2,000° C. in a gaseous N 2 atmosphere for 30 minutes to 5 hours, converting at least the rake face thereof into a sintered surface or heat-treated surface and then coating at least the rake face with diamond.
Claim 20
Dependent Claim
118 words
A process for the production of a diamond-coated throwaway insert, which comprises sintering a mixed powder to be a substrate, comprising Si 3 N 4 powder containing at least 50 % of a Si 3 N 4 , as a predominant component, and 1 to 50 wt % of at least one sintering assistant selected from the group consisting of Al 2 O 3 , Y 2 O 3 MgO AlN and SiO 2 at a temperature of 1,600° to 2,000° C. in a gaseous N 2 atmosphere for 30 minutes to 5 hours, converting at least the rake face thereof into a sintered surface or heat-treated surface and then coating at least the rake face with diamond.
Claim 21
Dependent Claim
57 words
The process for the production of a diamond-coated throwaway insert, as claimed in claim 15, wherein the heat-treated surface is obtained by grinding the silicon nitride sintered body and then subjecting to a heat treatment at a temperature of 1,300° to 2,000° C. in N 2 gas or an inert gas atmosphere of 1 to 3,000 atm.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1997-07-11 | 1998-01-10 | 1998-07-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2001-07-11 | 2002-01-10 | 2002-07-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2005-07-11 | 2006-01-10 | 2006-07-12 | $7700.00 | Window Closed / Lapsed |