US5374471A — Multilayer coated hard alloy cutting tool

Claim 1

Independent Claim 181 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (a) a primary layer consisting of a TiCN layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said primary layer is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(c) are deposited by chemical vapor deposition.

Claim 2

Dependent Claim 181 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (a) a primary layer consisting of a TiCN layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said primary layer is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(c) are deposited by chemical vapor deposition.

Claim 3

Dependent Claim 58 words

A coated hard alloy cutting tool as claimed in claim 1, wherein a surface region within a distance of 100 μm to 400 μm from said external surface is substantially free of free carbon particles, while free carbon particles are present in a region of said core located beyond 100-400 μm from said external surface of said substrate.

Claim 4

Dependent Claim 45 words

A coated hard alloy cutting tool as claimed in claim 1, wherein the Co content in a region of said core located beyond about a depth of 100 μm from said external surface of said substrate is within the range of from 4-8% by weight.

Claim 5

Dependent Claim 50 words

A coated hard alloy cutting tool as claimed in claim 1, wherein said substrate is provided with rake surfaces and flank surfaces, wherein the tensile residual stresses in said primary layer on said rake surfaces are not greater than tensile residual stresses in said primary layer on said flank surfaces.

Claim 6

Dependent Claim 219 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (a) a primary layer consisting of a TiCN layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said substrate is formed with rake surfaces and flank surfaces; wherein said primary layer on said rake surfaces is treated to produce compressive residual stresses of not more than 20 Kg/mm 2 ; wherein said primary layer on said flank surfaces is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(c) are deposited by chemical vapor deposition.

Claim 7

Dependent Claim 219 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (a) a primary layer consisting of a TiCN layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said substrate is formed with rake surfaces and flank surfaces; wherein said primary layer on said rake surfaces is treated to produce compressive residual stresses of not more than 20 Kg/mm 2 ; wherein said primary layer on said flank surfaces is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(c) are deposited by chemical vapor deposition.

Claim 8

Dependent Claim 191 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (d) a first intermediate layer consisting of a TiN layer; (a) a primary layer consisting of a TiCN layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said primary layer is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(d) are deposited by chemical vapor deposition.

Claim 9

Dependent Claim 191 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (d) a first intermediate layer consisting of a TiN layer; (a) a primary layer consisting of a TiCN layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said primary layer is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(d) are deposited by chemical vapor deposition.

Claim 10

Dependent Claim 58 words

A coated hard alloy cutting tool as claimed in claim 6, wherein a surface region within a distance of 100 μm to 400 μm from said external surface is substantially free of free carbon particles, while free carbon particles are present in a region of said core located beyond 100-400 μm from said external surface of said substrate.

Claim 11

Dependent Claim 25 words

A coated hard alloy cutting tool as claimed in claim 6, wherein the thickness of said first intermediate layer is not more than 1 μm.

Claim 12

Dependent Claim 43 words

A coated hard alloy cutting tool as claimed in claim 6, wherein the Co content in a region of said core located beyond about 100 μm depth from said external surface of said substrate is within the range of from 4-8% by weight.

Claim 13

Dependent Claim 53 words

A coated hard alloy cutting tool as claimed in claim 6, wherein said substrate is provided with rake surfaces and flank surfaces, and wherein said primary layer on said rake surfaces is provided with tensile residual stresses which are not greater than tensile residual stresses in said primary layer on said flank surfaces.

Claim 14

Dependent Claim 229 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (d) a first intermediate layer consisting of a TiN layer; (a) a primary layer consisting of a TiCN layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said substrate is formed with rake surfaces and flank surfaces; wherein said primary layer on said rake surfaces is treated to produce compressive residual stresses of not more than 20 Kg/mm 2 ; wherein said primary layer on said flank surfaces is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(d) are deposited by chemical vapor deposition.

Claim 15

Dependent Claim 229 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (d) a first intermediate layer consisting of a TiN layer; (a) a primary layer consisting of a TiCN layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said substrate is formed with rake surfaces and flank surfaces; wherein said primary layer on said rake surfaces is treated to produce compressive residual stresses of not more than 20 Kg/mm 2 ; wherein said primary layer on said flank surfaces is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(d) are deposited by chemical vapor deposition.

Claim 16

Dependent Claim 210 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (a) a primary layer consisting of a TiCN layer; (e) a second intermediate layer consisting of at least one layer selected from the group consisting of a TiC layer, a TiCO layer and a TiCNO layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said primary layer is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(c) and (e) are deposited by chemical vapor deposition.

Claim 17

Dependent Claim 210 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (a) a primary layer consisting of a TiCN layer; (e) a second intermediate layer consisting of at least one layer selected from the group consisting of a TiC layer, a TiCO layer and a TiCNO layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said primary layer is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(c) and (e) are deposited by chemical vapor deposition.

Claim 18

Dependent Claim 58 words

A coated hard alloy cutting tool as claimed in claim 12, wherein a surface region within a distance of 100 μm to 400 μm from said external surface is substantially free of free carbon particles, while free carbon particles are present in a region of said core located beyond 100-400 μm from said external surface of said substrate.

Claim 19

Dependent Claim 33 words

A coated hard alloy cutting tool as claimed in claim 12, wherein the thickness of said second intermediate layer of a TiCO layer or a TiCNO layer is not more than 1 μm.

Claim 20

Dependent Claim 43 words

A coated hard alloy cutting tool as claimed in claim 12, wherein the Co content in a region of said core located beyond about 100 μm depth from said external surface of said substrate is within the range of from 4-8% by weight.

Claim 21

Dependent Claim 52 words

A coated hard alloy cutting tool as claimed in claim 12, wherein said substrate is provided with rake surfaces and flank surfaces, wherein said primary layer on said rake surfaces is provided with tensile residual stresses which are not greater than tensile residual stresses in said primary layer on said flank surfaces.

Claim 22

Dependent Claim 248 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (a) a primary layer consisting of a TiCN layer; (e) a second intermediate layer consisting of at least one layer selected from the group consisting of a TiC layer, a TiCO layer and a TiCNO layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said substrate is formed with rake surfaces and flank surfaces; wherein said primary layer on said rake surfaces is treated to produce compressive residual stresses of not more than 20 Kg/mm 2 ; wherein said primary layer on said flank surfaces is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(c) and (e) are deposited by chemical vapor deposition.

Claim 23

Dependent Claim 248 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (a) a primary layer consisting of a TiCN layer; (e) a second intermediate layer consisting of at least one layer selected from the group consisting of a TiC layer, a TiCO layer and a TiCNO layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said substrate is formed with rake surfaces and flank surfaces; wherein said primary layer on said rake surfaces is treated to produce compressive residual stresses of not more than 20 Kg/mm 2 ; wherein said primary layer on said flank surfaces is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(c) and (e) are deposited by chemical vapor deposition.

Claim 24

Dependent Claim 218 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (d) a first intermediate layer consisting of a TiN layer; (a) a primary layer consisting of a TiCN layer; (e) a second intermediate layer consisting of at least one layer selected from the group consisting of a TiC layer, a TiCO layer and a TiCNO layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said primary layer is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(e) are deposited by chemical vapor deposition.

Claim 25

Dependent Claim 218 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (d) a first intermediate layer consisting of a TiN layer; (a) a primary layer consisting of a TiCN layer; (e) a second intermediate layer consisting of at least one layer selected from the group consisting of a TiC layer, a TiCO layer and a TiCNO layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said primary layer is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(e) are deposited by chemical vapor deposition.

Claim 26

Dependent Claim 58 words

A coated hard alloy cutting tool as claimed in claim 18, wherein a surface region within a distance of 100 μm to 400 μm from said external surface is substantially free of free carbon particles, while free carbon particles are present in a region of said core located beyond 100-400 μm from said external surface of said substrate.

Claim 27

Dependent Claim 25 words

A coated hard alloy cutting tool as claimed in claim 18, wherein the thickness of said first intermediate layer is not more than 1 μm.

Claim 28

Dependent Claim 33 words

A coated hard alloy cutting tool as claimed in claim 18, wherein the thickness of said second intermediate layer of a TiCO layer or a TiCNO layer is not more than 1 μm.

Claim 29

Dependent Claim 43 words

A coated hard alloy cutting tool as claimed in claim 18, wherein the Co content in a region of said core located beyond about 100 μm depth from said external surface of said substrate is within the range of from 4-8% by weight.

Claim 30

Dependent Claim 53 words

A coated hard alloy cutting tool as claimed in claim 18, wherein said substrate is provided with rake surfaces and flank surfaces, and wherein said primary layer on said rake surfaces is provided with tensile residual stresses which are not greater than tensile residual stresses in said primary layer on said flank surfaces.

Claim 31

Dependent Claim 256 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (d) a first intermediate layer consisting of a TiN layer; (a) a primary layer consisting of a TiCN layer; (e) a second intermediate layer consisting of at least one layer selected from the group consisting of a TiC layer, a TiCO layer and a TiCNO layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said substrate is formed with rake surfaces and flank surfaces; wherein said primary layer on said rake surfaces is treated to produce compressive residual stresses of not more than 20 Kg/mm 2 ; wherein said primary layer on said flank surfaces is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(e) are deposited by chemical vapor deposition.

Claim 32

Dependent Claim 256 words

A coated hard alloy cutting tool, comprising: a substrate comprising WC and Co, said substrate has a Co enriched surface layer of 50 μm from the external surface of said substrate and a core, the Co concentration of a region that is 5-10 μm from the external surface is from 15-25 wt %, the Co content of said surface layer is more than that of said core, the content of carbides of Ti, Ta and Nb in the surface layer is lower than the content of said core; and at least one coating deposited on said surface of said substrate, said coating, sequentially consists of: (d) a first intermediate layer consisting of a TiN layer; (a) a primary layer consisting of a TiCN layer; (e) a second intermediate layer consisting of at least one layer selected from the group consisting of a TiC layer, a TiCO layer and a TiCNO layer; (b) a secondary layer consisting of an Al 2 O 3 layer; and (c) a surface layer consisting of at least one layer selected from the group consisting of a TiCN layer and a TiN layer; wherein said substrate is formed with rake surfaces and flank surfaces; wherein said primary layer on said rake surfaces is treated to produce compressive residual stresses of not more than 20 Kg/mm 2 ; wherein said primary layer on said flank surfaces is treated to produce tensile residual stresses therein of not more than 10 Kg/mm 2 ; and wherein said layers (a)-(e) are deposited by chemical vapor deposition.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1997-12-19	1998-06-20	1998-12-20	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2001-12-19	2002-06-20	2002-12-20	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2005-12-19	2006-06-20	2006-12-20	$7700.00	Window Closed / Lapsed

Multilayer coated hard alloy cutting tool

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