US5750247A — Coated cutting tool having an outer layer of TiC

Claim 1

Independent Claim 136 words

A coated cutting tool for the milling of ductile iron, the cutting tool comprising: a rake face and a flank face, a cutting edge at the a juncture of the rake face and the flank face, and the cutting tool having a coating and a substrate; the substrate comprising a tungsten carbide based cemented carbide having a bulk composition of no more than 7 weight percent tantalum, no more than 3 weight percent niobium, no more than 5 weight percent titanium, no more than 1 weight percent chromium, between about 5 and about 13 weight percent cobalt, and the balance tungsten carbide; and the coating comprising an innermost coating scheme including at least one layer adjacent to the substrate, and the coating further including an outermost layer comprising titanium carbide applied by chemical vapor deposition layer.

Claim 2

Dependent Claim 136 words

A coated cutting tool for the milling of ductile iron, the cutting tool comprising: a rake face and a flank face, a cutting edge at the a juncture of the rake face and the flank face, and the cutting tool having a coating and a substrate; the substrate comprising a tungsten carbide based cemented carbide having a bulk composition of no more than 7 weight percent tantalum, no more than 3 weight percent niobium, no more than 5 weight percent titanium, no more than 1 weight percent chromium, between about 5 and about 13 weight percent cobalt, and the balance tungsten carbide; and the coating comprising an innermost coating scheme including at least one layer adjacent to the substrate, and the coating further including an outermost layer comprising titanium carbide applied by chemical vapor deposition layer.

Claim 3

Dependent Claim 24 words

The coated cutting tool of claim 1 wherein the chemical vapor deposition occurs at a temperature between about 900° C. and about 1050° C.

Claim 4

Dependent Claim 25 words

The coated cutting tool of claim 1 wherein the chemical vapor deposition occurs at a temperature of between about 300° C. and about 850° C.

Claim 5

Dependent Claim 51 words

The coated cutting tool of claim 1 wherein the innermost coating scheme comprises a single layer of titanium carbonitride applied by chemical vapor deposition at a temperature between about 900° C. and about 1050° C., and the CVD layer of titanium carbide is adjacent to the CVD layer of titanium carbonitride.

Claim 6

Dependent Claim 52 words

The coated cutting tool of claim 1 wherein the innermost coating scheme comprises a single layer of titanium carbonitride applied by chemical vapor deposition at a temperature of between about 300° C. and about 850° C., and the CVD layer of titanium carbide is adjacent to the CVD layer of titanium carbonitride.

Claim 7

Dependent Claim 28 words

The coated cutting tool of claim 5 wherein the CVD coating scheme is applied at a pressure of between about 700 mm Hg and about 800 mm Hg.

Claim 8

Dependent Claim 61 words

The coated cutting tool of claim 1 wherein the innermost coating scheme comprises a layer of titanium nitride applied by physical vapor deposition directly to the substrate, and a layer of titanium carbonitride applied by physical vapor deposition to the PVD layer of titanium nitride, and the CVD layer of titanium carbide is adjacent to the PVD layer of titanium carbonitride.

Claim 9

Dependent Claim 41 words

The coated cutting tool of claim 1 wherein the innermost coating scheme comprises a layer of titanium aluminum nitride applied by physical vapor deposition, and the CVD layer of titanium carbide is adjacent to the PVD layer of titanium aluminum nitride.

Claim 10

Dependent Claim 24 words

The coated cutting tool of claim 1 wherein the innermost coating scheme has a thickness of between about 2 micrometers and about 4 micrometers.

Claim 11

Dependent Claim 22 words

The coated cutting tool of claim 1 wherein the outermost CVD layer of titanium carbide has a thickness of about 1.5 micrometers.

Claim 12

Dependent Claim 47 words

The coated cutting tool of claim 1 wherein the substrate has a hardness of between about 89 and about 94 Rockwell A, a magnetic coercive force of between about 125 and about 320 oersted, and a magnetic saturation value between about 80 percent and about 100 percent.

Claim 13

Dependent Claim 72 words

The coated cutting tool of claim 1 wherein the composition of the bulk composition comprises: no more than 0.1 weight percent tantalum, no more than 0.1 weight percent niobium, no more than 0.1 weight percent titanium, between about 0.3 and about 0.5 weight percent chromium, between about 5.7 and about 6.3 weight percent cobalt, and the balance tungsten carbide, and wherein the tungsten carbide has an average grain size of 1-5 micrometers.

Claim 14

Dependent Claim 67 words

The coated cutting tool of claim 1 wherein the composition of the bulk composition comprises: between about 2.9 and about 3.6 weight percent tantalum, no more than about 0.3 weight percent niobium, no more than about 0.5 weight percent titanium, between about 5.7 and about 6.4 weight percent cobalt, and the balance tungsten carbide, and wherein the tungsten carbide has an average grain size of 1-6 micrometers.

Claim 15

Dependent Claim 69 words

The coated cutting tool of claim 1 wherein the composition of the bulk composition comprises: between about 3.2 and about 3.8 weight percent tantalum, between about 1.2 and about 1.8 weight percent niobium, between about 1.7 and about 2.3 weight percent titanium, between about 6.2 and about 6.4 weight percent cobalt, and the balance tungsten carbide, and wherein the tungsten carbide has an average grain size of 1-7 micrometers.

Claim 16

Dependent Claim 68 words

The coated cutting tool of claim 1 wherein the composition of the bulk composition comprises: between about 1.4 and about 2.3 weight percent tantalum, between about 0.3 and about 0.6 weight percent niobium, no more than about 0.5 weight percent titanium, between about 11.0 and about 12.0 weight percent cobalt, and the balance tungsten carbide, and wherein the tungsten carbide has an average grain size of 1-6 micrometers.

Claim 17

Dependent Claim 51 words

The coated cutting tool of claim 1 wherein the composition of the bulk composition comprises: no more than 0.1 weight percent tantalum, no more than 0.1 weight percent niobium, no more than about 0.1 weight percent titanium, between about 9.45 and about 10.15 weight percent cobalt, and the balance tungsten carbide.

Claim 18

Dependent Claim 50 words

The coated cutting tool of claim 1 wherein the composition of the bulk composition comprises: between 5.0 and 6.0 weight percent tantalum, no more than 0.4 weight percent niobium, between 1.7 and 2.3 weight percent titanium, between about 5.7 and about 6.3 weight percent cobalt, and the balance tungsten carbide.

Claim 19

Dependent Claim 49 words

The coated cutting tool of claim 1 wherein the composition of the bulk composition comprises: between 4.2 and 5.0 weight tantalum, between 0.6 and 1.4 weight percent niobium, between 3.2 and 3.8 weight percent titanium, between about 5.8 and about 6.2 weight percent cobalt, and the balance tungsten carbide.

Claim 20

Dependent Claim 20 words

The coated cutting tool of claim 18 comprising a layer of cobalt enrichment near a peripheral surface of the substrate.

Claim 21

Dependent Claim 137 words

A coated cutting tool for the milling of ductile iron, the cutting tool comprising: a rake face and a flank face, a cutting edge at the a juncture of the rake face and the flank face, and the cutting tool having a coating and a substrate; the substrate comprising a tungsten carbide based cemented carbide having a bulk composition of no more than 7 weight percent tantalum, no more than 3 weight percent niobium, no more than 5 weight percent titanium, no more than 1 weight percent chromium, between about 5 and about 13 weight percent cobalt, and the balance tungsten carbide; and the coating comprising an innermost coating scheme including at least one layer adjacent to the substrate, and the coating further including an outermost layer consisting essentially of titanium carbide applied by chemical vapor deposition.

Claim 22

Dependent Claim 137 words

A coated cutting tool for the milling of ductile iron, the cutting tool comprising: a rake face and a flank face, a cutting edge at the a juncture of the rake face and the flank face, and the cutting tool having a coating and a substrate; the substrate comprising a tungsten carbide based cemented carbide having a bulk composition of no more than 7 weight percent tantalum, no more than 3 weight percent niobium, no more than 5 weight percent titanium, no more than 1 weight percent chromium, between about 5 and about 13 weight percent cobalt, and the balance tungsten carbide; and the coating comprising an innermost coating scheme including at least one layer adjacent to the substrate, and the coating further including an outermost layer consisting essentially of titanium carbide applied by chemical vapor deposition.

Claim 23

Dependent Claim 53 words

The coated cutting tool of claim 20 wherein the innermost coating scheme consists essentially of a single layer of titanium carbonitride applied by chemical vapor deposition at a temperature between about 900° C. and about 1050° C., and the CVD layer of titanium carbide is adjacent to the CVD layer of titanium carbonitride.

Claim 24

Dependent Claim 54 words

The coated cutting tool of claim 20 wherein the innermost coating scheme consists essentially of a single layer of titanium carbonitride applied by chemical vapor deposition at a temperature of between about 300° C. and about 850° C., and the CVD layer of titanium carbide is adjacent to the CVD layer of titanium carbonitride.

Claim 25

Dependent Claim 28 words

The coated cutting tool of claim 22 wherein the CVD coating scheme is applied at a pressure of between about 700 mm Hg and about 800 mm Hg.

Claim 26

Dependent Claim 63 words

The coated cutting tool of claim 20 wherein the innermost coating scheme consist essentially of a layer of titanium nitride applied by physical vapor deposition directly to the substrate, and a layer of titanium carbonitride applied by physical vapor deposition to the PVD layer of titanium nitride, and the CVD layer of titanium carbide is adjacent to the PVD layer of titanium carbonitride.

Claim 27

Dependent Claim 41 words

The coated cutting tool of claim 20 wherein the innermost coating scheme comprises a layer of titanium aluminum nitride applied by physical vapor deposition, and the CVD layer of titanium carbide is adjacent to the PVD layer of titanium aluminum nitride.

Claim 28

Dependent Claim 24 words

The coated cutting tool of claim 20 wherein the innermost coating scheme has a thickness of between about 2 micrometers and about 4 micrometers.

Claim 29

Dependent Claim 22 words

The coated cutting tool of claim 20 wherein the outermost CVD layer of titanium carbide has a thickness of about 1.5 micrometers.

Claim 30

Dependent Claim 47 words

The coated cutting tool of claim 20 wherein the substrate has a hardness of between about 89 and about 94 Rockwell A, a magnetic coercive force of between about 125 and about 320 oersted, and a magnetic saturation value between about 80 percent and about 100 percent.

Claim 31

Dependent Claim 72 words

The coated cutting tool of claim 20 wherein the composition of the bulk composition comprises: no more than 0.1 weight percent tantalum, no more than 0.1 weight percent niobium, no more than 0.1 weight percent titanium, between about 0.3 and about 0.5 weight percent chromium, between about 5.7 and about 6.3 weight percent cobalt, and the balance tungsten carbide, and wherein the tungsten carbide has an average grain size of 1-5 micrometers.

Claim 32

Dependent Claim 67 words

The coated cutting tool of claim 20 wherein the composition of the bulk composition comprises: between about 2.9 and about 3.6 weight percent tantalum, no more than about 0.3 weight percent niobium, no more than about 0.5 weight percent titanium, between about 5.7 and about 6.4 weight percent cobalt, and the balance tungsten carbide, and wherein the tungsten carbide has an average grain size of 1-6 micrometers.

Claim 33

Dependent Claim 69 words

The coated cutting tool of claim 20 wherein the composition of the bulk composition comprises: between about 3.2 and about 3.8 weight percent tantalum, between about 1.2 and about 1.8 weight percent niobium, between about 1.7 and about 2.3 weight percent titanium, between about 6.2 and about 6.4 weight percent cobalt, and the balance tungsten carbide, and wherein the tungsten carbide has an average grain size of 1-7 micrometers.

Claim 34

Dependent Claim 68 words

The coated cutting tool of claim 20 wherein the composition of the bulk composition comprises: between about 1.4 and about 2.3 weight percent tantalum, between about 0.3 and about 0.6 weight percent niobium, no more than about 0.5 weight percent titanium, between about 11.0 and about 12.0 weight percent cobalt, and the balance tungsten carbide, and wherein the tungsten carbide has an average grain size of 1-6 micrometers.

Claim 35

Dependent Claim 51 words

The coated cutting tool of claim 20 wherein the composition of the bulk composition comprises: no more than 0.1 weight percent tantalum, no more than 0.1 weight percent niobium, no more than about 0.1 weight percent titanium, between about 9.45 and about 10.15 weight percent cobalt, and the balance tungsten carbide.

Claim 36

Dependent Claim 50 words

The coated cutting tool of claim 20 wherein the composition of the bulk composition comprises: between 5.0 and 6.0 weight percent tantalum, no more than 0.4 weight percent niobium, between 1.7 and 2.3 weight percent titanium, between about 5.7 and about 6.3 weight percent cobalt, and the balance tungsten carbide.

Claim 37

Dependent Claim 49 words

The coated cutting tool of claim 20 wherein the composition of the bulk composition comprises: between 4.2 and 5.0 weight tantalum, between 0.6 and 1.4 weight percent niobium, between 3.2 and 3.8 weight percent titanium, between about 5.8 and about 6.2 weight percent cobalt, and the balance tungsten carbide.

Claim 38

Dependent Claim 20 words

The coated cutting tool of claim 35 comprising a layer of cobalt enrichment near a peripheral surface of the substrate.

Claim 39

Independent Claim 95 words

A method of making a coated cutting tool comprising the steps of: providing a substrate that is a tungsten carbide based cemented carbide having a bulk composition of no more than 7 weight percent tantalum, no more than 3 weight percent niobium, no more than 5 weight percent titanium, no more than 1 weight percent chromium, between about 5 and about 13 weight percent cobalt, and the balance tungsten carbide; applying an innermost coating scheme to the substrate; and applying by chemical vapor deposition an outermost layer of titanium carbide to the inner coating scheme.

Claim 40

Independent Claim 95 words

A method of making a coated cutting tool comprising the steps of: providing a substrate that is a tungsten carbide based cemented carbide having a bulk composition of no more than 7 weight percent tantalum, no more than 3 weight percent niobium, no more than 5 weight percent titanium, no more than 1 weight percent chromium, between about 5 and about 13 weight percent cobalt, and the balance tungsten carbide; applying an innermost coating scheme to the substrate; and applying by chemical vapor deposition an outermost layer of titanium carbide to the inner coating scheme.

Claim 41

Dependent Claim 30 words

The method of making a coated cutting tool of claim 37 wherein the chemical vapor deposition of titanium carbide occurs at a temperature of between 900° C. and 1050° C.

Claim 42

Dependent Claim 32 words

The method of making a coated cutting tool of claim 37 wherein the chemical vapor deposition of titanium carbide occurs at a temperature of between about 300° C. and about 850° C.

Claim 43

Dependent Claim 43 words

The method of making a coated cutting tool of claim 37 wherein the step of applying the innermost coating scheme comprises applying a single layer of titanium carbonitride by chemical vapor deposition at a temperature of between about 900° C. and 1050° C.

Claim 44

Dependent Claim 44 words

The method of making a coated cutting tool of claim 37 wherein the step of applying the innermost coating scheme comprises applying a single layer of titanium carbonitride by chemical vapor deposition at a temperature of between about 300° C. and about 850° C.

Claim 45

Dependent Claim 53 words

The method of making a coated cutting tool of claim 37 wherein the step of applying the innermost coating scheme comprises applying a layer of titanium nitride by physical vapor deposition directly to the substrate and applying a layer of titanium carbonitride by physical vapor deposition to the PVD layer of titanium nitride.

Claim 46

Dependent Claim 32 words

The method of making a coated cutting tool of claim 37 wherein the step of applying the innermost coating scheme comprises applying a layer of titanium aluminum nitride by physical vapor deposition.

Claim 47

Dependent Claim 29 words

The method of making a coated cutting tool of claim 37 wherein the innermost coating scheme has an overall thickness of between about 2 micrometers and about 4 micrometers.

Claim 48

Dependent Claim 25 words

The method of making a coated cutting tool of claim 37 wherein the CVD titanium carbide outer layer has a thickness of about 1.5 micrometers.

Claim 49

Independent Claim 123 words

A method of milling ductile iron comprising the steps of: milling the ductile iron at a predetermined speed with a cemented carbide cutting tool having a substrate and a coating; wherein the substrate comprises a tungsten carbide based cemented carbide having a bulk composition of no more than 7 weight percent tantalum, no more than 3 weight percent niobium, no more than 5 weight percent titanium, no more than 1 weight percent chromium, between about 5 and about 13 weight percent cobalt, and the balance tungsten carbide; and the coating comprises an innermost coating scheme including at least one layer adjacent to the substrate, and the coating further including an outermost coating comprising a layer of titanium carbide applied by chemical vapor deposition.

Claim 50

Independent Claim 123 words

A method of milling ductile iron comprising the steps of: milling the ductile iron at a predetermined speed with a cemented carbide cutting tool having a substrate and a coating; wherein the substrate comprises a tungsten carbide based cemented carbide having a bulk composition of no more than 7 weight percent tantalum, no more than 3 weight percent niobium, no more than 5 weight percent titanium, no more than 1 weight percent chromium, between about 5 and about 13 weight percent cobalt, and the balance tungsten carbide; and the coating comprises an innermost coating scheme including at least one layer adjacent to the substrate, and the coating further including an outermost coating comprising a layer of titanium carbide applied by chemical vapor deposition.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2001-05-11	2001-11-10	2002-05-12	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2005-05-11	2005-11-10	2006-05-12	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2009-05-11	2009-11-10	2010-05-12	$7700.00	Window Closed / Lapsed

Coated cutting tool having an outer layer of TiC

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