CN111032913A - 经涂覆的切削刀具和涂覆所述切削刀具的方法 - Google Patents

经涂覆的切削刀具和涂覆所述切削刀具的方法 Download PDF

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CN111032913A
CN111032913A CN201880054022.2A CN201880054022A CN111032913A CN 111032913 A CN111032913 A CN 111032913A CN 201880054022 A CN201880054022 A CN 201880054022A CN 111032913 A CN111032913 A CN 111032913A
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cutting tool
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米卡埃尔·法洛克韦斯特
乔恩·安德森
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Abstract

一种经涂覆的切削刀具包含具有涂层的基材,所述涂层具有0.25μm至30μm的总厚度,其中所述涂层包含第一层和第二层,所述第一层是具有0.2μm至15μm厚度的耐磨PVD沉积层并且被布置在所述基材与所述第二层之间,并且其中所述第二层是Cr层。

Description

经涂覆的切削刀具和涂覆所述切削刀具的方法
技术领域
本发明涉及一种用于切屑形成金属机械加工的经涂覆的切削刀具。本发明还涉及一种涂覆所述切削刀具的方法。
背景技术
自20世纪80年代中期以来,人们一直在努力去改善切削刀具涂层的性质(如耐磨性)并从而改善其性能。当时,通常的做法是用TiN涂覆切削刀具。然而,由于其在高温下的抗氧化性相对较差,所以提出了以(Ti、Al)N的形式将Al合金化,并在20世纪80年代中期取得了良好的结果。如今,在最普通的硬质保护性涂覆材料中,将(Ti、Al)N类涂层用于金属切削应用中。(Ti、Al)N的立方B1结构作为整体层和/或层压涂覆结构的一部分而结合了有吸引力的机械性能,如高硬度以及抗高温和抗氧化性,从而在金属机械加工应用中提供良好的性能。(Ti、Al)N的技术优势及其优异的物理性能(特别是在高温下的物理性能)在一定程度上通过亚稳分解(spinodal decomposition)过程得以解释,在该亚稳分解过程期间,立方(Ti、Al)N同构分解成相干立方c-AlN富集域和c-TiN富集域。相干的c-AlN富集域和c-TiN富集域之间的弹性性质和晶格失配的结合导致显著的时效硬化,在该时效硬化期间,(Ti、Al)N薄层的硬度显示出增加了15%至20%。在进一步老化时,c-AlN转变成热力学稳定的六方纤锌矿型B4结构(即h-AlN),导致形成了机械性能降低的包含c-TiN和h-AlN的双相结构。
然而,在特定状况下,例如在工件材料的机械加工会引起很大的粘着磨损时,需要对目前的涂覆方案进行改进。
发明目的
本发明的目的是提供一种具有涂层的经涂覆的切削刀具,所述涂层通过优化刀具与工件之间的相互作用来改善切削性能。
本发明的另一个目的是提供一种用所述涂层对切削刀具进行涂覆的方法以及切削刀具用于对ISO M材料进行机械加工的用途。
发明内容
根据本发明的第一方面,提供了一种经涂覆的切削刀具,所述经涂覆的切削刀具包含具有涂层的基材,所述涂层具有0.25μm至30μm的总厚度,其中所述涂层包含第一层和第二层,并且其中所述第一层是具有0.2μm至15μm、优选0.2μm至10μm、最优选0.5μm至5μm的厚度的耐磨PVD沉积层,所述第一层被布置在所述基材与所述第二层之间,并且其中所述第二层是作为所述涂层的最外层的Cr(铬)层。
根据一个实施方案,所述Cr层具有金属Cr。
根据本发明的一个实施方案,所述Cr层的厚度为0.05μm至5μm,优选0.05μm至3μm。
根据本发明的一个实施方案,使用CuKα辐射在经涂覆的刀具上采集到的X射线衍射(XRD)θ-2θ扫描包含源自Cr层的体心立方(bcc)结构峰。
根据本发明的一个实施方案,所述Cr层具有bcc结构,所述bcc结构的晶体取向关系为0.3<R1<1,优选0.4<R1<1,其中R1=I(110)/(I(110)+I(200)+I(211)),并且其中I(110)、I(200)和I(211)分别为从通过CuKα辐射得到的θ-2θ扫描的伪Voigt峰曲线拟合结果中提取的关于bcc结构(110)、(200)和(211)Cr层衍射峰的XRD峰面积。
根据本发明的一个实施方案,所述Cr层具有bcc结构,所述bcc结构的晶体取向关系为0<R2<0.6,其中R2=I(200)/(I(110)+I(200)+I(211)),并且其中I(110)、I(200)和I(211)分别为从通过CuKα辐射得到的θ-2θ扫描的伪Voigt峰曲线拟合结果中提取的关于bcc结构(110)、(200)和(211)Cr层衍射峰的XRD峰面积。
根据本发明的一个实施方案,所述Cr层具有bcc结构,所述bcc结构的晶体取向关系为0<R3<0.2,其中R3=I(211)/(I(110)+I(200)+I(211)),并且其中I(110)、I(200)和I(211)分别为从通过CuKα辐射得到的θ-2θ扫描的伪Voigt峰曲线拟合结果中提取的关于bcc结构(110)、(200)和(211)Cr层衍射峰的XRD峰面积。
根据本发明的一个实施方案,所述Cr层的厚度与总涂层厚度之间的比例为0.01至2,优选0.01至1,最优选0.05至0.5。
根据本发明的一个实施方案,所述第一层具有H>20GPa、优选H>24GPa、最优选40GPa>H>24GPa的硬度,所述硬度通过纳米压痕实验测得。
根据一个实施方案,使用CuKα辐射采集到的X射线衍射(XRD)θ-2θ扫描包含源自第一层的NaCl型结构峰和源自Cr层的体心立方结构峰。
根据一个实施方案,所述(110)体心立方Cr峰的XRD峰强度与源自所述第一层的(200)NaCl结构峰的XRD峰强度之间的比例R4为0.05<R4<30,其中将XRD峰强度作为从通过CuKα辐射得到的θ-2θ扫描的伪Voigt峰曲线拟合结果中提取的峰面积进行评价。
根据本发明的一个实施方案,所述第一层具有NaCl型晶体结构,所述NaCl型晶体结构的晶体取向关系为0.5<RA≤1,其中RA=IA(200)/(IA(200)+IA(111)),并且其中IA(200)和IA(111)分别是从通过CuKα辐射得到的θ-2θ扫描的伪Voigt峰曲线拟合结果中提取的关于NaCl结构的(200)和(111)第一层衍射峰的XRD峰面积。
根据本发明的一个实施方案,所述峰面积比RA为0.6<RA≤1。
根据本发明的一个实施方案,所述峰面积比RA为0.5<RA<0.9。
根据本发明的一个实施方案,所述峰面积比RA为0.6<RA<0.9。
根据本发明的一个实施方案,所述峰面积比RA为0.5<RA<0.8。
根据本发明的一个实施方案,所述涂层可以以相对于总浓度为0至5原子%、优选0至2原子%、最优选0至1原子%的量包含少量的如下中的至少一种:氧(O)和碳(C)。
根据本发明的一个实施方案,所述第一层是(Ti1-xAlx)Ny层,其中0.1<x<0.7且0.6<y<1.1。
根据本发明的一个实施方案,所述第一层是NaCl结构立方相c-(Ti1-xAlx)Ny层,其中0.1<x<0.7,优选0.4<x<0.7,并且0.7<y<1.1。
根据本发明的一个实施方案,0.5<x<0.7。
根据本发明的一个实施方案,0.5<x<0.6。
根据本发明的一个实施方案,0.7<y<1.05。
根据本发明的一个实施方案,NaCl结构的c-(Ti1-xAlx)Ny层可任选地包含均小于5原子%的如下中的任一种:立方相c-TiN、立方相c-AlN和六方相h-AlN。
根据本发明的一个实施方案,所述第一层是具有5nm至50nm的子层厚度的NaCl结构的(Ti1-vAlv)Nw/(Ti1-aSia)Nb纳米层压物,其中0.1<v<0.7,优选0.4<v<0.7,0.7<w<1.1,0.02<a<0.25,优选0.05<a<0.15,并且0.7<b<1.1。
根据本发明的一个实施方案,所述第一层是(Ti1-mSim)Nn层,其中0≤m<0.25,优选0≤m<0.15,并且0.7<n<1.1。
根据本发明的一个实施方案,所述第一层是(Cr1-cAlc)Nd层,其中0.5<c<0.9,优选0.5<c<0.8,并且0.7<d<1.1。
根据本发明的一个实施方案,所述第一层是(Cr1-eAle)2O3层,其中0.5<e<0.9,优选0.5<e<0.8。
根据本发明的一个实施方案,所述基材包含如下中的至少一种:硬质合金、金属陶瓷、陶瓷、钢和立方氮化硼。
根据本发明的一个实施方案,所述基材包括包含WC和4重量%至15重量%的Co的硬质合金。
根据一个实施方案,所述涂层还可以包含除了所述第一层和所述第二层之外的第三层。所述第三层可以是可以被布置在所述基材与所述第一层之间或在所述第一层与所述第二层之间的单层或多层。
根据本发明的第二方面,提供了一种通过应用PVD(物理气相沉积)技术、优选阴极电弧沉积来制造包含主体和耐磨硬涂层的经涂覆的切削刀具的方法,所述方法包括:在施加50A至200A的蒸发电流、施加1.0Pa至7.0Pa、优选2.0Pa至5.0Pa的总气压的含纯Ar的气体气氛并且施加室温至500℃之间的沉积温度的情况下,通过使用纯Cr阴极来生长Cr层。所述Cr层被布置为所述涂层的最外层。
根据一个实施方案,上述方法包括施加0V至150V的基材负偏压。
根据本发明的一个实施方案,所述方法还包括在如下条件下通过阴极电弧蒸发来生长被布置在所述主体与所述Cr层之间的作为(Ti1-xAlx)Ny层(0.1<x<0.7且0.7<y<1.1)的第一层:使用复合的和/或合金化的(Ti、Al)阴极,50A至200A的蒸发电流,反应性气体气氛含有N2和可任选混合的Ar;总气压为1.0Pa至7.0Pa,优选2.5Pa至5Pa;基材负偏压为0V至300V,优选20V至150V,更优选30V至100V;温度为200℃至800℃,优选300℃至600℃。
根据本发明的一个实施方案,所述第一层是0.1<x<0.7且0.7<y<1.1的(Ti1-xAlx)Ny层,并且使用复合的和/或合金化的(Ti、Al)阴极来生长所述第一层。
根据本发明的第三方面,提供了根据上述实施方案中任一项的经涂覆的切削刀具的在如下方面的用途:根据切削速度和刀片几何形状,所述经涂覆的切削刀具在10m/分钟至400m/分钟、优选35m/分钟至300m/分钟、最优选50m/分钟至200m/分钟的切削速度下以0.05mm/转至0.5mm/转、优选0.1mm/转至0.4mm/转的平均进给用于ISO M材料(如奥氏体不锈钢)的机械加工。
定义
本文中所使用的术语“切削刀具”旨在表示适合于通过切屑去除(诸如车削、铣削或钻销)来进行金属切削的切削刀具。切削刀具的实例是可转位切削刀片、整体钻或端铣刀。
本文中所表示的术语“基材”应被理解为其上沉积有涂层的主体。切削刀具的共同点是,诸如切削刀具刀片的这种基材可以是纯主体或者是包括其上放置有其它材料的背衬体的主体,其中在前刀面上的切削刃上放置所述其它材料时,所述基材是所谓的带尖的主体,在以使其覆盖整个前刀面的方式放置所述其它材料时,所述基材是所谓的整面主体。带尖方案或整面方案经常用于基于多晶金刚石或多晶立方氮化硼材料的切削技术中。
附图说明
图1示出了根据本发明的实施方案的三个涂层的X射线衍射图。标记为“S”的峰源自基材,标记为“A”的峰源自第一层,并且标记为“Cr”的峰源自Cr层。
具体实施方式
根据本发明,提供了一种由基材和涂层构成的经涂覆的切削刀具。所述涂层包含第一层和第二层,其中第一层是耐磨的PVD沉积层并且第二层是Cr层。Cr层被布置为最外层,并且令人惊讶的是发现了Cr层在机械加工方面提供了改进的性能。Cr层是PVD沉积层并且具有0.05μm至3μm的厚度。
使用装配有Thermo Noran EDS的在20kV下运行并垂直入射到经涂覆的表面的LEOUltra 55扫描电子显微镜(SEM)通过能量色散光谱(EDS)分析面积来估算层的平均组成。使用内标和ZAF校正用于定量分析。使用Noran System Six(NSS ver 2)软件来估算金属组成。
使用Bruker AXS D8先进X射线衍射仪和CuKα辐射通过XRD以Bragg-Brentano构型进行涂层相检测和优选晶体取向评价。通常,对于多晶混合相材料中的每一相的检测限为小于5体积%。
图1示出了从根据本发明的实施方案的三个涂层采集的θ-2θX射线衍射图。将涂层相相对于JCPDS卡01-1261(Cr)和38-1420(c-TiAlN)进行检索,其中38-1420(c-TiAlN)必须被移位以匹配比c-TiN小的c-TiAlN的晶格参数。不能排除接近或低于衍射技术检测限的少量的立方相c-TiN相、立方相c-AlN相和六方相h-AlN相。
XRD衍射图中结晶峰的位置和强度(面积)是通过对每一个结晶峰进行伪Voigt函数拟合来确定的。此外,拟合函数还包含线性项,以说明由背景引起的残留散射。使用Bruker AXS Topas 2.1软件进行XRD数据峰拟合。根据本发明的实施方案,使用所得的峰面积来计算比例R1、R2、R3、R4和RA。
实施例1
使用硬质合金(WC-Co)切削刀具作为基材以通过阴极电弧蒸发进行层沉积,所述硬质合金(WC-Co)切削刀具的组成范围包含:6重量%至13重量%的Co粘合剂,其余为碳化钨(WC)和例如钛、钽或铌的其它碳化物以及各种量的粘合剂合金元素如铁、铬、镍、钼或这些元素的合金。
在沉积之前,将切削刀具在碱性溶液和醇的超声波浴中进行清洁。将***抽空至小于2.0×10-3Pa的压力,其后用Ar离子对刀具进行溅射清洁。然后,对于涂层I1至I10,在施加约150A的蒸发电弧电流和约50V的基材负偏压的情况下,在反应性N2气气氛中在4.5Pa的总气压下使用Ti0.45Al0.55阴极在450℃下淀积Ti0.47Al0.53N层。随后,在施加约150A的蒸发电弧电流的情况下,在Ar气气氛中在4Pa总气压下使用Cr阴极在没有外部加热的情况下在单独工序中沉积Cr层。改变用于Cr层的基材偏压和厚度,以制造如表1中所示的多种涂层,并且对于涂层I5至I10,在Cr沉积之前引入附加的Ar蚀刻。同时以与上述相同的参数制造不具有Cr层的参照Ti0.47Al0.53N涂层C1。另外,除了在约1Pa压力下在纯O2气氛中沉积了铬铝氧化物层的涂层I15和C6之外,使用类似的工艺参数通过阴极电弧蒸发沉积涂层I11至I15和涂层C2至C6的第一层。
将本发明的实施方案中所限定的XRD峰强度比示于表1中。
表1.涂层的规格和性质
Figure BDA0002387818610000091
*具有约10nm子层厚度的纳米层压物
**由于峰重叠而无法评价
***因为涂层不是NaCl结构而未评价
在对表面进行机械抛光之后,使用具有Berkovich金刚石尖端且最大尖端载荷为25mN的UMIS 2000纳米压痕***通过纳米压痕实验对与涂层I1至I10的第一层相对应的涂层C1的硬度进行评价。使用Oliver和Pharr的方法[W.C.Oliver和G.M.Pharr,材料研究杂志,第7卷,第1564页(1992年)(W.C.Oliver and G.M.Pharr,J.Mater.Res.7,1564(1992))]通过载荷-位移曲线对硬度进行评价。制作平均约30个压痕,并使用熔融石英参照样品来检查校准。此外,在对表面进行机械抛光之后,使用Berkovich金刚石尖端和4mN的最大尖端载荷通过纳米压痕实验对与涂层I11至I15的第一层相对应的涂层C2至C6的硬度进行评价。使用Oliver和Pharr的方法[W.C.Oliver和G.M.Pharr,材料研究杂志,第7卷,第1564页(1992年)]通过载荷-位移曲线对硬度进行评价。制作平均约20个压痕,并使用熔融石英参照样品来检查校准。将如此评价的涂层C1至C6的硬度示于表1中。标准误差估计为±2GPa。
实施例2
在316L的车削中对源自实施例1的具有约6重量%的Co且涂覆有本发明涂层I2至I4和比较涂层C1的WC-Co刀片(ISO几何形状TPUN160308)进行试验。使用如下数据以重复的5mm切削长度进行试验。
切削速度:80m/分钟
进给:0.2mm/转
切削深度:2mm
性能标准:侧面磨损
表2示出了本发明涂层相对于参照比较涂层具有较低的侧面磨损。
表2.相对侧面磨损
Figure BDA0002387818610000111
实施例3
利用如下数据在316L的车削中对源自实施例1的具有约13重量%的Co且涂覆有涂层I1和C1的WC-Co刀片(ISO几何形状TPUN160308)进行试验:
切削速度:150m/分钟
进给:0.2mm/转
切削深度:3mm
性能标准:侧面磨损
本发明涂层I1的所得到的侧面磨损是参照比较涂层的侧面磨损的约80%。
实施例4
利用如下数据在316L的铣削中对源自实施例1的具有约13重量%的Co且涂覆有涂层I1和C1的WC-Co刀片(ISO几何形状XOMX120408TR-ME08)进行试验:
铣刀:R417.69-2525.3-12-3A
切削速度:120m/分钟
进给:0.19mm/齿
切削深度:5mm
ae:3mm(12%)
性能标准:侧面磨损
本发明涂层I1的所得到的侧面磨损是参照比较涂层的侧面磨损的约65%。
实施例5
在316L的车削中对源自实施例1的具有约6重量%的Co且涂覆有本发明的涂层I2至I10和比较涂层C1的WC-Co刀片(ISO几何形状TPUN160308)进行试验。使用如下数据以重复的20mm切削长度进行试验。
切削速度:80m/分钟
进给:0.2mm/转
切削深度:2mm
性能标准:侧面磨损
表3示出了本发明涂层相对于参照比较涂层具有较低的侧面磨损。
表3.相对侧面磨损
Figure BDA0002387818610000121
实施例6
在滑动试验中对源自实施例1的具有约6重量%的Co且涂覆有本发明的涂层I1和I11至I15以及比较涂层C1至C6的WC-Co刀片(ISO几何形状SNUN120308)进行试验,所述滑动试验是使用商购获得的划痕仪(CSM Instruments
Figure BDA0002387818610000132
)来进行的。在试验中,将具有10mm直径和抛光的(Ra=25nm)半球形端面(半径5mm)的不锈钢(AISI 316L)销钉以抵靠经PVD涂覆的硬质合金刀片的方式负载。使用20N的标准负载和10mm/分钟的相对滑动速度在干燥条件下于环境空气(21℃至22℃,25%RH至26%RH)中进行滑动试验。滑动距离为10mm,并且将每一次试验重复3次。在试验期间,连续记录摩擦系数和声发射。
将每一种本发明涂层的所测量的摩擦系数相对于对应比较涂层的下降示于表4中。清楚的是,与其对应的比较涂层相比,本发明涂层显示出摩擦系数的显著降低。
表4
Figure BDA0002387818610000131

Claims (18)

1.一种经涂覆的切削刀具,所述经涂覆的切削刀具包含具有涂层的基材,所述涂层具有0.25μm至30μm的总厚度,
其中所述涂层包含第一层和第二层,并且
其中所述第一层是具有0.2μm至15μm、优选0.2μm至10μm、最优选0.5μm至5μm的厚度的耐磨PVD沉积层,并且所述第一层被布置在所述基材与所述第二层之间,
其特征在于,所述第二层是Cr层,并且所述Cr层是所述涂层的最外层。
2.根据前述权利要求中任一项所述的经涂覆的切削刀具,其中所述Cr层的厚度为0.05μm至5μm,优选0.05μm至3μm。
3.根据前述权利要求中任一项所述的经涂覆的切削刀具刀片,其中所述Cr层是PVD沉积层。
4.根据前述权利要求中任一项所述的经涂覆的切削刀具,其中所述Cr层具有晶体取向关系为0.3<R1<1的体心立方结构,
其中R1=I(110)/(I(110)+I(200)+I(211)),并且其中I(110)、I(200)和I(211)分别为从通过CuKα辐射得到的θ-2θ扫描的伪Voigt峰曲线拟合结果中提取的关于bcc结构(110)、(200)和(211)Cr层衍射峰的XRD峰面积。
5.根据前述权利要求中任一项所述的经涂覆的切削刀具,其中所述第一层是(Ti1-xAlx)Ny层,其中0.1<x<0.7且0.6<y<1.1。
6.根据前述权利要求中任一项所述的经涂覆的切削刀具,其中所述第一层是NaCl结构的c-(Ti1-xAlx)Ny层,其中0.1<x<0.7并且0.7<y<1.1。
7.根据权利要求5或6所述的经涂覆的切削刀具,其中0.5<x<0.6。
8.根据权利要求1至4中任一项所述的经涂覆的切削刀具,其中所述第一层是具有5nm至50nm的子层厚度的NaCl结构的(Ti1-vAlv)Nw/(Ti1-aSia)Nb纳米层压物,
其中0.1<v<0.7,优选0.4<v<0.7,
0.7<w<1.1,
0.02<a<0.25,优选0.05<a<0.15,以及
0.7<b<1.1。
9.根据权利要求1至4中任一项所述的经涂覆的切削刀具,其中所述第一层是(Ti1-mSim)Nn层,其中0≤m<0.25,优选0≤m<0.15,并且0.7<n<1.1。
10.根据权利要求1至4中任一项所述的经涂覆的切削刀具,其中所述第一层是(Cr1- cAlc)Nd层,其中0.5<c<0.9,优选0.5<c<0.8,并且0.7<d<1.1。
11.根据权利要求1至4中任一项所述的经涂覆的切削刀具,其中所述第一层是(Cr1- eAle)2O3层,其中0.5<e<0.9,优选0.5<e<0.8。
12.根据前述权利要求中任一项所述的经涂覆的切削刀具,其中所述Cr层厚度与所述总涂层厚度之间的比例为0.01至2,优选0.01至1,最优选0.05至0.5。
13.根据前述权利要求中任一项所述的经涂覆的切削刀具,其中所述第一层具有H>20GPa、优选H>24GPa的硬度。
14.根据权利要求1至10中任一项或权利要求12至13中任一项所述的经涂覆的切削刀具,其中所述第一层具有NaCl型结构,并且所述Cr层具有体心立方结构,
(110)体心立方Cr峰的XRD峰强度与源自所述第一层的(200)NaCl结构峰的XRD峰强度之间的比例R4为0.05<R4<30,其中将XRD峰强度作为从通过CuKα辐射得到的θ-2θ扫描的伪Voigt峰曲线拟合结果中提取的峰面积进行评价。
15.根据前述权利要求中任一项所述的经涂覆的切削刀具,其中所述基材包含如下中的至少一种:硬质合金、金属陶瓷、陶瓷、钢和立方氮化硼。
16.根据权利要求15所述的经涂覆的切削刀具,其中所述硬质合金包含WC和4重量%至15重量%的Co。
17.一种生产经涂覆的切削刀具的方法,所述方法包括以下步骤:
-通过PVD(物理气相沉积)技术、优选阴极电弧沉积利用具有0.25μm至30μm厚度的耐磨硬涂层对硬质合金、金属陶瓷、陶瓷、钢或立方氮化硼的基材进行涂布,其中所述涂层包含第一层和第二层,所述第二层是被布置为所述涂层的最外层的Cr层,
-在施加50A至200A的蒸发电流、施加1.0Pa至7.0Pa、优选2.0Pa至5.0Pa的总气压下的含纯Ar的气体气氛并且施加在室温至500℃之间的沉积温度的情况下,通过使用纯Cr阴极来生长Cr层。
18.根据权利要求17所述的方法,包括在如下条件下通过阴极电弧蒸发在所述基材与所述Cr层之间生长作为(Ti1-xAlx)Ny层的第一层,其中0.1<x<0.7且0.7<y<1.1:
使用复合的和/或合金化的(Ti、Al)阴极,
50A至200A的蒸发电流,
反应性气体气氛含有N2和可任选混合的Ar,
总气压为1.0Pa至7.0Pa,优选2.5Pa至5Pa;
基材负偏压为0V至300V,优选20V至150V,更优选30V至100V;
温度为200℃至800℃,优选300℃至600℃。
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