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US 2014/0212232 A1Published application
Coating Layer with Microstructure Serrated Edge
AssigneeNanoMech, Inc.
InventorsAjay P. Malshe, Wenping Jiang
Life of this patent
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Abstract
A cutting tool formed by a coating layer on a substrate has cutting edges that feature serrations. The linear dimensions of the serrations may vary from a few nanometers up to 10 microns. The serrations result in a smoother cut edge on the workpiece, particularly when the workpiece is formed of certain materials that are seen as particularly difficult to cut, such as hardened steels.
Claims19
A cutting tool, comprising:
- a. a substrate, wherein the substrate comprises a material selected from the set consisting of carbides, nitrides, carbonitrides, polycrystalline cubic boron nitride (PCBN), PCBN tip-brazed material, cermets, and steels;
- and
- b. a coating on the substrate, wherein the coating comprises a material selected from the set consisting of carbides, nitrides, oxides, and carbon, wherein the material is one of continuous and discontinuous, further wherein the coating is infiltrated with a material selected from the set consisting of titanium nitride, hafnium nitride, zirconia nitride, titanium carbide, hafnium carbide, titanium carbonitride, and hafnium carbonitride, further wherein the coating comprises at least one cutting edge, wherein the at least one cutting edge comprises an aperiodic plurality of serrations, the aperiodic plurality of serrations comprising a plurality of protrusions and a plurality of valleys, wherein at least a subset of the aperiodic plurality of serrations are aperiodic in at least a first linear dimension, and further wherein the subset of the plurality of serrations are aperiodic in at least one aperiodic scale.
A method for producing a cutting tool, comprising the method steps of:
- a. depositing a first material to the substrate to produce a coating on the substrate, using a technique selected from the set consisting of electrostatic spray coating (ESC), electrostatic spray deposition (ESD), ultrasonic spray deposition (USD), and hybrids of at least two of ESC, ESD, and USD techniques, wherein the substrate comprises a material selected from the set consisting of carbides, nitrides, carbonitrides, polycrystalline cubic boron nitride (PCBN), PCBN tip-brazed materials, cermets, and steels, and wherein the coating is one of continuous and discontinuous, and the first material comprises a material selected from the set consisting of carbides, oxides, nitrides, and carbon;
- b. infiltrating the coating on the substrate with a second material using a chemical vapor infiltration (CVI) technique, wherein the second material is selected from the group consisting of titanium nitride, hafnium nitride, zirconia nitride, titanium carbide, hafnium carbide, titanium carbonitride, and hafnium carbonitride;
- and
- c. applying a post-deposition process selected from the set consisting of laser radiation, infrared (IR) radiation, or microwave sintering,
- wherein a coated substrate is produced that comprises a cutting edge, wherein the cutting edge comprises a plurality of aperiodic serrations, and wherein the plurality of aperiodic serrations comprise a plurality of protrusions and a plurality of valleys.
2 more elements
Dependencies are inferred from the claim text.