Thick thermal barrier coating for superabrasive tool and method of making the same

Abstract

The present disclosure relates to cutting tool edges that include on a rake face a superabrasive layer and a HPHT sintered or HPHT bonded cap layer. The cap layer improves adhesion between the superabrasive layer and an optional coating system for the cutting insert and acts as a thick anti-friction layer and/or a thermal barrier coating.

1 . (canceled) 
     
     
         2 . (canceled) 
     
     
         3 . (canceled) 
     
     
         4 . (canceled) 
     
     
         5 . (canceled) 
     
     
         6 . (canceled) 
     
     
         7 . (canceled) 
     
     
         8 . (canceled) 
     
     
         9 . (canceled) 
     
     
         10 . (canceled) 
     
     
         11 . (canceled) 
     
     
         12 . (canceled) 
     
     
         13 . (canceled) 
     
     
         14 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . (canceled) 
     
     
         17 . (canceled) 
     
     
         18 . A method of manufacturing a cutting insert, the method comprising:
 bonding a cap layer to a surface of a superabrasive layer of a substrate structure by a high pressure/high temperature (HPHT) process;   shaping the substrate structure with the bonded cap layer to a shape of a cutting insert; and   coating a rake face and a flank face of the cutting insert with a coating system, wherein the flank face interconnects the rake face, the coating system including at least one ceramic layer, wherein the cap layer has a composition including a cermet, a ceramic or a metal, wherein the cap layer is not disposed on the plurality of flank face of the cutting insert, and wherein a thickness of the cap layer is about 20 μm to about 200 μm.   
     
     
         19 . The method according to  claim 18 , wherein the coating system includes at least one ceramic layer having a composition including a nitride, boride, carbide or an oxide. 
     
     
         20 . The method according to  claim 19 , wherein the at least one ceramic layer has a composition including TiN, TiC, TiCN, TiSiN, SiN, alumina, AlN, ZrO2, ZrN, Chromia and combinations and/or alloys thereof. 
     
     
         21 . (canceled) 
     
     
         22 . (canceled) 
     
     
         23 . (canceled) 
     
     
         24 . (canceled) 
     
     
         25 . (canceled) 
     
     
         26 . (canceled) 
     
     
         27 . (canceled) 
     
     
         28 . (canceled) 
     
     
         29 . (canceled) 
     
     
         30 . (canceled) 
     
     
         31 . A method of manufacturing a cutting element, comprising:
 providing a superabrasive layer on a rake face of the cutting element, wherein the cutting element comprises a plurality of flank faces interconnect the rake face; and   sintering or bonding a cap layer at high temperature high pressure (HTHP) to the superabrasive layer on the rake face; wherein the cap layer includes one or more layers each having a composition including a cermet, a ceramic or a metal, wherein the cap layer is not disposed on the plurality of flank faces of the cutting insert; and wherein a thickness of the cap layer is about 20 μm or thicker.   
     
     
         32 . The method according to  claim 31 , further comprising depositing a coating system onto the cap layer on the rake face and onto a flank face of the cutting insert. 
     
     
         33 . The method according to  claim 31 , wherein the superabrasive layer has a composition including polycrystalline boron nitride (PCBN) or polycrystalline diamond (PCD). 
     
     
         34 . The method according to  claim 31 , wherein the thickness of the cap layer is about 30 μm to about 200 μm. 
     
     
         35 . The method according to  claim 31 , wherein the thickness of the cap layer is less than about 150 μm. 
     
     
         36 . The method according to  claim 31 , wherein the cermet includes WC/Co or TiCN/Co and has a metal content of 0.5 w/w to 25 w/w. 
     
     
         37 . The method according to  claim 31 , wherein the ceramic includes a nitride, boride, carbide or an oxide. 
     
     
         38 . The method according to  claim 31 , wherein the ceramic is alumina, AlN, or ZrO 2 . 
     
     
         39 . The method according to  claim 31 , wherein the metal includes Ta, Nb, Mo, or refractory metals. 
     
     
         40 . The method according to  claim 32 , wherein the coating system includes at least one ceramic layer. 
     
     
         41 . The method according to  claim 40 , wherein the at least one ceramic layer has a composition including TiN, TiC, TiCN, TiSiN, SiN, alumina, AlN, ZrO 2 , ZrN, chromia and combinations and/or alloys thereof. 
     
     
         42 . The method according to  claim 31 , wherein the cutting insert includes a chamfer and wherein the thickness of the cap layer is equal to or less than a height of the chamfer. 
     
     
         43 . A method of manufacturing a superabrasive tool, comprising:
 providing a superabrasive layer on a first face of a cutting insert, wherein the cutting insert comprises a second face interconnecting the rake face; and   sintering or bonding a cap layer at high pressure high temperature (HPHT) to the superabrasive layer on the face; wherein the cap layer includes one or more layers each having a composition including a cermet, a ceramic or a metal, wherein the cap layer is not disposed on the face of the cutting insert; and wherein a thickness of the cap layer is about 20 μm or thicker.   
     
     
         44 . The method according to  claim 43 , further comprising providing a support body, wherein the superabrasive layer is sintered to a first surface of the support body. 
     
     
         45 . The method according to  claim 43 , further comprising depositing a coating system onto the cap layer. 
     
     
         46 . The method according to  claim 45 , wherein the coating system includes at least one ceramic layer having a composition including a nitride, boride, carbide or an oxide. 
     
     
         47 . The method according to  claim 46 , wherein the at least one ceramic layer has a composition including TiN, TiC, TiCN, TiSiN, SiN, alumina, AlN, ZrO 2 , ZrN, chromia and combinations and/or alloys thereof.