Cvi bonded and coated pcbn to wc tool body

Abstract

A cutting tool and a method of making a cutting tool are provided. The cutting tool may comprise a sintered superabrasive tip, a tool body and a non-brazing material. The sintered superabrasive tip may have a plurality of superhard particles. The tool body may retain the superabrasive tip. The non-brazing material fills a gap between the superabrasive tip and the tool body. The method of making a cutting tool may comprise steps of providing a superabrasive tip; providing a tool body; filling a gap between the superabrasive tip and the tool body with a non-brazing material; and depositing a first coating to the non-brazing material.

We claim: 
     
         1 . A cutting tool, comprising:
 a sintered superabrasive tip having a plurality of superhard particles;   a tool body retaining the superabrasive tip; and   a non-brazing material filling a gap between the superabrasive tip and the tool body.   
     
     
         2 . The cutting tool of the  claim 1 , wherein the superhard particles are selected from a group of cubic boron nitride, diamond, diamond composite, and ceramic materials. 
     
     
         3 . The cutting tool of the  claim 1 , wherein the non-brazing material is at least one of zeolite, cubic boron nitride, diamond, and ceramic. 
     
     
         4 . The cutting tool of the  claim 1 , further comprises coatings on the non-brazing material. 
     
     
         5 . The cutting tool of the  claim 1 , wherein the non-brazing material has melting point at least 1000° C. 
     
     
         6 . The cutting tool of the  claim 4 , wherein the coatings comprise at least one of Group IVB compounds containing C, N, O, B. 
     
     
         7 . The cutting tool of the  claim 1 , wherein the tool body is made at least one of tungsten carbide, ceramic, or cermet. 
     
     
         8 . The cutting tool of the  claim 4 , wherein the coatings cover the sintered superabrasive tip and the tool body. 
     
     
         9 . A method, comprising:
 providing a superabrasive tip;   providing a tool body;   filling a gap between the superabrasive tip and the tool body with a non-brazing material; and   depositing a first coating to the non-brazing material.   
     
     
         10 . The method of the  claim 9 , further comprising depositing the first coating is an infiltrant coating to bond the superabrasive tip, the tool body, and non-brazing materials together. 
     
     
         11 . The method of the  claim 10 , wherein the first coatings comprise at least one of Group IVB compounds containing C, N, O, B. 
     
     
         12 . The method of the  claim 9 , further comprising depositing a second coating or sequence of multilayered coatings to the sintered superabrasive tip, the tool body, and the non-brazing material. 
     
     
         13 . The method of the  claim 12 , wherein the second coating or sequence of multilayered coatings comprises at least one layer of high temperature resistant oxide coating. 
     
     
         14 . The method of the  claim 12 , wherein the high temperature resistant oxide coating is aluminum oxide coating. 
     
     
         15 . The method of the  claim 11 , further comprising bonding the non-brazing material, sintered superabrasive tip and the tool body. 
     
     
         16 . The method of the  claim 9 , wherein the deposition of the first coating is via chemical vapor deposition. 
     
     
         17 . The method of the  claim 9 , wherein the deposition of the first coating is via chemical vapor infiltration. 
     
     
         18 . A cutting tool, comprising:
 a sintered superabrasive tip having a plurality of superhard particles;   a tool body retaining the superabrasive tip;   infiltrant bond coating between the superabrasive tip and tool body; and   high temperature resistant coatings deposited to the sintered superabrasive tip and the tool body.   
     
     
         19 . The cutting tool of the  claim 18 , further comprising a non-brazing material disposed between the superabrasive tip and the tool body. 
     
     
         20 . The cutting tool of the  claim 18 , wherein high temperature resistant coating is aluminum oxide. 
     
     
         21 . The cutting tool of the  claim 19 , wherein the non-brazing material is bonded to the superabrasive tip and the tool body. 
     
     
         22 . The cutting tool of the  claim 18 , wherein the superabrasive tip has superhard particles wherein the superabrasive particles are selected from a group of cubic boron nitride, diamond, diamond composite, and ceramic materials. 
     
     
         23 . The cutting tool of the  claim 19 , wherein the non-brazing material comprises at least one of zeolite, cubic boron nitride, diamond, and ceramic material. 
     
     
         24 . The cutting tool of the  claim 23 , wherein the non-brazing material is bonded by a high temperature coating or coatings. 
     
     
         25 . The cutting tool of the  claim 18 , wherein the high temperature coating is selected from at least one of Group IVB compounds containing C, N, O, B. 
     
     
         26 . The cutting tool of the  claim 18 , wherein the sintered superabrasive tip has a backing support. 
     
     
         27 . The cutting tool of the  claim 26 , wherein the backing support is hard metal support. 
     
     
         28 . The cutting tool of the  claim 27 , wherein the hard metal support is tungsten carbide.