Tool with wear detection

Patent metadata

Field	Value
Publication number	US-12485491-B2
Application number	US-202218081635-A
Country	US
Kind code	B2
Filing date	Dec 14, 2022
Priority date	Dec 14, 2021
Publication date	Dec 2, 2025
Grant date	Dec 2, 2025

Abstract

A coated tool, such as a rotating, cutting tool, includes a tool body and a multilayer wear protection coating system. The wear protection system coats a functional surface of the tool body that is subject to wear and includes a first undoped diamond layer and a second undoped diamond layer disposed over the first undoped diamond layer. The first undoped diamond layer is electrically conductive and exhibits grain boundary conductivity from delocalized electrons. The second undoped diamond layer is electrically insulating. The first undoped diamond layer is 4-20 microns thick and is made with diamond grains whose size ranges from 4-10 nm. The first and second diamond layers are applied by chemical vapor deposition (CVD) using a hot-wire method. The wear protection system also includes an additional undoped diamond layer that is electrically insulating and is disposed between the functional surface of the tool body and the first diamond layer.

First claim

What is claimed is:

1 . A coated tool comprising:
a tool body; and a multilayer wear protection coating system that coats a functional surface of the tool body that is subject to wear, wherein the multilayer wear protection coating system includes:
a first undoped diamond layer; and
a second undoped diamond layer disposed over the first undoped diamond layer, wherein the first undoped diamond layer is electrically conductive, wherein the first undoped diamond layer is comprised of graphite disposed between diamond grains formed without using doping gas, wherein the diamond grains have a grain size of 15 nm or less, wherein the diamond grains have a crystal structure of bonds based on a sp 3 -hybridized carbon atomic orbital structure, wherein the first undoped diamond layer exhibits grain boundary conductivity from delocalized electrons, and wherein the second undoped diamond layer is electrically insulating.

2 . The coated tool of claim 1 , wherein the tool body is made of a metal-ceramic composite.

3 . The coated tool of claim 1 , wherein the first undoped diamond layer is comprised of diamond grains having a grain size, and wherein the grain size has a range from 4 nm to 10 nm.

4 . The coated tool of claim 1 , wherein the first undoped diamond layer has a first thickness, wherein the first thickness of the first undoped diamond layer has a range of 4 μm to 20 μm, wherein the second undoped diamond layer has a second thickness, and wherein the second thickness of the second undoped diamond layer has a range of 4 μm to 20 μm.

5 . The coated tool of claim 1 , wherein the first undoped diamond layer and the second undoped diamond layer are applied by chemical vapor deposition (CVD) using a hot-wire method.

6 . The coated tool of claim 1 , wherein the tool body is comprised of hard material particles embedded in a binder matrix, wherein the hard material particles include a substance selected from the group consisting of: a carbide, a nitride, a boride, an oxide and a silicide, and wherein the binder matrix includes cobalt or nickel.

7 . The coated tool of claim 1 , wherein the tool body is comprised of hard material particles that include a compound selected from the group consisting of: a carbide, a nitride, a boride, an oxide and a silicide of a metal of group IV, V or VI of the periodic table of elements.

8 . The coated tool of claim 1 , wherein the tool body is comprised of a compound selected from the group consisting of: titanium carbide, titanium nitride, titanium carbonitride, tungsten carbide, (W, Co) 6 C, vanadium carbide, niobium carbide, tantalum carbide, chromium carbide, molybdenum carbide, titanium diboride, zirconium diboride, hafnium diboride, silicon nitride, titanium aluminum nitride, aluminum oxide, zirconium oxide, chromium oxide and MgAl 2 O 4 spinel.

9 . The coated tool of claim 1 , wherein the multilayer wear protection coating system further includes an additional undoped diamond layer, wherein the additional undoped diamond layer is electrically insulating, and wherein the additional undoped diamond layer is disposed between the functional surface of the tool body and the first undoped diamond layer.

10 . The coated tool of claim 1 , wherein the multilayer wear protection coating system further includes a third undoped diamond layer and a fourth undoped diamond layer, wherein the third undoped diamond layer is disposed over the second undoped diamond layer, wherein the fourth undoped diamond layer is disposed over the third undoped diamond layer, wherein the third undoped diamond layer is electrically conductive, and wherein the fourth undoped diamond layer is electrically insulating.

11 . The coated tool of claim 1 , wherein the coated tool is a rotating, cutting tool.

12 . A method of manufacturing a coated tool, comprising:
applying a first undoped diamond layer over a functional surface of a tool body, wherein the first undoped diamond layer is applied using chemical vapor deposition (CVD) from an atmosphere of methane and hydrogen in a CVD chamber, wherein the first undoped diamond layer is electrically conductive, and wherein the first undoped diamond layer exhibits grain boundary conductivity from delocalized electrons; and applying a second undoped diamond layer over the first undoped diamond layer, wherein the second undoped diamond layer is electrically insulating, and wherein as the first undoped diamond layer is applied, a mass flow rate of the methane is maintained in a range of 75-105 standard cubic centimeters per minute.

13 . The method of claim 12 , wherein the chemical vapor deposition (CVD) is performed using a hot-wire method, and wherein a wire made of tungsten is used in the hot-wire method.

14 . The method of claim 12 , wherein the hydrogen is admixed with the methane in molar excess of the methane.

15 . The method of claim 12 , wherein a temperature is maintained in the CVD chamber during the chemical vapor deposition (CVD) between 650° C. and 1100° C., and wherein a pressure is maintained in the CVD chamber during the chemical vapor deposition (CVD) between 1 mbar and 10 mbar.

16 . The method of claim 12 , wherein the tool body is ceramic.

17 . The method of claim 12 , wherein the first undoped diamond layer is comprised of diamond grains having a grain size in a range from 4 nm to 10 nm.

18 . The method of claim 12 , wherein the first undoped diamond layer has a thickness in a range of 4 μm to 20 μm.

19 . A method of manufacturing a coated tool, comprising:
applying a first undoped diamond layer over a functional surface of a tool body, wherein the first undoped diamond layer is formed using chemical vapor deposition (CVD) from an atmosphere of methane and hydrogen in a CVD chamber, wherein the first undoped diamond layer is formed without using doping gas, wherein the first undoped diamond layer is electrically conductive, and wherein the first undoped diamond layer exhibits grain boundary conductivity from delocalized electrons; and applying a second undoped diamond layer over the first undoped diamond layer, wherein the second undoped diamond layer is electrically insulating.

Assignees

• Guehring Kg

Inventors

• Garrn Immo
• Gluche Peter

Classifications

• B23B2228/44

  Materials having grain size less than 1 micrometre, e.g. nanocrystalline · CPC title

• B23B2228/41

  Highly conductive · CPC title

• B23B2228/36

  Multi-layered · CPC title

• B23B2228/24

  Hard, i.e. after being hardened · CPC title

• B23B2228/105

  with specified thickness · CPC title