Abstract: A coated cutting insert and a method for making the same. The coated cutting insert has a substrate with a substrate surface. There is a backing coating scheme on the substrate surface, and a TiAl2O3 coating layer wherein the TiAl2O3 coating layer is deposited using chemical vapor deposition from a gaseous composition including AlCl3, H2, TiCl4, CO2 and HCl.

Abstract: In one aspect, cutting tools are described having coatings adhered thereto which, in some embodiments, can demonstrate desirable wear resistance and increased cutting lifetimes. A coated cutting tool, in some embodiments, comprises a substrate and a coating adhered to the substrate, the coating comprising a polycrystalline layer of TiZrAl2O3.

Abstract: In one aspect, methods of making freestanding metal matrix composite articles and alloy articles are described. A method of making a freestanding composite article described herein comprises disposing over a surface of the temporary substrate a layered assembly comprising a layer of infiltration metal or alloy and a hard particle layer formed of a flexible sheet comprising organic binder and the hard particles. The layered assembly is heated to infiltrate the hard particle layer with metal or alloy providing a metal matrix composite, and the metal matrix composite is separated from the temporary substrate. Further, a method of making a freestanding alloy article described herein comprises disposing over the surface of a temporary substrate a flexible sheet comprising organic binder and powder alloy and heating the sheet to provide a sintered alloy article. The sintered alloy article is then separated from the temporary substrate.

Abstract: In one aspect, methods of making cladded articles are described herein. A method of making a cladded article, in some embodiments, comprises disposing over a surface of a metallic substrate a sheet comprising organic binder and powder metal or powder alloy having a solidus temperature at least 100° C. less than the metallic substrate and heating the powder metal or powder alloy to provide a sintered metal or sintered alloy cladding metallurgically bonded to the metallic substrate.

Abstract: Refractory coatings for cutting tool applications and methods of making the same are described herein which, in some embodiments, permit incorporation of increased levels of aluminum into nitride coatings while reducing or maintaining levels of hexagonal phase in such coatings. Coatings and methods described herein, for example, employ cubic phase forming compositions for limiting hexagonal phase in nitride coatings of high aluminum content.

Abstract: In one aspect, articles are described herein comprising wear-resistant claddings. An article described herein, in some embodiments, comprises a metallic substrate and a cladding adhered to the substrate, the cladding including a metal matrix composite layer comprising at least one hard particle tile having a pore structure infiltrated with matrix metal or matrix alloy. Infiltration of the pore structure of the hard particle tile by the matrix metal or alloy can render the tile fully dense or substantially fully dense.

Abstract: A method for making a coated article wherein the method includes the following steps: providing a substrate; and depositing an aluminum oxynitride coating layer from a gaseous mixture. The gaseous mixture contains the following components: 30.0-65.0 volume percent nitrogen, 0.7-1.3 volume percent aluminum tri-chloride; 1.0-2.0 volume percent ammonia, 0.1-1.5 carbon dioxide, 1.5-4.5 volume percent hydrogen chloride, optional components of carbon monoxide and/or argon, and hydrogen as the balance.

Abstract: In one aspect, composite articles are described comprising multifunctional coatings. A composite article described herein, in some embodiments, comprises a substrate and a coating adhered to the substrate, the coating comprising an inner layer and an outer layer, the inner layer comprising a presintered metal or alloy and the outer layer comprising particles disposed in a metal or alloy matrix.

Abstract: In one aspect, cutting tools are described having coatings adhered thereto. A coated cutting tool, in some embodiments, comprises a substrate and a coating adhered to the substrate, the coating comprising at least one composite layer deposited by chemical vapor deposition comprising an aluminum oxynitride phase and a metal oxide phase, the metal oxide phase including at least one oxide of a metallic element selected from Group IVB of the Periodic Table.

Abstract: In one aspect, coated cutting tools are described herein. A coated cutting tool described herein comprises a substrate and a coating adhered to the substrate, the coating comprising at least one composite layer deposited by chemical vapor deposition, the composite layer comprising an aluminum oxynitride phase, a metal oxide phase including zirconium oxide, a zirconium sulfur nitride phase and a metal oxynitride phase in addition to the aluminum oxynitride phase, the metal oxynitride phase comprising zirconium oxynitride.

Abstract: A coated wear-resistant member, as well as a method for making the same, includes a substrate and a coating scheme. The coating scheme has a region of alternating coating sublayers. One coating sublayer is TixAlySi100-x-yN wherein 40 atomic percent?x?80 atomic percent; 15 atomic percent?y?55 atomic percent; 4 atomic percent?100?x?y?15 atomic percent. The other coating sublayer is TipAl100-pN wherein 45 atomic percent?p?100 atomic percent. The method for making a coated wear-resistant member includes the steps of providing the substrate, and depositing the region of alternating coating sublayers.

Abstract: A coated cutting insert for removing material from a workpiece that includes a substrate is disclosed. A wear-resistant coating on the substrate that includes an alumina layer and a Zr- or Hf-carbonitride outer layer deposited on the alumina layer. The Zr- or Hf-carbonitride outer layer is subjected to a post-coat wet blasting treatment. The wet blasting changes the stress condition of the exposed alumina coating layer from an initial tensile stress condition to a compressive stress condition.

Abstract: A coated article such as a coated cutting tool or coated wear part, which includes a substrate and a coating scheme on the substrate. The coating scheme has a titanium-containing coating layer, and an aluminum oxynitride coating layer on the titanium-containing coating layer. The aluminum oxynitride includes a mixture of phases having a hexagonal aluminum nitride type structure (space group: P63mc), a cubic aluminum nitride type structure (space group: Fm-3m), and optionally amorphous structure. The aluminum oxynitride coating layer has a composition of aluminum in an amount between about 20 atomic percent and about 50 atomic percent, nitrogen in an amount between about 40 atomic percent and about 70 atomic percent, and oxygen in an amount between about 1 atomic percent and about 20 atomic percent.

Abstract: A coated article such as a coated cutting tool or coated wear part, which includes a substrate and a coating scheme on the substrate. The coating scheme has a titanium-containing coating layer, and an aluminum oxynitride coating layer on the titanium-containing coating layer. The aluminum oxynitride includes a mixture of phases having a hexagonal aluminum nitride type structure (space group: P63mc), a cubic aluminum nitride type structure (space group: Fm-3m), and optionally amorphous structure. The aluminum oxynitride coating layer has a composition of aluminum in an amount between about 20 atomic percent and about 50 atomic percent, nitrogen in an amount between about 40 atomic percent and about 70 atomic percent, and oxygen in an amount between about 1 atomic percent and about 20 atomic percent.

Abstract: A wear resistant multilayer nitride hard coating for substrates. The hard coating includes a first layer of titanium aluminum nitride and a second layer comprising a plurality of sublayer groups. Each sublayer group includes a first sublayer of titanium silicon nitride and a second sublayer of titanium aluminum nitride. The composition of the titanium aluminum nitride, both in the first layer and in the sublayer groups, is (TixAl1-x)N, wherein 0.4?x?0.6. The composition of the titanium silicon nitride sublayers is (TiySi1-y)N, wherein 0.85?y?0.98, and all of the silicon is in solid solution in the titanium silicon nitride such that no silicon phase or silicon nitride phase exists in this sublayer. The combined amount of aluminum and silicon present in the sublayer groups being narrowly controlled such that the sum of x and y is in the range of 1.38 to 1.46.

Abstract: A coated polycrystalline cubic boron nitride cutting insert useful in a cutting tool for removing material from a workpiece, and a method for making the same. The cutting insert including a polycrystalline cubic boron nitride substrate with a rake surface and at least one flank surface, and a cutting edge formed at the juncture between the rake surface and the flank surface. A wear-resistant coating scheme is on the polycrystalline cubic boron nitride substrate. The wear-resistant coating scheme includes the following coating layers. An inner coating layer region is on at least some of the rake surface and at least some of the flank surface of the polycrystalline cubic boron nitride substrate. An alumina-containing coating layer region, which has at least one exposed alumina coating layer, is on the inner coating layer region.

Abstract: A coated ceramic cutting insert for removing material from a workpiece, as well as a method for making the same, that includes a ceramic substrate with a rake surface and at least one flank surface wherein a cutting edge is at the juncture therebetween. A wear-resistant coating scheme that includes an alumina-containing base coating layer region, which has at least one exposed alumina coating layer, deposited by chemical vapor deposition on the substantially all of the surfaces of the ceramic substrate that experience wear during removal of material from the workpiece. The exposed alumina coating layer exhibits a blasted stress condition ranging between about 50 MPa (tensile stress) and about ?2 GPa (compressive) as measured by XRD using the Psi tilt method and the (024) reflection of alumina. The exposed alumina coating layer is the result of wet blasting a titanium-containing outer coating layer region from the surface of the alumina-containing base coating layer region.

Abstract: In one aspect, the present invention provides coated cutting tools comprising a PcBN substrate wherein a layer of single phase ?-alumina is deposited by chemical vapor deposition directly on one or more surfaces of the substrate.

Abstract: A coated article has a substrate and a coating scheme, which has a PVD coating region. The PVD coating region contains aluminum, yttrium, nitrogen and at least one element selected from the group of titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten and silicon. The sum of the aluminum and yttrium contents is between about 3 atomic percent and about 55 atomic percent of the sum of aluminum, yttrium and the other elements. The yttrium content is between about 0.5 atomic percent and about 5 atomic percent of the sum of aluminum, yttrium and the other elements. There is also a method of making the coated article that includes steps of providing the substrate and depositing the above coating scheme with the PVD coating region.

Abstract: A coated ceramic cutting insert for removing material from a workpiece, as well as a method for making the same, that includes a ceramic substrate with a rake surface and at least one flank surface wherein a cutting edge is at the juncture therebetween. A wear-resistant coating scheme that includes an alumina-containing base coating layer region, which has at least one exposed alumina coating layer, deposited by chemical vapor deposition on the substantially all of the surfaces of the ceramic substrate that experience wear during removal of material from the workpiece. The exposed alumina coating layer exhibits a blasted stress condition ranging between about 50 MPa (tensile stress) and about ?2 GPa (compressive) as measured by XRD using the Psi tilt method and the (024) reflection of alumina. The exposed alumina coating layer is the result of wet blasting a titanium-containing outer coating layer region from the surface of the alumina-containing base coating layer region.