Single-crystal – oriented-crystal – and epitaxy growth processes; – Processes of growth from liquid or supercritical state – Havin growth from molten state
Patent
1998-03-20
1999-08-10
Hiteshew, Felisa
Single-crystal, oriented-crystal, and epitaxy growth processes;
Processes of growth from liquid or supercritical state
Havin growth from molten state
117 95, 117923, 423446, 4272556, G30B 2504
Patent
active
059353236
DESCRIPTION:
BRIEF SUMMARY
FIELD OF INVENTION
The present invention relates to a base material covered with a diamond coating and the manufacturing process thereof which is used of recutting tools such as cutting chips, drills, and end mills, whetstone tools, and wear resistant abrasion tools. Particularly, it relates to a diamond coated material and the manufacturing process thereof, which diamond coated material has no warpage, flat shape and tenacious adherence with a base material, by dispersion reduction of internal stress provided in the diamond coating during forming.
BACKGROUND
According to the development of vapor-phase synthesis of diamond, development of diamond coating tools formed by vapor-phase synthesis has been actively pursued, wherein diamond material has been coated on a base material for tools such as cutting chips, drills, and end mills. In the case of directly coating the diamond on a base material for a tool by direct vapor-phase synthesis, the diamond coating may peel off from the base material depending on the method due to the stress resulting from thermal expansion coefficient difference between the materials of the base material and diamond, that is to say, residual stress produced from temperature difference during coating of the diamond on the base material, during cooling after coating, and therefore the productis deficient for practical usage. On the other hand, diamond material has been coated in advance on a specific base material by vapor-phase synthesis, and then the base material covered with the diamond coating obtained has been soldered directly attaching the base material and tool; or the base material has been removed by polishing after soldering, directly attaching the diamond surface and tool; or the diamond coating alone has been soldered to the tool after peeling the diamond coating from the diamond coated base material. In these methods, the thicker the diamond coating is, the more the residual stress increases, and in case of a thin base material, warpage occurs of the base material covered with the diamond coating. Once warpage occurs, troubles increase such as a longer polishing time is required to polish the coating surface, or the diamond coating is easily cracked during soldering to the tool. For example, laid-open Japanese patents Hei 1-167211, Hei 3-197677, and Hei 4-992278 disclose that formation of the coating is carried out in plural steps in order to improve tenacious adherence during forming of the diamond coating on the base material, and so the precipitated coating has a multilayered structure. Moreover, laid-open Japanese patent Hei-306195 proposes prevention of warpage of the coating during forming the diamond coating.
Laid-open Japanese patent Hei 1-167211 discloses a diamond-like carbon coating and the synthesis thereof having small coating stress and smooth surface flatness comprising diamond like carbon layer including a high content of amorphous carbon and that include a low content of amorphous carbon. The objective of this patent is to obtain a diamond like carbon layer having a flat surface and high light transmissivity for coating of a lens or window and providing a protective film for a magnetic disk, and it produces a coating of diamond like carbon formed by alternate precipitation of diamond like carbon layer including a high content of amorphous carbon and that includes a low content of amorphous carbon was obtained by periodically changing the temperature of the base material, electromagnetic wave energy such as microwave and high frequency, concentration of carbon source, and reaction pressure. However, the objective of this patent is to obtain a diamond like carbon layer having flat surface and high light transmissivity, and in order to obtain a coating having smooth surface flatness without surface polishing such as lapping after forming coating, the uppermost surface layer needs to have smooth surface flatness but to have low hardness of diamond like carbon layer including high content of amorphous carbon; and therefore it is not suitable for use as
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patent: 5635243 (1997-06-01), Turchan et al.
patent: 5648127 (1997-07-01), Turchan
patent: 5707409 (1998-01-01), Martin et al.
Kitagawa Takahiro
Tanga Michifumi
Hiteshew Felisa
Toyo Kohan Co. Ltd.
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