scholarly journals DLC and DLC-WS2 Coatings for Machining of Aluminium Alloys

Coatings ◽  
2019 ◽  
Vol 9 (3) ◽  
pp. 192 ◽  
Author(s):  
Tomasz Brzezinka ◽  
Jeff Rao ◽  
Jose Paiva ◽  
Joern Kohlscheen ◽  
German Fox-Rabinovich ◽  
...  
Keyword(s):  
Wear Rate ◽  
Tool Life ◽  
Physical Vapor Deposition ◽  
Methodological Approach ◽  
Cutting Tools ◽  
Vacuum Arc ◽  
Limiting Factor ◽  
Dlc Coating ◽  
Operational Life ◽  
Filtered Cathodic Vacuum Arc

Machine-tool life is one limiting factor affecting productivity. The requirement for wear-resistant materials for cutting tools to increase their longevity is therefore critical. Titanium diboride (TiB2) coated cutting tools have been successfully employed for machining of AlSi alloys widely used in the automotive industry. This paper presents a methodological approach to improving the self-lubricating properties within the cutting zone of a tungsten carbide milling insert precoated with TiB2, thereby increasing the operational life of the tool. A unique hybrid Physical Vapor Deposition (PVD) system was used in this study, allowing diamond-like carbon (DLC) to be deposited by filtered cathodic vacuum arc (FCVA) while PVD magnetron sputtering was employed to deposit WS2. A series of ~100-nm monolayer DLC coatings were prepared at a negative bias voltage ranging between −50 and −200 V, along with multilayered DLC-WS2 coatings (total thickness ~500 nm) with varying number of layers (two to 24 in total). The wear rate of the coated milling inserts was investigated by measuring the flank wear during face milling of an Al-10Si. It was ascertained that employing monolayer DLC coating reduced the coated tool wear rate by ~85% compared to a TiB2 benchmark. Combining DLC with WS2 as a multilayered coating further improved tool life. The best tribological properties were found for a two-layer DLC-WS2 coating which decreased wear rate by ~75% compared to TiB2, with a measured coefficient of friction of 0.05.

Precision Coating of ta-C Films on Quartz Surfaces

2020 ◽  
Author(s):  
Kotaro Kawai ◽  
Yuki Hirata ◽  
Hiroki Akasaka ◽  
Naoto Ohtake
Keyword(s):  
Cutting Tools ◽  
Three Dimensional ◽  
High Hardness ◽  
Carbon Films ◽  
Vacuum Arc ◽  
High Wear Resistance ◽  
Chemical Inertness ◽  
Filtered Cathodic Vacuum Arc ◽  
Surface Morphologies

Abstract Diamond-like carbon (DLC) films have excellent properties such as high hardness, low friction coefficient, high wear resistance, chemical inertness and so on. Because DLC film is considered as an effective coating material to improve their surface properties, this films are used in various applications such as parts for automobiles engines, hard disk surfaces, cutting tools and dies, and so on. DLC films consist of a mixture of sp2 bonded carbon atoms and sp3 bonded carbon atoms. Among them, ta-C film is known as the hardest and strongest film since it mainly consists of sp3 bonded carbon atoms. One of deposition methods to form ta-C is Filtered Cathodic Vacuum Arc (FCVA). The characteristic of this method is that it is possible to remove the droplets and form a high-quality film.. However, even though lots of mechanical components which require ta-C coating have three-dimensionally shapes, it is difficult to coat ta-C film three dimensionally by using FCVA process. At present, researches on 3D deposition of amorphous carbon films on three dimensional components is still insufficient, and investigation reports on the deposition mechanism and characterization of the deposited films are even more limited. In this study, we tried to deposit films on 3D components by the FCVA method and evaluated the microstructure and surface morphologies of films. Although films were coated successfully in the entire surfaces, different properties were showed depending on the location of components. These properties were investigated by Raman spectroscopy and laser microscope.

scholarly journals Improvement of structure and quality of nanoscale multilayered composite coatings, deposited by filtered cathodic vacuum arc deposition method

2016 ◽  
Vol 7 ◽  
pp. 184798041668080 ◽  
Author(s):  
Alexey A Vereschaka ◽  
Anatoly S Vereschaka ◽  
Andre DL Batako ◽  
Boris J Mokritskii ◽  
Anatoliy Y Aksenenko ◽  
...  
Keyword(s):  
Composite Coating ◽  
Surface Defects ◽  
Composite Coatings ◽  
Cutting Tools ◽  
Vacuum Arc ◽  
Multilayered Composite ◽  
Vacuum Arc Deposition ◽  
Filtered Cathodic Vacuum Arc ◽  
Longitudinal Turning ◽  
Arc Deposition

This article studies the specific features of cathode vacuum arc deposition of coatings used in the production of cutting tools. The detailed analysis of the major drawbacks of arc-Physical Vapour Deposition (PVD) methods has contributed to the development of the processes of filtered cathodic vacuum arc deposition to form nanoscale multilayered composite coatings of increased efficiency. This is achieved through the formation of nanostructure, increase in strength of adhesion of coating to substrate up to 20%, and reduction of such dangerous coating surface defects as macro- and microdroplets up to 80%. This article presents the results of the studies of various properties of developed nanoscale multilayered composite coating. The certification tests of carbide tool equipped with cutting inserts with developed nanoscale multilayered composite coating compositions in longitudinal turning (continuous cutting) and end symmetric milling, and intermittent cutting of steel C45 and hard-to-cut nickel alloy of NiCr20TiAl showed advantages of tool with nanoscale multilayered composite coating as compared to the tool without coating. The lifetime of the carbide inserts with developed NMCC based on the system of Ti–TiN–(NbZrTiCr)N (filtered cathodic vacuum arc deposition) was increased up to 5–6 times in comparison with the control tools without coatings and up to 1.5–2.0 times in comparison with nanoscale multilayered composite coating based on the system of Ti–TiN–(NbZrTiCr)N (standard arc-PVD technology).

Control of Structure and Properties of Nanostructured Multilayer Composite Coatings Applied to Cutting Tools as a Way to Improve Efficiency of Technological Cutting Operations

2015 ◽  
Vol 37 ◽  
pp. 51-57 ◽  
Author(s):  
Anatoliy Stepanovich Vereschaka ◽  
Alexey Anatolevich Vereschaka ◽  
D.V. Sladkov ◽  
A.Yu. Aksenenko ◽  
N.N. Sitnikov
Keyword(s):  
Composite Coatings ◽  
Cutting Tools ◽  
Nitrogen Pressure ◽  
Lattice Parameter ◽  
Vacuum Arc ◽  
Structures And Properties ◽  
Arc Current ◽  
Coating Synthesis ◽  
Cathode Arc ◽  
Filtered Cathodic Vacuum Arc

The study considers the challenge of improving the efficiency of dry finishing and semi-finishing turning of (P10-P20) steel with carbide tools with complex composition coatings by directed selection of the composition and properties of the coatings through the control of the parameters of the filtered cathodic vacuum-arc deposition (FCVAD). The conducted tests have confirmed the feasibility and effectiveness of the control of compositions, structures, and properties of complex composite coatings of Ti-TiN-TiAlN type by varying the parameters of the FCVAD process. In particular, it has been found out that the ratio of Ti/Al, which greatly affects the important properties of the coating (grain size, lattice parameter, microhardness, fracture toughness, etc.), can be changed at constant compositions of cathodes by varying such parameters of coating synthesis as titanium cathode arc current, nitrogen pressure, and substrate shear stress. It has been shown that Ti-TiN-TiAlN coating produced at different values of the parameters of synthesis significantly changes the cutting properties of carbide tool and thus allows optimizing the coating composition for a variety of machining conditions.The developed methods are also applicable for multi-component complex composite coatings.

Development of Assisted Filtered Cathodic Vacuum Arc Deposition of Nano-Dispersed Multi-Layered Composite Coatings on Cutting Tools

2013 ◽  
Vol 581 ◽  
pp. 62-67 ◽  
Author(s):  
Alexey Anatolevich Vereschaka
Keyword(s):  
Composite Coatings ◽  
Cutting Tools ◽  
High Energy ◽  
Layered Composite ◽  
Vacuum Arc ◽  
Wide Range ◽  
High Energy Ions ◽  
Vacuum Arc Deposition ◽  
Filtered Cathodic Vacuum Arc ◽  
Tool Types

This paper presents the results of development and application of processes for modification of various properties of working surfaces of cutting tools by condensing vapor and ion flows in assisting impulse or constant exposure to high-energy ions. The paper shows features of the technology and equipment for the formation of wear-resistant components, which modify the structure and properties of working surfaces of various edge cutting tool types in a wide range of temperatures, in order to improve tool life and reliability. Various properties of the modifying components were studied, and their ability to improve the operational efficiency of different types of carbide cutting tools for cutting various materials was shown.

scholarly journals Friction and Wear Mechanisms of Cu/ta-C Coatings Under PAO-4 and PAO-4 with MoDTC Lubrication

2020 ◽  
Vol 01 (04) ◽  
pp. 183-187
Author(s):  
Decelyne Elly Binjua ◽  
Seock-Sam Kim ◽  
Young-Jun Jang ◽  
Jong-Kuk Kim
Keyword(s):  
Friction Coefficient ◽  
Wear Rate ◽  
Friction And Wear ◽  
Vacuum Arc ◽  
Dlc Coatings ◽  
Base Oil ◽  
Tetrahedral Amorphous Carbon ◽  
Friction And Wear Mechanisms ◽  
Alpha Olefin ◽  
Filtered Cathodic Vacuum Arc

The tribological behavior of various types of DLC coatings in formulated and non-formulated lubricants are needed for proper usage of these coatings. In this research, the friction and wear mechanism of four different DLC coatings in poly-alpha-olefin type 4 (PAO-4) with and without MoDTC were investigated using ball-on-disc tribometer. One ta-C (tetrahedral amorphous carbon) and three Cu/ta-C (copper doped ta-C) with different sputter power of 50 W, 150 W, and 200 W coatings were deposited on silicon wafers by using FCVA (filtered cathodic vacuum arc) technique for this research. The results indicate that ta-C coating on silicon wafer has the lowest average friction coefficient (CoF) and better wear resistance than Cu/ta-C coating when lubricated under PAO-4 oil with MoDTC. Cu/ta-C with sputter powers of 150 W and 200 W exhibited the highest average friction coefficient under PAO-4 oil with MoDTC. Meanwhile, the average CoF for all samples were similar under PAO-4 base oil. In terms of wear, ta-C coating showed the highest wear rate under PAO-4 base oil then followed by Cu/ta-C with sputter power of 50 W. Nonetheless, Cu/ta-C with sputter powers of 150 W and 200 W exhibited significantly low wear rate under PAO-4 base oil compared to PAO-4 oil with MoDTC.

Effect of residual elements on the machinability of leaded free machining steels

1980 ◽  
Vol 295 (1413) ◽  
pp. 87-88 ◽  
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Tool Material ◽  
High Speed Steel ◽  
Low Carbon ◽  
Wear Rates

The machinability of a material can be defined in terms of the wear rate of the cutting tool used to machine the material. The lower the tool wear rate or the greater the tool life the better the machinability. The wear processes of cutting tools are complicated, but recent work has shown that cutting tool wear rates during machining can be directly related to tool material wear rates when rubbing in a modified crossed cylinder wear experiment (Mills & Akhtar 1975). The wear of cutting tools can be simulated by simple experiments. Here I present results on the effect of total residual levels in leaded low carbon free machining steels on the tool life of M2 high speed steel. The results will be discussed in terms of a simple wear model.

DUPLEX Al2O3/DLC COATING ON 15SiCp/2024 ALUMINUM MATRIX COMPOSITE USING COMBINED MICROARC OXIDATION AND FILTERED CATHODIC VACUUM ARC DEPOSITION

2012 ◽  
Vol 19 (04) ◽  
pp. 1250036 ◽  
Author(s):  
WENBIN XUE ◽  
HUA TIAN ◽  
JIANCHENG DU ◽  
MING HUA ◽  
XU ZHANG ◽  
...  
Keyword(s):  
Friction Coefficient ◽  
Matrix Composite ◽  
Carbon Film ◽  
Microarc Oxidation ◽  
Aluminum Matrix ◽  
Aluminum Matrix Composite ◽  
Vacuum Arc ◽  
Low Friction ◽  
Dlc Coating ◽  
Filtered Cathodic Vacuum Arc

Microarc oxidation (MAO) treatment produces a thick Al2O3 coating on the 15SiCp/2024 aluminum matrix composite. After pretreatment of Ti ion implantation, a thin diamond-like carbon film (DLC) was deposited on the top of polished Al2O3 coating by a pulsed filtered cathodic vacuum arc (FCVA) deposition system with a metal vapor vacuum arc (MEVVA) source. The morphology and tribological properties of the duplex Al2O3 /DLC multiplayer coating were investigated by Raman spectroscopy, scanning electron microscopy (SEM) and SRV ball-on-disk friction tester. It is found that the duplex Al2O3 /DLC coating had good adhesion and a low friction coefficient of less than 0.07. As compared to a single Al2O3 or DLC coating, the duplex Al2O3 /DLC coating on aluminum matrix composite exhibited a better wear resistance against ZrO2 ball under dry sliding, because the Al2O3 coating as an intermediate layer improved load support for the top DLC coating on 15SiCp/2024 composite substrate, meanwhile the top DLC coating displayed low friction coefficient.

Nano-Scale Multi-Layered Coatings for Cutting Tools Generated Using Assisted Filtered Cathodic-Vacuum-Arc Deposition (AFCVAD)

2013 ◽  
Vol 325-326 ◽  
pp. 1454-1459 ◽  
Author(s):  
A.A. Vereschaka ◽  
A.S. Vereschaka ◽  
S.N. Grigoriev ◽  
D.V. Sladkov
Keyword(s):  
High Efficiency ◽  
Cutting Tools ◽  
Deposition Process ◽  
High Energy ◽  
Vacuum Arc ◽  
Properties Of Coatings ◽  
Vacuum Arc Deposition ◽  
Filtered Cathodic Vacuum Arc ◽  
Carbide Inserts ◽  
Arc Deposition

The subject of this study were nano-nanoscale multilayer coatings formed using the process of filtered cathodic vacuum arc deposition in assisting high-energy ions of chromium. We used a special emitter (implantor) to generate chromium ions with high energy. Such key parameters of coatings as composition, structure, a thickness, hardness, adhesion in relation to a substrate obtained at various energy of chrome ions have been studied. It is establish the positive change of key properties of coating deposited on carbide inserts WC/CrC/Co, WC / (Co-Re), TiC/TaC/Co at assisted impact of ions Cr at ion acceleration voltage within the range of 10-40 kV. The results of measurement of parameters of coatings with use nanoindentometer are consistent with the X-ray analysis of the stresses in the coating (XSA study). The mechanisms of the effect of modified properties of coatings formed in assisting the filtered cathodic vacuum arc deposition on the properties of the carbide inserts in cutting structural steels and hard-to-cut nickel alloys have confirmed the high efficiency of the deposition process developed coatings and coating compositions.

scholarly journals Increase in Efficiency of End Milling of Titanium Alloys Due to Tools with Multilayered Composite Nano-Structured Zr-ZrN-(Zr,Al)N and Zr-ZrN-(Zr,Cr,Al)N Coatings

Coatings ◽  
2018 ◽  
Vol 8 (11) ◽  
pp. 395 ◽  
Author(s):  
Alexey Vereschaka ◽  
Maksim Oganyan ◽  
Yuri Bublikov ◽  
Nikolay Sitnikov ◽  
Konstantin Deev ◽  
...  
Keyword(s):  
Titanium Alloys ◽  
Metal Cutting ◽  
End Milling ◽  
Cutting Tools ◽  
Vacuum Arc ◽  
Multilayered Composite ◽  
Vacuum Arc Deposition ◽  
Filtered Cathodic Vacuum Arc ◽  
Life Parameter

The study deals with an increase in the tool life parameter for metal-cutting tools and efficiency of end milling for titanium alloys, due to the use of tools with multilayered composite nano-structured Zr–ZrN–(Zr,Al)N and Zr–ZrN–(Zr,Cr,Al)N coatings, deposited through the technology of the filtered cathodic vacuum arc deposition (FCVAD). The studies included the microstructured investigations using SEM, the analysis of chemical composition (Energy-dispersive X-ray spectroscopy, EDXS), the determination of the value of critical failure force (with the use of scratch testing), and the measurement of the microhardness of the coatings under study. The cutting tests were conducted in end milling of titanium alloys at various cutting speeds. The mechanisms of wear and failure for end milling cutters with the coatings under study were studied in milling. The studies determined the advantages of using a tool with the coatings under study compared to an uncoated tool, as well as to tools with the commercial Ti–TiN coating and the nano-structured Ti–TiN–(Ti,Al)N coating. Adding Cr to the composition of the coating can significantly increase the hardness, while the coating retains sufficient ductility and brittle fracture resistance, which allows for a best result when milling titanium alloys.

Increased Operating Properties of Cutting Ceramics by Application of Nanostructured Multilayer Wear-Resistant Coating

2017 ◽  
Vol 50 ◽  
pp. 90-104 ◽  
Author(s):  
Alexey Anatolevich Vereschaka ◽  
Marina Aleksandrovna Volosova ◽  
Alexey A. Krapostin ◽  
Andre Batako ◽  
Anton Evgenievich Seleznev
Keyword(s):  
High Speed ◽  
Composite Coatings ◽  
Cutting Tools ◽  
Physical And Mechanical Properties ◽  
Deposition Process ◽  
Layered Composite ◽  
Vacuum Arc ◽  
Ceramic Substrates ◽  
Filtered Cathodic Vacuum Arc ◽  
Longitudinal Turning

This paper presents the results of the development of nanoscale multi-layered composite coatings for improving the contact performance of ceramic cutting tools. These nanocoatings help reducing brittle fracture of cutting edges and ensure a balanced wear of tool contact areas during dry high-speed machining of hardened steels. A filtered cathodic vacuum arc deposition process was used to generate the nanoscale multi-layered composite coatings (NMCC) with improved physical and mechanical properties and adhesion strength to ceramic substrate. In this work, thermodynamic criteria were used to evaluate the selected composition of NMCC, and the crystal-chemical, physical, mechanical and cutting properties and wear mechanisms were studied. Ti-(TiAl)N-(ZrNbTiAl)N coating was deposited on Al2O3, Al2O3-TiC and Si3N4 ceramic substrates. Test results showed that the wear mechanism of the coated tool was predominantly due to adhesive-fatigue processes. The development of wear was observed to be centered on the rake and flank faces of the tool without brittle chipping. The results of high-speed longitudinal turning of hardened steel X153CrMoV12 showed an increase in tool life by a factor of 1.5 against the uncoated tools and a factor of 1.3 compared with standard PVD coating Ti-(TiAl)N.

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