Development of DLC Coated Tool for Cutting of Aluminum Alloy －Influence of Deposition Condition on Cutting Characteristic－

2008 ◽  
Vol 389-390 ◽  
pp. 163-168
Author(s):  
Kazushi Minaki ◽  
Koichi Kitajima ◽  
Yu Nakahira ◽  
Masami Ohnishi ◽  
Takashi Sugimoto ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Internal Stress ◽  
Material Surface ◽  
Deposition Condition ◽  
Dlc Film ◽  
Ductile Materials ◽  
Dlc Coating ◽  
Work Material ◽  
Tool Surface ◽  
Hydrocarbon Gas

Conventional coating tools have a high affinity for ductile materials, like aluminum alloy, so cutting chips tend to adhere to cutting edge and work material surface. Therefore, chipping is caused, and surface texture is degraded. In order to solve these problems, recently, DLC (Diamond-Like-Carbon) has been applied to coating material. In this research, it is curried out cutting of Aluminum alloy by the use of DLC coating tool, and examined influence of DLC coating conditions on cutting characteristics. So far we have been concerned with the effect of type of hydrocarbon gas (acethylene:C2H2, methane:CH4) on cutting. As a result, it is revealed that cohesion of chips decreases, and surface roughness of work material improves in the case of acethylene-DLC. On the other hand, internal stress is produced by deference in hardness between tool surface and DLC film, and which is considered cause of film peeling [1]. Therefore, we examined interlayer between DLC film and tool surface in order to relax of internal stress. As a result, it was cleared that Titanium interlayer excels in adhesion.

scholarly journals Study on the Influence of Surface Temperature Field of Aluminum Alloy Etched by Laser Water Jet Composite Machining

Materials ◽  
2020 ◽  
Vol 13 (14) ◽  
pp. 3206
Author(s):  
Xuehui Chen ◽  
Xin Xu ◽  
Wei Liu ◽  
Lei Huang ◽  
Hao Li ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Temperature Field ◽  
Surface Temperature ◽  
Process Parameters ◽  
Water Jet ◽  
Laser Machining ◽  
Material Surface ◽  
Laser Etching ◽  
Surface Temperature Field

This paper studies the compound effect of liquid medium and laser on the workpiece and analyses the law of material surface temperature change during the processing. Taking 7075-T6 aluminum alloy as the research object, the surface temperature field of aluminum alloy processed using water-jet-assisted laser machining under different process parameters was simulated using finite element software. In addition, the temperature field of the material surface was detected in real-time using the self-built water-jet-assisted laser machining temperature field detection system, and the processing results were observed and verified using an optical microscope, scanning electron microscope, and energy spectrum analyzer. The results show that when the water jet inflow angle is 45°, the heat-affected area of the material surface is the smallest, and the cooling effect of the temperature field of the material surface is better. Considering the liquidus melting point of 7075 aluminum alloys, it is concluded that the processing effect is better when the water jet velocity is 14 m·s−1, the laser power is 100 W, and the laser scanning speed is 1.2 mm·s−1. At this time, the quality of the tank is relatively good, there are no cracks in the bottom of the tank, and there is less slag accumulation. Compared with anhydrous laser etching, water-jet-assisted laser etching can reduce the problems of micro-cracks, molten slag, and the formation of a recast layer in laser etching and improve the quality of the workpiece, and the composition of the bottom slag does not change. This study provides theoretical guidance and application support for the selection and optimization of process parameters for water-jet-assisted laser etching of aluminum alloy and further enriches the heat transfer mechanism of multi-field coupling in the process of water-jet-assisted laser machining.

EFFECT OF SURFACE ROUGHNESS ON THE ADHESIVE AND TRIBOLOGICAL CHARACTERISTICS OF DLC COATING PREPARED ON Co-Cr-Mo ALLOY

2002 ◽  
Vol 16 (06n07) ◽  
pp. 952-957 ◽  
Author(s):  
D. Sheeja ◽  
B. K. Tay ◽  
H. M. Lam ◽  
S. K. Ng
Keyword(s):  
Surface Roughness ◽  
Life Span ◽  
Substrate Surface ◽  
Resistance Coefficient ◽  
Metal Alloy ◽  
Deposition Condition ◽  
Dlc Coatings ◽  
Dlc Coating ◽  
Short Life Span ◽  
Substrate Surface Roughness

The Co-Cr-Mo alloy is extensively used for tribological applications, including orthopaedic components in total joint replacements. High quality diamond-like carbon (DLC) coatings on metal/alloy substrates are of great interest as they are able to protect them from severe wear and thus prolong the life span of the component. Since the roughness of the metal/alloy varies depending on the applications, a study has been carried out to investigate the effect of substrate surface roughness on the microstructure, sliding life, wear-resistance, coefficient of friction, adhension and hardness of DLC coatings prepared on Co-Cr-Mo alloy substrates under the same deposition condition. The microstructure of the films studied using Raman spectroscopy suggests that the film prepared on a smoother surface contains slightly higher fraction of sp 3 bonded carbon atoms. The characterization using a pin-on-disk tribometer reveals that, the film prepared on the roughest sample (Ra ~ 0.06 μm) exhibits a very short life span of about 20 cycles compared to the film that is prepared on a relatively smoother surface (Ra ~ 0.02 μm), which exhibits a life span of about 340,000 cycles. In order to investigate the origin of this improved property of the DLC film on the smoother surface, adhesive strength and hardness of the films were studied by using a micro-scratch tester and a Nano-indenter, respectively. The results suggest that the film prepared on the smoother surface exhibits better adhesion (higher critical load) and relatively higher hardness.

Wear Properties of DLC and Plasma Sprayed WC Structure Coating

2007 ◽  
Vol 127 ◽  
pp. 245-250 ◽  
Author(s):  
Mitsuyasu Yatsuzuka ◽  
Yoshihiro Oka ◽  
Akifumi Tomita ◽  
Noritaka Murata ◽  
Mitsuaki Hirota
Keyword(s):  
Friction Coefficient ◽  
Wear Rate ◽  
Testing Machine ◽  
Carbon Film ◽  
Wear Testing ◽  
Wear Properties ◽  
Dlc Film ◽  
Coated Metal ◽  
Hydrocarbon Gas ◽  
Plasma Sprayed

Diamond-like carbon film (DLC) with an interlayer of plasma sprayed tungsten-carbide (WC) was prepared on an aluminum alloy substrate (A5052) by a hybrid process of plasma-based ion implantation and deposition using hydrocarbon gas. Typical thicknesses of DLC and WC films were 1 μm and 100 μm, respectively. The hardness and friction coefficient of DLC were typically 15 GPa and 0.15, respectively. The durability of DLC/WC/A5052 system was evaluated from the measurement of the friction coefficient by a ball-on-disk friction tester in which the loaded ball was drawn repeatedly across a sample and the load was increased with each traverse. For the DLC/A5052 system, which has no WC interlayer, the DLC film was broken quickly because of distortion of the substrate. For the DLC/WC/A5052 system, on the other hand, the DLC film was excellent in durability for long running. The wear rate of rubber rotor to the metal rotor was measured by a roller-pitching-type wear testing machine, showing large reduction in wear rate using DLC-coated metal rotor.

Cutting Performance of Diamond-Like Carbon Coated Tool in Cutting of Aluminum Alloys

2010 ◽  
Vol 638-642 ◽  
pp. 368-373 ◽  
Author(s):  
Tadahiro Wada
Keyword(s):  
Aluminum Alloy ◽  
Aluminum Alloys ◽  
Tool Wear ◽  
Cutting Force ◽  
Coating Layer ◽  
Cutting Performance ◽  
Diamond Like Carbon ◽  
Dlc Coating ◽  
Coated Tool ◽  
Alloy 6061

In cutting aluminum alloy 6061, continuous chips have a negative influence on the machining operation. Usually, Pb is added in order to break continuous chips. However, from the standpoint of environmental protection, it is necessary to improve chip breakability without adding Pb. One effective measure is improving chip breakability by adding Si in aluminum alloy 6061. However, the influence of Si content on tool wear has not been fully examined. In this study, in order to clarify the influence of a diamond-like carbon (DLC) coating layer on cutting performance, aluminum alloys having different Si contents were turned. The substrate of the tool material was high speed steel (1.4%C). The chip configuration, cutting force and tool wear were experimentally investigated. The following results were obtained: (1) The DLC coating layer was effective for decreasing the cutting force. (2) In cutting Al-2mass%Si alloy, the wear progress of the DLC-coated tool was slower than that of the un-coated tool. The length of a chip with the DLC-coated tool was shorter than that with the un-coated tool.

scholarly journals Effect of the Combination of DLC Film and Alcohol Mist in Turning of Aluminum Alloy

2012 ◽  
Vol 78 (9) ◽  
pp. 777-781 ◽  
Author(s):  
Tomohiro YOKOTA ◽  
Takekazu SAWA ◽  
Masahiro YOKOUCHI
Keyword(s):  
Aluminum Alloy ◽  
Dlc Film

scholarly journals Surface Structuring of Diamond-Like Carbon Films by Chemical Etching of Zinc Inclusions

Coatings ◽  
2019 ◽  
Vol 9 (2) ◽  
pp. 125 ◽  
Author(s):  
Ruriko Hatada ◽  
Stefan Flege ◽  
Berthold Rimmler ◽  
Christian Dietz ◽  
Wolfgang Ensinger ◽  
...  
Keyword(s):  
Zinc Concentration ◽  
Plasma Source ◽  
Carbon Films ◽  
Metal Particles ◽  
Diamond Like Carbon ◽  
Dlc Film ◽  
Plasma Source Ion Implantation ◽  
Zinc Concentrations ◽  
Hydrocarbon Gas ◽  
Deposition Techniques

A diamond-like carbon (DLC) film with a nanostructured surface can be produced in a two-step process. At first, a metal-containing DLC film is deposited. Here, the combination of plasma source ion implantation using a hydrocarbon gas and magnetron sputtering of a zinc target was used. Next, the metal particles within the surface are dissolved by an etchant (HNO3:H2O solution in this case). Since Zn particles in the surface of Zn-DLC films have a diameter of 100–200 nm, the resulting surface structures possess the same dimensions, thus covering a range that is accessible neither by mask deposition techniques nor by etching of other metal-containing DLC films, such as Cu-DLC. The surface morphology of the etched Zn-DLC films depends on the initial metal content of the film. With a low zinc concentration of about 10 at.%, separate holes are produced within the surface. Higher zinc concentrations (40 at.% or above) lead to a surface with an intrinsic roughness.

Research on the Material Differences of 7050-T7451 Aluminum Alloy

2015 ◽  
Vol 727-728 ◽  
pp. 115-118
Author(s):  
Wei Han Wang ◽  
Wei Fang Zhang ◽  
Wei Zhang ◽  
Jin Song Yang
Keyword(s):  
Grain Size ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Fracture Analysis ◽  
Microstructure Analysis ◽  
Tensile Fracture ◽  
Material Surface ◽  
Material Microstructure ◽  
Reduction Of Area ◽  
Toughness Characteristic

Microstructure analysis and tensile fracture analysis were conducted on the domestic and imported 7050-T7451 aluminum alloy to investigate the material differences between them. Tensile test shows that the yield strength and tensile strength of domestic 7050-T7451 aluminum alloy are both higher than imported 7050-T7451 aluminum alloy, however, the material elongation and the reduction of area are both lower than imported material. Microstructure analysis shows that compared with domestic 7050-T7451 aluminum alloy, in the imported 7050-T7451 aluminum alloy, the degree of recrystallization and anisotropy is less, and the grain size is smaller. In addition, the transition from material surface to center organization of imported 7050-T7451 aluminum alloy is more smooth and uniform than domestic material. From tensile fracture analysis, it concluded that the domestic 7050-T7451 aluminum alloy has large grain size, low structural homogeneity, and little toughness characteristic of fracture, and those characteristics cause low elongation and low reduction of area of domestic 7050-T7451 aluminum alloy.

Self-Lubricated Modification for Silicon Nitride Ceramic Ball Surface

2010 ◽  
Author(s):  
Le Gu ◽  
Guangze Tang ◽  
Chuanwei Zhang ◽  
Cuini Jing ◽  
Liqin Wang
Keyword(s):  
Silicon Nitride ◽  
Solid Lubricants ◽  
Test Results ◽  
Silicon Nitride Ceramic ◽  
Ceramic Ball ◽  
Dlc Film ◽  
Dlc Coating ◽  
Ceramic Surfaces ◽  
Mos2 Film ◽  
Ball Surface

Some thin films were prepared as solid lubricants on the surfaces of silicon nitride ceramic disk and ball. DLC film about 500–800 nm thickness was deposited on the ceramic surfaces using ion implantation and deposition technology. The surface roundness measure results, as well as 80 to 90 nm, showed that DLC film was shaped uniformly on the ceramic ball surfaces. The ball-on-disk tests showed DLC coating on silicon nitride surfaces could lead the friction coefficient to about 0.1 and endure about 7h at 1.5GPa and 30 mm/s. Ball milling technology was employed to prepare MoS2 film on the ceramic ball surfaces. The film thickness and tribological test results showed that the thin MoS2 film on the ball surfaces, which hardly changed the surface roughness, also improved their wear behaviors.

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