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Coatings 2017, 7(9), 149; https://doi.org/10.3390/coatings7090149

Hybrid Ti-MoS2 Coatings for Dry Machining of Aluminium Alloys

1
Surface Engineering and Nanotechnology Institute (SENTi), Cranfield University, Cranfield MK43 0AL, UK
2
Department of Mechanical Engineering, McMaster University, 1280 Main St. W., Hamilton, ON L8S4L7, Canada
3
Kennametal Shared Services Gmbh, Altweiherstr 27-31, Ebermannstadt 91320, Germany
*
Author to whom correspondence should be addressed.
Received: 19 August 2017 / Revised: 5 September 2017 / Accepted: 13 September 2017 / Published: 16 September 2017
(This article belongs to the Special Issue Coatings for Cutting Tools)
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Abstract

Combinatorial deposition, comprising filtered cathodic vacuum arc (FCVA) and physical vapor deposition (PVD) magnetron sputtering is employed to deposit molybdenum disulphide (MoS2) and titanium (Ti) thin films onto TiB2-coated tool inserts specifically designed for the dry machining of aluminium alloys. Titanium is deposited by FCVA while MoS2 is magnetron sputtered. The deposition set up allows several compositions of Ti-MoS2 to be deposited simultaneously, with Ti content ranging between 5 and 96 at. %, and their machining performances to be evaluated. Milling took place using a CNC Vertical Machining Center at a 877 mm/min feed rate. The effect of different coating compositional ratios on the degree of aluminium sticking when a milling insert is used to face mill an Al alloy (SAE 6061) was investigated using a combination of energy-dispersive X-ray spectroscopy (EDX) and X-ray photoelectron spectroscopy (XPS) analysis. XPS studies suggest that the greater degree of Al sticking on the rake face of the inserts is due to the formation of greater amounts of non-protective Ti-O phases. EDX mapping of the milling inserts after machining reveal that a Ti:MoS2 ratio of around 0.39 prevents Al from sticking to the tool edges. Since we prevent Al from sticking to the tool surface, the resultant machined surface finish is improved thus validating the machining performance of TiB2-coated tools using optimum compositions of Ti:MoS2 thin film coatings. View Full-Text
Keywords: self-lubricating composites; molybdenum disulphide; SEM; EDS; XPS; milling; aluminium self-lubricating composites; molybdenum disulphide; SEM; EDS; XPS; milling; aluminium
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).
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Brzezinka, T.L.; Rao, J.; Chowdhury, M.; Kohlscheen, J.; Fox Rabinovich, G.S.; Veldhuis, S.C.; Endrino, J.L. Hybrid Ti-MoS2 Coatings for Dry Machining of Aluminium Alloys. Coatings 2017, 7, 149.

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