Search Results (104)

In this work, for the first time, we applied and determined the mechanical characteristics of protective coatings made of high-entropy alloy (TiZrVCrAl)N with different architectures onto the surface of Ti-6Al-4V alloy with the initial coarse-grained and ultrafine-grained structure using arc physical vapor deposition. We designed and prepared three coating architectures: a monolayer nitride coating (TiZrVCrAl)N, a multilayer coating consisting of nine alternating layers of TiZrVCrAl and (TiZrVCrAl)N, and a multilayer coating consisting of 720 alternating layers of (TiZrVCrAl)N and TiN, with a total thickness not exceeding 2 microns. We evaluated their protective performances by nanoindentation and scratch tests. Importantly, the effect of the substrate microstructure on the coatings’ performance is investigated by comparing their mechanical behavior on coarse-grained and ultrafine-grained Ti-6Al-4V. Our experimental results show that the coating performance improves with increasing number of layers in the coating, and this effect is even more pronounced for the multilayer coating deposited on the ultrafine-grained titanium alloy substrate. We also find that the (TiZrVCrAl)N/TiN (720 layers) multilayer coating deposited on the UFG Ti-6Al-4V alloy substrate exhibits the highest H/E- and H³/E²-values, indicating the coating’s high innovative potential for performance in extreme conditions. The origins of this phenomenon are analyzed and discussed. Full article

This work focuses on obtaining a titanium nitride coating on the surfaces of titanium and its alloy powders using a novel method, self-shearing reactive milling, under a nitrogen pressure of 50 bar. The Ti, Ti6Al4V, and Ti-5553 spherical powders were milled for up to 10 h at ambient temperature without grinding balls. As a result of the experiments, a thin, brittle TiN coating formed on the powders’ surfaces. The cross-sections of the milled powders reveal that the TiN layer thickness is in the nanometer range (about 500 nm). By analyzing the sequence of X-ray diffraction patterns, it is evident that only for the Ti6Al4V powder milled for 10 h, two peaks are observed that can be attributed to a TiN phase. On the other hand, Raman spectroscopy revealed characteristic TiN spectra even for samples collected at the initial stage of self-shearing reactive milling. An important aspect of the experiment was the preservation of the spherical shape of the milled powders, which makes them a potential feedstock for additive manufacturing of functionally graded biomaterials. Full article

The article considers issues related to improving the surface characteristics of titanium Gr2 using one of the lightest, cheapest and most ecological methods—electrospark deposition with low pulse energy and with ultradisperse electrodes TiB₂-TiAl with nanosized additives of NbC and ZrO₂. Using profilometric, metallographic, XRD, SEM and EDS methods, the change in the geometric characteristics, composition, structure, micro and nanohardness of the coatings as a function of the electrical parameters of the ESD regime has been studied. The results show that the use of TiB₂-TiAl electrodes and low pulse energy allows the formation of dense, continuous and uniform coatings that demonstrate a significant reduction in roughness, inherent irregularities and structural defects of electrospark coatings. Coatings with minimal defects, with crystalline–amorphous structures, with newly formed intermetallic and wear-resistant double and triple phases of the type AlTi₃, TiAl₃, TiB, TiN_0.3, Al₂O₃, AlB₂, TiC_0.3N_0.7, Ti_3.2B_1.6N_2.4, Al_2.86O_3.45N_0.55 have been obtained. Possibilities have been found for controlling and obtaining specific values for the roughness and thickness of coatings in the ranges Ra = 1.5–3.2 µm and δ = 8–19.5 µm, respectively. The electrical parameters of the modes ensure the production of coatings with previously known thickness and roughness, with increased microhardness up to 13 GPa, with the maximum possible content of deliberately synthesized high-hard phases and with ultra-fine-grained structures have been defined. Full article

In this study, the asymmetrical rolling technique was employed to fabricate 75 μm-thick Ti-6Al-4V ultra-thin strips from the initial 0.45 mm sheet without intermediate annealing, aiming for applications in fuel cell bipolar plates. The rolled strips exhibited good surface quality without cracking. In order to enhance both the mechanical response and the shaping capability of Ti-6Al-4V strips produced by asymmetric rolling, the material was subjected to annealing at various temperatures, and the resulting changes in microstructural features and mechanical performance were systematically examined. The findings indicated that the cold-rolled Ti-6Al-4V exhibited a microstructure primarily composed of subgrains with an average size of approximately 0.41 μm, a feature that contributed to improved corrosion resistance and enhanced ductility after annealing. When the alloy was subjected to heat treatment within the range of 650–800 °C, it was observed that annealing temperatures below 700 °C favored microstructural changes governed predominantly by recovery processes and the onset of recrystallization. At 700 °C, the grains became equiaxed and uniformly distributed, and the dislocation density significantly decreased. The tensile strength reached 887 MPa, while the elongation increased to 13.7%, achieving an excellent strength-ductility balance. Once the annealing temperature rose above 700 °C, noticeable grain growth took place, accompanied by a more pronounced grain-size gradient and a renewed increase in dislocation density. Meanwhile, the dimples observed on the fracture surface became finer, collectively contributing to a decline in tensile elongation. The Ti-6Al-4V ultra-thin strip annealed at 700 °C was used for bipolar plate stamping, producing fine micro-channels with an aspect ratio of 0.43. Finally, TiN coating was applied to the surface, which significantly improved the corrosion resistance and reduced the interfacial contact resistance (ICR), meeting the performance requirements for bipolar plates. Full article

During the machining of nickel-based superalloys using coated tools, a significant amount of cutting heat is generated. This study employs ABAQUS finite element analysis software to establish two-dimensional orthogonal cutting simulation models for three types of coated tools: single-layer AlTiN, double-layer AlTiN/AlCrN, and AlCrN/AlTiN. The research focuses on simulating the cutting temperature and cutting stress of carbide tools with these three different coating types and thicknesses when machining nickel-based superalloy GH4169. The simulation results indicate that the double-layer AlCrN/AlTiN-coated tool exhibits lower maximum cutting temperature and cutting stress on the tool rake face and tool substrate during the cutting process. Compared to the other two coated tools, the cutting temperature and cutting stress on the rake face are reduced by up to 13.2% and 13.3%, respectively. When the AlCrN/AlTiN coating thickness is 2.5 μm with a ratio of 1.5:1, the maximum cutting temperature and cutting stress are minimized. During the cutting process with coated tools, the cutting speed, coating type, and coating thickness significantly influence the maximum cutting temperature and cutting stress. Therefore, investigating the effects of cutting speed, coating type, and coating thickness on carbide-coated tools can reduce tool wear, extend tool life, and thereby improve machining efficiency. Full article

This study aims to evaluate the tribological performance of commercial PVD coatings in alleviating material transfer under unlubricated contact in the hot forming of aluminum alloy. The commercial PVD coatings included AlCrN, TiAlN, and Arc-DLC coatings, deposited on the forming tool surface. The warm and hot upsetting sliding test (WHUST) was used as a friction test in this study to reproduce the severe contact conditions from the hot forming process of AA6082-T6 aluminum alloy. The WHUST was performed at 300 °C, 400 °C, and 500 °C to investigate the effect of temperature on the tribological performance of each coating. The results found that the AlCrN and TiAlN coatings exhibited similar performance. They dominated the initial aluminum transfer by adhesive bonding. In contrast, the Arc-DLC coating mainly caused the initial aluminum transfer by mechanical plowing due to its lower chemical affinity to the aluminum alloy. In addition, the tribological performance of each coating highly depended on the temperature. Higher temperatures resulted in both stronger intermetallic bonding at the interface and lower yield strength of the aluminum alloy. These behaviors led to the variations in the coefficient of friction, the 3D topography and the SEM morphology along the wear track of the specimen, and the thickness of the adhered aluminum layer on the coating surface. In comparison, the Arc-DLC coating provided better tribological performance in mitigating the aluminum transfer than the others. Full article

The unique cutting–burnishing coupling effect in BTA deep hole drilling generates a high-hardness and -brittleness white layer (ultrafine martensitic layer), which will degrade component performance and accelerate tool wear. This work investigated the formation mechanism and the mechanical properties of the white layer generated in three distinct regions (the cutting edge radius zone, cutting–burnishing corner zone, and guide pad edge zone) through nanoindentation, SEM and BSE. The microstructure and thickness of the white layer under different feedrates are investigated. The correlations between the white layer, the structure of guide pads, and wear behaviors of the TiN- and TiCN/Al₂O₃-coated guide pads are revealed. Variations in hardness are observed across different zones. The white layer undergoes a soft-to-hard transition due to rapid quenching and the cutting–burnishing effect at the sharp corner. The highest hardness (9.758 GPa) was observed in the guide pad zone, accompanied by grain refinement. The chamfered TiN-coated guide pad exhibits superior wear resistance but suffers fatigue cracking and adhesive wear in the initial guiding zone. The TiCN/Al₂O₃-coated pad with rounded corners experiences brittle spalling in the mid-to-rear guiding zone. These findings enhance the understanding of the white layer formation in deep hole drilling and provide a foundation for tool optimization. Full article

With the rapid development of advanced machining technologies such as high-speed cutting, dry cutting, and ultra-precision cutting, as well as the widespread application of various difficult-to-machine materials, the surface degradation problems such as wear, oxidation, and delamination faced by tools in the service process have become increasingly prominent, seriously restricting the performance and service life of tools. Nanocoatings, with their distinct nano-effects, provide superior hardness, thermal stability, and tribological properties, making them an effective solution for cutting tools in increasingly demanding working environments. For example, the hardness of the CrAlN/TiSiN nano-multilayer coating can reach 41.59 GPa, which is much higher than that of a single CrAlN coating (34.5–35.8 GPa). This paper summarizes the most common nanocoating material design, coating deposition technologies, performance evaluation indicators, and characterization methods currently used in cutting tools. It also discusses how to improve nanocoating performance using modulation analysis of element content, coating composition, geometric structure, and coating thickness. Finally, this paper considers the future development of nanocoatings for cutting tools in light of recent research hotspots. Full article

Micro-sandblasting pretreatment was applied to AlTiSiN-coated WC–Co tools to enhance cutting performance in 316 L stainless steel milling. An L₉(3³) Taguchi orthogonal array varied passivation pressure (0.1, 0.2, and 0.3 MPa), gun traverse speed (60, 80, and 100 m/min), and tool rotation speed (20, 30, and 40 r/min). Coating thickness varied only from 0.93 to 1.19 μm, and surface roughness remained within 0.044–0.077 μm, confirming negligible thickness and roughness effects. Under optimized conditions, coating adhesion strength and nano-hardness both exhibited significant improvements. A weighted-scoring method balancing these two responses identified the optimal pretreatment parameters as 0.1 MPa, 80 m/min, and 20 r/min. Milling tests at 85 m/min—using flank wear VBₘₐₓ = 0.1 mm as the failure criterion—demonstrated a cutting distance increase from 4.25 m (untreated) to 12.75 m (pretreated), a 200% improvement. Wear progressed through three stages: rapid initial wear, extended steady wear due to Al₂O₃ protective-film formation and Si-induced oxygen-diffusion suppression, and accelerated wear. Micro-sandblasting further prolonged the steady-wear phase by removing residual cobalt binder, exposing WC grains, and offsetting tensile residual stresses. These findings establish a practical, cost-effective micro-sandblasting pretreatment strategy that significantly enhances coating adhesion, hardness, and tool life, providing actionable guidance for improving the durability and machining performance of coated carbide tools in difficult-to-cut applications. Full article

Enhanced hard coatings with exceptional mechanical and thermal qualities have prompted substantial study into multicomponent nitride systems. TiAl(Si)N coatings have emerged as viable possibilities owing to their remarkable hardness, thermal stability, and oxidation resistance. This work involved the fabrication of thickness-varied TiAl(Si)N gradient coatings using reactive magnetron sputtering, employing a controlled modulation of aluminum and silicon content across the film thickness. Three samples, with thicknesses of ~400 nm, ~600 nm, and ~800 nm, were deposited under uniform Ar/N₂ gas flow ratios, and their microstructural, mechanical, and tribological characteristics were rigorously examined. SEM investigation demonstrated a significant change across thicknesses. XRD results validated the emergence of a predominant cubic TiAl(Si)N phase alongside a secondary hexagonal AlN phase, signifying partial phase segregation. The nanoindentation results indicated that Sample 2 exhibited the maximum hardness (~38 GPa) and Young’s modulus (~550 GPa) due to an optimized equilibrium between solid solution strengthening and nanocomposite production. Tribological testing revealed that Sample 1 displayed the lowest and most consistent friction coefficient, corresponding to its superior H/E and H3/E2 ratios, which signify improved elasticity and resistance to plastic deformation. The findings emphasize that the implementation of a compositional gradient, especially in the distribution of Si and Al, markedly affects the microstructure and performance of TiAl(Si)N coatings. Gradient structures enhance the microstructure, optimize hardness, and increase the friction coefficient. Ongoing refinement of gradient profiles and deposition parameters may further improve the characteristics of TiAl(Si)N coatings, facilitating their wider industrial use. Full article

The creation of coatings by the cathodic arc evaporation method has outstanding advantages: these coatings are highly durable and wear-resistant, especially since the method has an intense ionization process and the atoms can penetrate deep into the surface substrates, resulting in excellent adhesion. Furthermore, this approach provides precise control over the chemical composition and thickness of the coating, ensuring consistent quality across the entire surface. However, uneven evaporation and ejection of molten metal droplets from the cathode during cathode arc deposition produce particles and droplets, resulting in an uneven coating surface. This study presents a new design for a magnetically controlled cathode arc source to effectively reduce particles and droplets during the cathodic arc deposition of multi-component alloy targets for nitride-based hard coatings. The study compares the performance of a new source with a conventional magnetic-controlled arc source for depositing TiAlNbSiN and AlCrSiN films. In the conventional source, the magnetic field is generated by a permanent magnet (PM), whereas in the new source, it is generated and controlled using an electromagnet (EM). Both films are produced using multi-component alloy targets (TiAlNbSi and AlCrSi) with identical composition ratios. The plasma characteristics of the two different arc sources are investigated using an optical emission spectrometer (OES), and the surface morphology, structural characteristics, deposition rate, uniformity, and surface roughness (Sa) are examined using scanning electron microscopy (SEM). When the EM was applied to have high plasma density, the hardness of the TiAlNbSiN film deposited with the novel arc source measured 31.2 ± 1.9 GPa, which is higher than that of the PM arc source (28.3 ± 1.4 GPa). In contrast, the AlCrSiN film created using a typical arc source exhibited a hardness of only 25.5 ± 0.6 GPa. This lower hardness may be due to insufficient ion kinetic energy to enhance stress blocking and increase hardness, or the presence of the h-AlN phase in the film, which was not detected by XRD. The electromagnet arc source, with its adequate ion bombardment velocity, facilitated a complementary effect between grain growth and stress blocking, leading to a remarkable hardness of 32.6 ± 0.5 GPa. Full article

To increase the wear and corrosion resistance of (α + β) titanium-aluminium-vanadium (Ti6Al4V) alloy, ceramic tantalum oxide coatings were deposited by direct current (DC) magnetron sputtering at three different substrate temperatures—400, 450, and 500 °C. The crystallographic structure, surface morphology, chemical compositions, film adhesion, and hardness of the coatings were described using XRD, SEM, EDS, scratch tests, and microhardness measurements. The samples’ ability to withstand corrosion was assessed using electrochemical studies. Results revealed that thin films have an amorphous or crystalline structure dependent on temperature. The film’s thicknesses varied between 560 and 600 nm. With the increase in deposition temperature, the hardness of the film rose. All oxide coatings were tightly adherent to the titanium alloy substrate, and critical force increased from about 8.6 up to 20 N when the temperature rose from 400 to 500 °C. During the polarisation investigations, after 1 h of immersion, a drop in current density (j_corr) verified an improvement in the corrosion resistance of the amorphous and well-crystalline coatings. A two-layer model of the surface film accurately describes the coated systems’ electrochemical behaviour. However, according to the EIS analysis, the well-crystalline film deteriorates greatly, whereas the amorphous film prevents penetration during the 7-day immersion test in SBF. The wettability tests demonstrated the hydrophilic nature of the coatings, and after seven days, the mineralisation of calcium phosphate proves the coatings become bioactive in simulated bodily fluid (SBF). Thus, we produced films of tantalum oxide, which, with the proper deposition parameters, may prove to be appropriate surfaces for titanium-based implant bio-applications. Full article

This study aims to determine the extent to which coating composition and workpiece properties impact machinability and tool selection when turning Compacted Graphite Iron (CGI) under extreme roughing conditions. Two CGI workpieces, differing in pearlite content and graphite nodularity, were machined at a cutting speed of 180 m/min, feed rate of 0.18 mm/rev, and depth of cut of 3 mm. To assess the impact of tool properties across a wide range of commercially available tools, four diverse multilayered cemented carbide tools were evaluated: Tool A and Tool B with a thin AlTiSiN PVD coating, Tool C with a thick Al₂O₃-TiCN CVD coating, and Tool D with a thin Al₂O₃-TiC PVD coating. The machinability of CGI and wear mechanisms were analyzed using pre-cutting characterization, in-process optical microscopy, and post-test SEM analysis. The results revealed that CGI microstructural variations only affected tool life for Tool A, with a 110% increase in tool life between machining CGI Grade B and Grade A, but that the effects were negligible for all other tools. Tool C had a 250% and 70% longer tool life compared to the next best performance (Tool A) for CGI Grade A and CGI Grade B, respectively. With its thick CVD-coating, Tool C consistently outperformed the others due to its superior protection of the flank face and cutting edge under high-stress conditions. The cutting-induced stresses played a more significant role in the tool wear process than minor differences in workpiece microstructure or tool properties, and a thick CVD coating was most effective in addressing the tool wear effects for the extreme roughing conditions. However, differences in tool life for Tool A showed that tool behavior cannot be predicted based on a single system parameter, even for extreme conditions. Instead, tool properties, workpiece properties, cutting conditions, and their interactions should be considered collectively to evaluate the extent that an individual parameter impacts machinability. This research demonstrates that a comprehensive approach such as this can allow for more effective tool selection and thus lead to significant cost savings and more efficient manufacturing operations. Full article

Today, the machining of heat-resistant alloys based on triple, quad, or penta equilibria high-entropy alloy systems of elements (ternary, quaternary, quinary iron-, titanium-, or nickel-rich alloys), including dual-phase by Gibb’s phase rule, steels of the austenite class, and nickel- and titanium-based alloys, are highly relevant for the airspace and aviation industry, especially for the production of gas turbine engines. Cutting tools in contact with those alloys should withstand intensive mechanical and thermal loads (tense state of 1.38·10⁸–1.54·10⁸ N/m², temperature up to 900–1200 °C). The most spread material for those tools is cutting ceramics based on oxides, nitrides of the transition and post-transition metals, and metalloids. This work considers the wear resistance of the cutting insert of silicon nitride with two unique development coatings — titanium–zirconium nitride coating (Ti,Zr)N and complex quad nitride coating with TiN content up to 70% (Ti,Al,Cr,Si)N with a thickness of 3.8–4.0 µm on which microtextures were produced by the assisted electric discharge machining with the electrode-tool of ø0.25 mm. The microtextures were three parallel microgrooves of R0.13^+0.02 mm at a depth of 0.025₋₀.₀₅. The operational life was increased by ~1.33 when the failure criterion in turning nickel alloy was 0.4 mm. Full article

This study examines coatings based on Ti-Al system intermetallics deposited in a nitrogen environment. The research investigates the structure, phase composition, chemical composition, and mechanical properties of coatings with varying ratios of Ti-Al to TiAlN layer thicknesses. Multiple analytical techniques, including nanoindentation, sclerometry, microhardness measurements, electron microscopy, X-ray diffractometry, and transmission electron microscopy, were employed. The results demonstrate that the coating architecture significantly influences its physical and mechanical properties. Notably, coatings with a variable thickness gradient structure exhibit the best properties and are the most promising for practical applications, offering enhanced hardness, wear resistance, and adhesion strength. Furthermore, the findings indicate that a carefully selected combination of layers can be used to control coating properties across a wide range, making these coatings highly suitable for demanding industrial applications. Full article