coated carbide\u00a0tools<\/a>\u2014TiN, TiAlN, TiN-MoS\u2082, and CrAlTiN\u2014were used to process the same material, PCrNi3MoVA steel, and the wear of the tools was evaluated to compare the durability of the different coated tools. The surface morphology of the coatings for the TiN, TiAlN, TiN-MoS\u2082, and CrAlTiN tools is shown in Figure 5, all at a magnification of 600x. The figure illustrates significant differences in surface morphology among the four coatings, indicating that the incorporation of composite elements has greatly altered the crystallization state of the TiN compound.<\/p>\nThe TiN coating shows a uniform surface microstructure with relatively small grains. In contrast, the TiAlN coating has a rougher surface morphology with larger grain structures. The addition of Al results in numerous bright white hard particles of aluminum oxide or aluminum nitride appearing in the TiN lattice. The TiN-MoS\u2082 coating features a substantial distribution of flake-like mixed structures, mainly composed of MoS\u2082 uniformly dispersed within the TiN\/MoS\u2082coating, contributing to its self-lubricating properties. The CrAlTiN coating exhibits relatively fine grains and a dense, uniform structure with a significant presence of hard particles on the surface.<\/p>\n
The cutting test conditions for the coated tools are shown in Table 1. During the experiments, the conditions were kept constant, and the cutting time was recorded until the wear land width (VBc) on the flank face exceeded 0.6 mm, which was used as the criterion for tool life evaluation. The comparison of cutting life for the tools is presented in Figure 6.<\/p>\n
From Figure 6, the ranking of cutting life for the four coated tools is as follows: CrAlTiN > TiN-MoS\u2082 > TiAlN > TiN. This indicates that the Cr and Al elements in the TiN coating form hard phases, and the addition of Al is beneficial for the formation of aluminum oxides, which helps prevent further oxidation during the cutting process, thereby enhancing the tool’s oxidation resistance and contributing to an increase in cutting life. Additionally, the MoS\u2082 lubricating phase helps reduce the friction coefficient and improve the wear resistance of the tools, further extending their service life.<\/p>\n
<\/p>\n
<\/p>\n
In summary, the analysis indicates that the multi-component composite coatings effectively leverage the advantages of various coating materials, resulting in enhanced overall performance, excellent wear resistance, toughness, and reduced friction. This helps to minimize built-up edge formation while providing resistance to mechanical and thermal shocks, significantly extending tool life. Therefore, it is anticipated that the usage of multi-component composite coated tools will continue to increase in the future.<\/p>\n
<\/p>\n
XRD Analysis<\/h2>\n
XRD analysis was conducted on the CrAlTiN tool coating, which exhibited the best cutting performance, with the results shown in Figure 8. The XRD patterns reveal that at room temperature, the crystalline phases of the coating are primarily composed of Cr, CrN, Cr\u2082N, and TiN, with no amorphous phases detected. Further high-resolution scanning of the coating surface shows a significant distribution of hard phase particles. Combined with X-ray diffraction analysis, it is evident that these hard phases mainly consist of Cr, CrN, Cr\u2082N, and TiN grains. These hard grains contribute to the improved cutting life of the coated tools.<\/p>\n
<\/p>\n
Application Prospects<\/h1>\n
Coating technology for tools has proven to be an effective way to enhance the cutting performance of carbide\u00a0tools, improve cutting efficiency, and reduce processing costs. Since its introduction in the late 1970s, it has rapidly developed and been adopted worldwide. By the late 1980s, the proportion of complex carbide\u00a0tools using coatings in industrialized countries exceeded 60%, significantly improving cutting efficiency and yielding notable economic benefits. Currently, over 80% of carbide\u00a0tools used in CNC machines in Japan and Germany are coated, and the adoption of coatings in countries like Russia is also increasing.<\/p>\n
However, the usage of coated tools in China remains limited, with even high-performance CNC machines often relying on standard carbide\u00a0tools with inferior cutting performance. This restricts the full potential of expensive equipment. Therefore, developing composite coating processes for carbide\u00a0tools is crucial for shifting China away from its reliance on imported high-performance tools and advancing the local coating technology.<\/p>\n
Although coated carbide\u00a0tools are priced 50% to 100% higher than standard tools, their superior cutting performance, longer tool life, and higher production efficiency lead to lower costs per part compared to uncoated tools. This is particularly beneficial for complex tools with longer manufacturing cycles, such as gear cutters and broaches, where using coated tools not only offsets the coating costs but also provides significant economic benefits and better machining quality<\/p>\n
Furthermore, coated tools facilitate dry cutting, eliminating the increased production costs and environmental pollution associated with cutting fluids, thus protecting worker health. Therefore, from both economic and social benefit perspectives, using coated carbide\u00a0tools is advantageous. In the future, as research into multi-component and multilayer composite coating technologies progresses, the lifespan of coated carbide\u00a0tools will further improve, significantly lowering manufacturing costs and broadening the application of these coatings.<\/p>\n
<\/p>\n
Conclusion<\/h1>\n
This study utilized the closed-field unbalanced magnetron sputtering PVD coating process to prepare composite coatings such as TiN, TiAlN, TiN-MoS\u2082, and CrAlTiN. Comparative tests of the mechanical and cutting performance of these coatings yielded the following results:<\/p>\n
1.Nano-indentation analysis showed the order of nano-hardness for the four tool coatings as follows: CrAlTiN > TiAlN > TiN > TiN-MoS\u2082. The elastic modulus was found to be proportional to hardness, and Vickers microhardness measurements further validated the accuracy of the nano-indentation tests.<\/p>\n
2.Under dry cutting conditions while drilling PCrNi3MoVA steel, the cutting life of the coated tools ranked as: CrAlTiN > TiN-MoS\u2082 > TiAlN > TiN, indicating that multi-component composite coatings offer significantly better cutting performance than standard TiN coatings, marking a promising direction for the future development of coated tools.<\/p><\/div>\n
<\/p>","protected":false},"excerpt":{"rendered":"
In modern cutting tool materials, carbide\u00a0dominates. The development of coated carbide\u00a0tools around 1968 marked a significant revolution in the field of tool materials, advancing the level and capability of cutting processes considerably. The heat resistance of these tools has increased to over 1000-1200\u00b0C, while the processing temperature for Physical Vapor Deposition (PVD) typically remains below…<\/p>","protected":false},"author":2,"featured_media":22883,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_jetpack_memberships_contains_paid_content":false,"footnotes":""},"categories":[92],"tags":[],"jetpack_featured_media_url":"https:\/\/www.meetyoucarbide.com\/wp-content\/uploads\/2024\/09\/t01c48d2b4445d64285.jpg","jetpack_sharing_enabled":true,"_links":{"self":[{"href":"https:\/\/www.meetyoucarbide.com\/fr\/wp-json\/wp\/v2\/posts\/22877"}],"collection":[{"href":"https:\/\/www.meetyoucarbide.com\/fr\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.meetyoucarbide.com\/fr\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.meetyoucarbide.com\/fr\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.meetyoucarbide.com\/fr\/wp-json\/wp\/v2\/comments?post=22877"}],"version-history":[{"count":3,"href":"https:\/\/www.meetyoucarbide.com\/fr\/wp-json\/wp\/v2\/posts\/22877\/revisions"}],"predecessor-version":[{"id":22886,"href":"https:\/\/www.meetyoucarbide.com\/fr\/wp-json\/wp\/v2\/posts\/22877\/revisions\/22886"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.meetyoucarbide.com\/fr\/wp-json\/wp\/v2\/media\/22883"}],"wp:attachment":[{"href":"https:\/\/www.meetyoucarbide.com\/fr\/wp-json\/wp\/v2\/media?parent=22877"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.meetyoucarbide.com\/fr\/wp-json\/wp\/v2\/categories?post=22877"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.meetyoucarbide.com\/fr\/wp-json\/wp\/v2\/tags?post=22877"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}