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

Abstract

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).

Delamination and Longitudinal Cracking in Multilayered Composite Nanostructured Coatings and Their Influence on Cutting Tool Wear Mechanism and Tool Life

“…The unit was equipped with an arc evaporator with filtration of vapor-ion flow. In this study, the process, termed filtered cathodic vacuum-arc deposition (FCVAD) [10][11][12][13][14][15][16], was used for deposition of coatings on the tools to significantly reduce the formation of the droplet phase during formation of the coating. The use of the FCVAD process does not cause structural changes in carbide and provides the following:…”

“…These studies proved that the introduction of zirconium nitride in the coating composition significantly reduces the tendency to cracking. The problems of cracking and brittle fracture of coatings consisting of Ti-TiN-(Ti,Cr,Al)N, Zr-(Zr,Cr)N-CrN, and Ti-TiN-(Ti,Cr,Al)N and Ti-(Al,Cr)N-(Ti,Al)N, Ti-(Al,Cr)N-(Ti, Cr,Al)N, and Zr-(Al,Cr)N-(Zr,Cr,Al)N also were addressed in papers [10][11][12][13][14][15][16]. A detailed review of existing papers in the field of crack formation in multilayered coatings, with classification of types of cracks and analysis of the mechanisms of their formation, is given in [17].…”

“…• If earlier studies show significant increase in cutting properties and reliability of the tool [10][11][12][13][14][15][16].…”

“…The thicknesses of the coatings used in the studies were 2.4-5.0 μm. A wide range of thicknesses were selected on the basis of previous studies (in particular [10][11][12][13][14][15][16]), indicating the improvement in cutting performance with increase in coating thickness. The basic properties of the NMCC under study are presented in Table 2.…”

Phase composition and microstructure of WC–Co alloys obtained by selective laser melting

“…One of the examples of work with refractory materials by the SLM method is the obtaining of WC-Co bulk alloys [8,9]. WCCo alloys are widely used in industry as cutting tools [10,11] including tools with multilayer coatings [12,13], and also can be used as wear-resistant bulk materials [14], wearresistant [15] and anticorrosion coatings [16].…”