The Critical Raw Materials in Cutting Tools for Machining Applications: A Review

Rizzo, A.; Goel, Saurav; Grilli, Maria Luisa; Rodríguez, Iglesias; Jaworska, L.; Lapkovskis, Vjačeslavs; Novák, Pavel; Postolnyi, Bogdan; Valerini, D.

doi:10.3390/ma13061377

Cited by 95 publications

(39 citation statements)

References 252 publications

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“…They are related to securing the supply chain (through raw materials diplomacy and developing own mining and recycling), extending the lifetime of the products containing CRMs, developing more sustainable production methods for materials containing CRMs, and introducing new CRM-free materials. In absence of having immediate availability of raw materials, novel solutions for improving raw material production, recycling CRMs, reducing CRM consumption, and substituting CRMs move to the top of the agenda [8,13,14]. One of the technologies capable of solving some of the discussed challenges is the additive manufacturing (AM) of metals and nonmetallic materials.…”

Section: Introductionmentioning

confidence: 99%

Powder Bed Fusion Additive Manufacturing Using Critical Raw Materials: A Review

et al. 2021

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The term “critical raw materials” (CRMs) refers to various metals and nonmetals that are crucial to Europe’s economic progress. Modern technologies enabling effective use and recyclability of CRMs are in critical demand for the EU industries. The use of CRMs, especially in the fields of biomedicine, aerospace, electric vehicles, and energy applications, is almost irreplaceable. Additive manufacturing (also referred to as 3D printing) is one of the key enabling technologies in the field of manufacturing which underpins the Fourth Industrial Revolution. 3D printing not only suppresses waste but also provides an efficient buy-to-fly ratio and possesses the potential to entirely change supply and distribution chains, significantly reducing costs and revolutionizing all logistics. This review provides comprehensive new insights into CRM-containing materials processed by modern additive manufacturing techniques and outlines the potential for increasing the efficiency of CRMs utilization and reducing the dependence on CRMs through wider industrial incorporation of AM and specifics of powder bed AM methods making them prime candidates for such developments.

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Section: Introductionmentioning

confidence: 99%

Powder Bed Fusion Additive Manufacturing Using Critical Raw Materials: A Review

et al. 2021

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“…Coated tools have been shown to meet the high demands of different cutting processes. Cemented carbides are currently one of the major representatives of cutting tools materials for machining different metallic alloys [2]. One of the main issues concerning coated tool materials is achieving proper adhesion between substrate and coating since it has shown to have a major impact on the cutting tool wear resistance and its service lifetime [2][3][4].…”

Section: Introductionmentioning

confidence: 99%

“…Cemented carbides are currently one of the major representatives of cutting tools materials for machining different metallic alloys [2]. One of the main issues concerning coated tool materials is achieving proper adhesion between substrate and coating since it has shown to have a major impact on the cutting tool wear resistance and its service lifetime [2][3][4]. Among many types of coatings (Ti,Al)N systems have exhibited excellent properties while being relatively easily deposited on cemented carbide substrates [5].…”

Section: Introductionmentioning

confidence: 99%

Exploitation and Wear Properties of Nanostructured WC-Co Tool Modified with Plasma-Assisted Chemical Vapor Deposition TiBN Coating

Šnajdar

Sakoman

Ćorić

et al. 2021

Metals

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In recent years, coated cemented carbides have often been the first choice for a wide variety of tool inserts and applications. Its success as a cutting tool material arises from the unique combination of wear resistance and toughness, and its ability to be formed into complex shapes. The structure obtained by sintering nanoparticle powders provides a significant improvement in product properties, such as higher cutting speeds, lower tool tolerances, and longer service life. In this study, a multi-layered gradient coating, deposited on nanostructured cemented carbides by plasma-assisted chemical vapor deposition (PACVD) was investigated with emphasis on its wear and exploitation properties. TiBN coating was deposited on nanostructured cemented carbide samples with the addition of 5 wt% Co, 10 wt% Co and 15 wt% Co. The samples were consolidated by one cycle hot isostatic pressing (HIP) technique. Complex architecture built of TiN and TiB2 gradient multilayer sequence block was deposited on each type of substrate. Wear resistance of the obtained samples was determined by erosion wear testing and dry sliding wear testing (ball-on-flat test). The friction coefficients of ~0.22 obtained for coated samples by the ball-on-flat test show a decrease in friction when compared to uncoated samples values of ~0.32. The absence of coating rupture was confirmed by wear track depth measurements showing a wear trace depth of ~1.2 μm. Exploitation properties i.e., tool life determination of samples was obtained using single-point turning tool test and compared to commercial cutting tool insert type K10 tested under the same conditions. All the conducted tests show excellent wear and exploitation properties of the newly developed TiBN coating under chosen conditions, including cutting speed, vc = 200 m/min, depth of cut, ap = 1 mm, and feed, fn = 0.2 mm. Coated WC-Co samples with 15 wt% Co, having withstood 15 min of machining with flank wear trace size less than 0.3 mm, suggest significant improvement when compared to trace size of 0.56 mm obtained for K10 commercial cutting insert.

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“…To obtain an effective and durable tool, it is necessary to employ a suitable heat treatment or surface layer modification technology or to deposit a coating with the required properties. Another important aspect is to select a steel grade that exhibits properties meeting the requirements for a given tool application and maximizes the tool durability during the cold-or hot-working [1][2][3]. Still, studies are conducted to develop new materials [4] and methods for shaping microstructure, particularly surface layer, of tool steels [5].…”

Section: Introductionmentioning

confidence: 99%

Tribological Behaviour of K340 Steel PVD Coated with CrAlSiN Versus Popular Tool Steel Grades

Drozd¹,

Walczak²,

Szala³

et al. 2020

Preprint

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The tribological performance of metalwork steel tools is of vital importance in both cold and hot working processes. One solution for improving metal tool life is the application of coatings. This paper investigates the effect of CrAlSiN thin-film PVD-deposition on the tribological behaviour of tool steel K340. The sliding wear performance of the coated K340 steel is analysed in relation to both the uncoated K340 steel and a range of tool steels dedicated to hot- and cold-working, such as X155CrVMo12-1, X37CrMoV5-1, X40CrMoV5-1, 40CrMnMo7 and 90MnCrV8. The investigated tool steels were heat-treated, while K340 was subjected to thermochemical treatment and then coated with a CrAlSiN hard film (K340/CrAlSiN). The hardness, chemical composition, phase structure and microstructure of steels K340 and K340/CrAlSiN are examined. Tribological tests were conducted using the ball-on-disc tester in compliance with the ASTM G99 standard. The tests were performed under dry unidirectional sliding conditions, using an Al2O3 ball as a counterbody. The wear factor and coefficient of friction are estimated and analysed with respect to hardness and alloying composition of the materials under study. SEM observations are made to identify the sliding wear mechanisms of the analysed tool steels and PVD-coated K340 steel. In contrast to the harsh abrasive-adhesive wear mechanism observed for uncoated tool steels, the abrasive wear dominates in case of the AlCrSiN. The deposited thin film effectively prevents the K304 substrate from harsh wear severe degradation. Moreover, thanks to the deposited coating, the K304/CrAlSiN sample has a COF of 0.529 and a wear factor of K=5.68×10−7 m3 N−1 m−1, while the COF of the reference tool steels ranges from 0.702 to 0.885 and their wear factor ranges from 1.68×10−5 m3 N−1 m−1 to 3.67×10−5 m3 N−1 m−1. The CrAlSiN deposition reduces the wear of the K340 steel and improves its sliding properties, which makes it a promising method for prolonging the service life of metalwork tools.

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The Critical Raw Materials in Cutting Tools for Machining Applications: A Review

Cited by 95 publications

References 252 publications

Powder Bed Fusion Additive Manufacturing Using Critical Raw Materials: A Review

Powder Bed Fusion Additive Manufacturing Using Critical Raw Materials: A Review

Exploitation and Wear Properties of Nanostructured WC-Co Tool Modified with Plasma-Assisted Chemical Vapor Deposition TiBN Coating

Tribological Behaviour of K340 Steel PVD Coated with CrAlSiN Versus Popular Tool Steel Grades

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