Skip to main content
SpringerLink
Log in

Evaluation of wear mechanisms of PVD and CVD coatings deposited on cemented carbide substrates applied to hard turning

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

A good understanding of the coating wear mechanism is essential in relation to tailoring the coating properties to the application, with a focus on increasing the tool performance. When a coated cemented carbide tool is applied in processes with high thermal and mechanical loads (e.g., hard turning process), the cutting tool can suddenly collapse with the deterioration of the coating. The focus of this research was to track the sequence of events that leads to the deterioration of coating materials (PVD TiAlN and MT CVD TiCN/Al2O3/TiN), to reveal the real wear mechanisms associated with coated cemented carbide cutting tools applied to hard turning. The tool wear was evaluated by focus variation microscopy (FVM) and scanning electron microscopy (SEM), before and after cutting edge collapse, during the hard turning of quenched and tempered AISI 4340 steel. The mechanisms associated with the progression of wear on MT CVD coatings involve abrasion, crack nucleation, propagation, the formation of crack networks, delamination, detachment between coating layers, and spalling. The deterioration of PVD coatings is related to the abrasion wear mechanism and the high deformation values at the cutting edge, which leads to the nucleation of cracks in the coating, reducing the bonding strength between the coating and the tool substrate, leading to spalling of the coating. The tool life of the PVD coating was three times longer than that of the CVD coating. The wear mechanisms acting on the coating is the main factor that influences the end of tool life.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

References

  1. Bobzin K (2017) High-performance coatings for cutting tools. CIRP J Manuf Sci Technol 18:1–9. https://doi.org/10.1016/j.cirpj.2016.11.004

    Article  Google Scholar 

  2. García J, Collado Ciprés V, Blomqvist A, Kaplan B (2019) Cemented carbide microstructures: a review. Int J Refract Met Hard Mater 80:40–68. https://doi.org/10.1016/j.ijrmhm.2018.12.004

    Article  Google Scholar 

  3. Bouzakis KD, Michailidis N, Skordaris G, Bouzakis E, Biermann D, M’Saoubi R (2012) Cutting with coated tools: coating technologies, characterization methods and performance optimization. CIRP Ann Manuf Technol 61:703–723. https://doi.org/10.1016/j.cirp.2012.05.006

    Article  Google Scholar 

  4. Holmberg K, Mattheus A (2009) Coating tribology: properties, mechanisms, techniques and applications in surface engineering, 2nd edn. Elsevier, Amsterdam

    Google Scholar 

  5. Childs T, Maekawa K, Obikawa T, Yamane Y (2000) Metal machining theory and applications, 1st edn. Wiley, London

    Google Scholar 

  6. Tkadletz M, Schalk N, Daniel R, Keckes J, Czettl C, Mitterer C (2016) Advanced characterization methods for wear resistant hard coatings: a review on recent progress. Surf Coat Technol 285:31–46. https://doi.org/10.1016/j.surfcoat.2015.11.016

    Article  Google Scholar 

  7. Sveen S, Andersson JM, M’Saoubi R, Olsson M (2013) Scratch adhesion characteristics of PVD TiAlN deposited on high speed steel, cemented carbide and PCBN substrates. Wear. 308:133–141. https://doi.org/10.1016/j.wear.2013.08.025

    Article  Google Scholar 

  8. Bouzakis KD, Klocke F, Skordaris G, Bouzakis E, Gerardis S, Katirtzoglou G, Makrimallakis S (2011) Influence of dry micro-blasting grain quality on wear behaviour of TiAlN coated tools. Wear. 271:783–791. https://doi.org/10.1016/j.wear.2011.03.010

    Article  Google Scholar 

  9. Fox-Rabinovich GS, Kovalev AI, Aguirre MH, Beake BD, Yamamoto K, Veldhuis SC, Endrino JL, Wainstein DL, Rashkovskiy AY (2009) Design and performance of AlTiN and TiAlCrN PVD coatings for machining of hard to cut materials. Surf Coat Technol 204:489–496. https://doi.org/10.1016/j.surfcoat.2009.08.021

    Article  Google Scholar 

  10. Thakur A, Gangopadhyay S (2016) Influence of tribological properties on the performance of uncoated, CVD and PVD coated tools in machining of Incoloy 825. Tribol Int 102:198–212. https://doi.org/10.1016/j.triboint.2016.05.027

    Article  Google Scholar 

  11. Ginting A, Skein R, Cuaca D, Herdianto, Pieter, Masyithah Z (2018) The characteristics of CVD- and PVD-coated carbide tools in hard turning of AISI 4340. Measurement 129:548–557. https://doi.org/10.1016/j.measurement.2018.07.072

    Article  Google Scholar 

  12. Boing D, de Oliveira AJ, Schroeter RB (2018) Limiting conditions for application of PVD (TiAlN) and CVD (TiCN/Al2O3/TiN) coated cemented carbide grades in the turning of hardened steels. Wear. 416–417:54–61. https://doi.org/10.1016/j.wear.2018.10.007

    Article  Google Scholar 

  13. Boing D, Schroeter RB, de Oliveira AJ (2018) Three-dimensional wear parameters and wear mechanisms in turning hardened steels with PCBN tools. Wear. 398–399:69–78. https://doi.org/10.1016/j.wear.2017.11.017

    Article  Google Scholar 

  14. Vereschaka AA, Grigoriev SN (2017) Study of cracking mechanisms in multi-layered composite nano-structured coatings. Wear. 378–379:43–57. https://doi.org/10.1016/j.wear.2017.01.101

    Article  Google Scholar 

  15. Trent EM, Wright PK (2000) Metal cutting, 4th edn. Butterworth–Heinemann, Woburn

    Google Scholar 

  16. Astakhov VP (2012) Tribology of metal cutting, 1st edn. Elsevier Science, Oxford

    Google Scholar 

  17. Sandvik Coromant (2010) Application guide: Heat resistant super alloys. 128. http://www.sandvik.coromant.com/SiteCollectionDocuments/downloads/global/technical guides/en-us/C-2920-034.pdf

  18. Sandvik Coromant (2016) Steel turning endurance: new innovation delivers best practice solutions to daily machining challenges. 11. https://www.sandvik.coromant.com/SiteCollectionDocuments/campaigns/cutting-steel-inserts/assets/white-paper-eng.pdf

  19. Vereschaka AA, Grigoriev SN, Sitnikov NN, Batako AD (2017) Delamination and longitudinal cracking in multi-layered composite nano-structured coatings and their influence on cutting tool life. Wear. 390–391:209–219. https://doi.org/10.1016/j.wear.2017.07.021

    Article  Google Scholar 

  20. Diniz AE, de Oliveira AJ (2008) Hard turning of interrupted surfaces using CBN tools. J Mater Process Technol 195:275–281. https://doi.org/10.1016/j.jmatprotec.2007.05.022

    Article  Google Scholar 

Download references

Acknowledgments

The authors would like to thank Sandvik Coromant® for supplying the cutting tools, Alicona® for providing resources and discussions regarding the measurement methods, Third Wave Systems® for providing resources for the turning process finite element analysis, and Villares Metals® for supplying the steel alloys.

Funding

The authors would like to acknowledge financial support from FAPESC (Foundation for Research and Innovation Support of the Santa Catarina State – Brazil) within the research project “Machining of Hardened Steels – 2015TR304.”

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Technology, Innovation, and Manufacturing Center, Brusque University Center, 123 Dorval Luz St, Santa Terezinha, Brusque, SC, 88352-400, Brazil

    Denis Boing

  2. Department of Mechanical Engineering, Technology Center, Federal University of Rio Grande do Norte, Natal, RN, Brazil

    Adilson José de Oliveira

  3. Department of Mechanical Engineering, Laboratory of Precision Mechanics, Federal University of Santa Catarina, Florianópolis, SC, Brazil

    Rolf Bertrand Schroeter

Authors
  1. Denis Boing
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Adilson José de Oliveira
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Rolf Bertrand Schroeter
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Denis Boing.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Boing, D., de Oliveira, A.J. & Schroeter, R.B. Evaluation of wear mechanisms of PVD and CVD coatings deposited on cemented carbide substrates applied to hard turning. Int J Adv Manuf Technol 106, 5441–5451 (2020). https://doi.org/10.1007/s00170-020-05000-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-05000-x

Keywords

Search

Navigation