Skip to main content
SpringerLink
Log in

Advanced Characterization Techniques of Multi-material Machining Tool Coatings

  • Conference paper
  • First Online:
Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems (FAIM 2023)

Part of the book series: Lecture Notes in Mechanical Engineering ((LNME))

  • 872 Accesses

Abstract

Characterization techniques are of the utmost importance to determine the properties of a material, especially before the performance of experimental tests, as it will make it possible to optimize it. Multi-material machining is a manufacturing process that sustains diverse challenges, namely the fast tool wear caused by the composite fibres’ abrasive nature, as well as the need to cut through interface zones between the metal and the composite, being subject to two or more different cutting patterns at the same time. A proper coating is one of the answers to this problem; however, it must be correctly characterized so that premature wear of the tool does not occur, and its lifetime can be extended as much as possible but without damaging the substrate. Several characterization techniques are used in machining tool coatings, for example, for diamond, the most important are the atomic force microscopy (AFM) and scanning electron microscopy (SEM), X-ray diffraction (XRD), Raman spectroscopy, the pin-on-disc test, the micro-abrasion, the scratch test, and nano/microindentation. This manuscript reviews of the use of these methods by the authors in the literature, some of which combined them for a complete characterization of the coating, obtaining good results in their analysis. Hence, the objective of the study is to allow the reunion of all the information needed to know to decide which coating to choose for a specific application.

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

Access this chapter

Log in via an institution
Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 219.00
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 279.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

Similar content being viewed by others

References

  1. del Sol, I., Rivero, A., de Lacalle, L.N.L., Gamez, A.J.: Thin-wall machining of light alloys: a review of models and industrial approaches. Materials 12(12), 2012 (2019)

    Google Scholar 

  2. Suárez, A., Aldalur, E., Veiga, F., Artaza, T., Tabernero, I., Lamikiz, A.: Wire arc additive manufacturing of an aeronautic fitting with different metal alloys: from the design to the part. J Manuf Process 64(January), 188–197 (2021)

    Article  Google Scholar 

  3. Cianetti, F., Ciotti, M., Palmieri, M., Zucca, G.: On the evaluation of surface fatigue strength of a stainless-steel aeronautical component. Metals 9(4), 1–20 (2019)

    Article  Google Scholar 

  4. Rizzo, A., et al.: The critical raw materials in cutting tools for machining applications: a review. Materials 13(6), 1377 (2020)

    Google Scholar 

  5. Abdullah, M.S., Abdullah, A.B., Samad, Z.: Review of hole-making technology for composites. Hole-Making and Drilling Technology for Composites, pp. 1–15 (2019)

    Google Scholar 

  6. Geier, N., Davim, J.P., Szalay, T.: Advanced cutting tools and technologies for drilling carbon fibre reinforced polymer (CFRP) composites: a review. Compos. Part A Appl. Sci. Manuf. 125, 105552 (2019)

    Article  Google Scholar 

  7. Xu, J., Mkaddem, A., el Mansori, M.: Recent advances in drilling hybrid FRP/Ti composite: a state-of-the-art review. Compos. Struct. 135, 316–338 (2016)

    Article  Google Scholar 

  8. Xu, J., el Mansori, M.: Experimental study on drilling mechanisms and strategies of hybrid CFRP/Ti stacks. Compos Struct. 157, 461–482 (2016)

    Article  Google Scholar 

  9. Reddy, R.H.N., Alphonse, M., Raja, V.K.B., Palanikumar, K., Sanjay, D.R.S.K., Sudhan, K.v.M.: Evaluating the wear studies and tool characteristics of coated and uncoated HSS drill bit - a review. Mater. Today Proc. 46, 3779–3785 (2020)

    Google Scholar 

  10. Wang, R., Yang, D., Wang, W., Wei, F., Lu, Y., Li, Y.: Tool wear in nickel-based superalloy machining: an overview. Processes 10(11), 2380 (2022)

    Google Scholar 

  11. He, Q., Paiva, J.M., Kohlscheen, J., Beake, B.D., Veldhuis, S.C.: An integrative approach to coating/carbide substrate design of CVD and PVD coated cutting tools during the machining of austenitic stainless steel. Ceram Int. 46(4), 5149–5158 (2020)

    Article  Google Scholar 

  12. Aditharajan, A., Radhika, N., Saleh, B.: Recent advances and challenges associated with thin film coatings of cutting tools: a critical review. Transactions of the Institute of Metal Finishing. Taylor and Francis Ltd. (2022)

    Google Scholar 

  13. Andrade, M.F.C., Martinho, R.P., Silva, F.J.G., Alexandre, R.J.D., Baptista, A.P.M.: Influence of the abrasive particles size in the micro-abrasion wear tests of TiAlSiN thin coatings. Wear 267(1–4), 12–18 (2009)

    Article  Google Scholar 

  14. Silva, F.J.G., Martinho, R.P., Alexandre, R.J.D., Baptista, A.P.M.: Increasing the wear resistance of molds for injection of glass fiber reinforced plastics. Wear 271(9–10), 2494–2499 (2011)

    Article  Google Scholar 

  15. Martinho, R.P., Andrade, M.F.C., Silva, F.J.G., Alexandre, R.J.D., Baptista, A.P.M.: Micro-abrasion wear behaviour of TiAlCrSiN nanostructured coatings. Wear 267(5–8), 1160–1165 (2009)

    Article  Google Scholar 

  16. Fernandes, L., Silva, F.J.G., Alexandre, R.: Study of TiAlN PVD coating on stamping dies used in tinplate food package production. Micromachines 10(3), 182 (2019)

    Google Scholar 

  17. Giasin, K., Ayvar-Soberanis, S., French, T., Phadnis, V.: 3D finite element modelling of cutting forces in drilling fibre metal laminates and experimental hole quality analysis. Applied Composite Materials 24(1), 113–137 (2017)

    Google Scholar 

  18. Gouveia, R., Silva, F., Reis, P., Baptista, A.: Machining duplex stainless steel: comparative study regarding end mill coated tools. Coatings 6(4), 51 (2016)

    Article  Google Scholar 

  19. Silva, F.J.G., Martinho, R.P., Martins, C., Lopes, H., Gouveia, R.M.: Machining GX2CrNiMoN26-7-4 DSS alloy : milling operations. Coatings 9, 1–21 (2019)

    Article  Google Scholar 

  20. Martinho, R.P., Silva, F.J.G., Martins, C., Lopes, H.: Comparative study of PVD and CVD cutting tools performance in milling of duplex stainless steel. Int. J. Adv. Manuf. Technol. 102(5–8), 2423–2439 (2019)

    Article  Google Scholar 

  21. Bouzakis, K.D., Michailidis, N., Skordaris, G., Bouzakis, E., Biermann, D., M’Saoubi, R.: Cutting with coated tools: coating technologies, characterization methods and performance optimization. CIRP Ann Manuf. Technol. 61(2), 703–723 (2012)

    Article  Google Scholar 

  22. Sousa, V.F.C., Silva, F.J.G., Alexandre, R., Fecheira, J.S., Silva, F.P.N.: Study of the wear behaviour of TiAlSiN and TiAlN PVD coated tools on milling operations of pre-hardened tool steel. Wear 476, 203695 (2021)

    Google Scholar 

  23. Fernandes, L., Silva, F.J.G., Andrade, M.F., Alexandre, R., Baptista, A.P.M., Rodrigues, C.: Improving the punch and die wear behavior in tin coated steel stamping process. Surf. Coat Technol. 332, 174–189 (2017)

    Article  Google Scholar 

  24. Zhang, L., Zhao, Z., Bai, P., Du, W.: EBSD investigation on microstructure evolution of in-situ synthesized TiC/Ti6Al4V composite coating. Mater Lett. 290, 129449 (2021)

    Google Scholar 

  25. Martinho, R.P., Silva, F.J.G., Alexandre, R.J.D., Baptista, A.P.M.: TiB 2 nanostructured coating for GFRP injection moulds. J. Nanosci. Nanotechnol. 11(6), 5374–5382 (2011)

    Article  Google Scholar 

  26. Sousa, V.F.C., Castanheira, J., Silva, F.J.G., Fecheira, J.S., Pinto, G., Baptista, A.: Wear behavior of uncoated and coated tools in milling operations of ampco (Cu-be) alloy. Applied Sciences (Switzerland) 11(16), 7762 (2021)

    Google Scholar 

  27. Martinho, R.P., Silva, F.J.G., Baptista, A.P.M.: Cutting forces and wear analysis of Si3N4 diamond coated tools in high speed machining. Vacuum 82(12), 1415–1420 (2008)

    Article  Google Scholar 

  28. Martinho, R.P., Silva, F.J.G., Baptista, A.P.M.: Wear behaviour of uncoated and diamond coated Si3N4 tools under severe turning conditions. Wear 263(7–12) SPEC. ISS., 1417–1422 (2007)

    Google Scholar 

  29. Silva, F.J.G., et al.: Microwave plasma chemical vapour deposition diamond nucleation on ferrous substrates with Ti and Cr interlayers. Diam Relat. Mater. 11(9), 1617–1622 (2002)

    Article  Google Scholar 

  30. Hu, J., Chou, Y.K., Thompson, R.G., Burgess, J., Street, S.: Characterizations of nano-crystalline diamond coating cutting tools. Surf Coat Technol. 202(4–7), 1113–1117 (2007)

    Article  Google Scholar 

  31. Silva, F.J.G., Fernandes, A.J.S., Costa, F.M., Baptista, A.P.M., Pereira, E.: Unstressed PACVD diamond films on steel pre-coated with a composite multilayer. Surf. Coat Technol. 191(1), 102–107 (2005)

    Article  Google Scholar 

  32. Silva, F.J.G., Fernandes, A.J.S., Costa, F.M., Teixeira, V., Baptista, A.P.M., Pereira, E.: Tribological behaviour of CVD diamond films on steel substrates. Wear 255(7–12), 846–853 (2003)

    Article  Google Scholar 

  33. Osmond, L., Cook, I., Slatter, T.: Tribological properties of multilayer CVD coatings deposited on sialon ceramic milling inserts. J. Manufact. Materials Process. 7(2), 67 (2023)

    Google Scholar 

  34. Silva, F.J.G., Casais, R.C.B., Baptista, A.P.M., Marques, M.J., Sousa, V.C., Alexandre, R.: Comparative study of the wear behavior of B4C Monolayered and CrN/CrCN/DLC multilayered physical vapor deposition coatings under high contact loads: an experimental analysis. J. Tribol. 144(3), 031701 (2022)

    Google Scholar 

  35. Silva, F., Martinho, R., Andrade, M., Baptista, A., Alexandre, R.: Improving the wear resistance of moulds for the injection of glass fibre-reinforced plastics using PVD coatings: a comparative study. Coatings 7(2), 28 (2017)

    Google Scholar 

  36. Çay, V.V.: Effects of abrasive particle type, load and sliding distance on micro-abrasion resistance of high speed steel coated with AlCrN or AlTiN. Medziagotyra 27(1), 50–56 (2021)

    Google Scholar 

  37. Casais, R., Baptista, A.M., Silva, F.J., Andrade, F., Sousa, V., Marques, M.J.: Experimental study on the wear behavior of B4C and TiB2 monolayered PVD coatings under high contact loads. Int. J. Adv. Manuf. Technol. 120(9–10), 6585–6604 (2022)

    Article  Google Scholar 

  38. Pacella, M., st. John, M.G.J., Dolatabadi, N., Badiee, A.: Microhardness and wear behaviour of polycrystalline diamond after warm laser shock processing with and without coating. Int. J. Refract Metals Hard Mater. 82, 215–226 (2019)

    Google Scholar 

  39. Nunes, V., Silva, F.J.G., Andrade, M.F., Alexandre, R., Baptista, A.P.M.: Increasing the lifespan of high-pressure die cast molds subjected to severe wear. Surf. Coat Technol. 332, 319–331 (2017)

    Article  Google Scholar 

Download references

Acknowledgements

The authors gratefully acknowledge the funding of Project Hi-rEV – Recuperação do Setor de Componentes Automóveis (C644864375–00000002) cofinanced by Plano de Recuperação e Resiliência (PRR), República Portuguesa through NexGeneration EU.

Author information

Authors and Affiliations

  1. FEUP – Faculty of Engineering, University of Porto, 4200-065, Porto, Portugal

    R. D. F. S. Costa, A. M. P. Jesus, S. L. S. Simões & M. L. S. Barbosa

  2. INEGI – Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Industrial, 400, 4200-465, Porto, Portugal

    R. D. F. S. Costa, A. M. P. Jesus & S. L. S. Simões

Authors
  1. R. D. F. S. Costa
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. A. M. P. Jesus
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. S. L. S. Simões
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. M. L. S. Barbosa
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to R. D. F. S. Costa .

Editor information

Editors and Affiliations

  1. TEMA - Centre for Mechanical Technology and Automation, Department of Mechanical Engineering, University of Aveiro, Porto, Portugal

    Francisco J. G. Silva

  2. TEMA - Centre for Mechanical Technology and Automation, Department of Mechanical Engineering, University of Aveiro, Aveiro, Portugal

    António B. Pereira

  3. Department of Mechanical Engineering, ISEP – School of Engineering, Polytechnic of Porto, Porto, Portugal

    Raul D. S. G. Campilho

Rights and permissions

Reprints and permissions

Copyright information

© 2024 The Author(s), under exclusive license to Springer Nature Switzerland AG

About this paper

Check for updates. Verify currency and authenticity via CrossMark

Cite this paper

Costa, R.D.F.S., Jesus, A.M.P., Simões, S.L.S., Barbosa, M.L.S. (2024). Advanced Characterization Techniques of Multi-material Machining Tool Coatings. In: Silva, F.J.G., Pereira, A.B., Campilho, R.D.S.G. (eds) Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems. FAIM 2023. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-38241-3_28

Download citation

  • DOI: https://doi.org/10.1007/978-3-031-38241-3_28

  • Published:

  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-031-38240-6

  • Online ISBN: 978-3-031-38241-3

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics

Search

Navigation