Elevated temperature repetitive micro-scratch testing of AlCrN, TiAlN and AlTiN PVD coatings

In developing advanced wear-resistant coatings for tribologically extreme highly loaded applications such as high speed metal cutting a critical requirement is to investigate their behaviour at elevated temperature since the cutting process generates frictional heat which can raise the temperature in the cutting zone to 700–900 °C or more. High temperature micro-tribological tests provide severe tests for coatings that can simulate high contact pressure sliding/abrasive contacts at elevated temperature. In this study ramped load micro-scratch tests and repetitive micro-scratch tests were performed at 25 and 500 °C on commercial monolayer coatings (AlCrN, TiAlN and AlTiN) deposited on cemented carbide cutting tool inserts. AlCrN exhibited the highest critical load for film failure in front of the moving scratch probe at both temperatures but it was prone to an unloading failure behind the moving probe. Scanning electron microscopy showed significant chipping outside the scratch track which was more extensive for AlCrN at both room and elevated temperature. Chipping was more localised on TiAlN although this coating showed the lowest critical loads at both test temperatures. EDX analysis of scratch tracks after coating failure showed tribo-oxidation of the cemented carbide substrate. AlTiN showed improved scratch resistance at higher temperature. The von Mises, tensile and shear stresses acting on the coating and substrate sides of the interface were evaluated analytically to determine the main stresses acting on the interface. At 1 N there are high stresses near the coating-substrate interface. Repetitive scratch tests at this load can be considered as a sub-critical load micro-scale wear test which is more sensitive to adhesion differences than the ramped load scratch test. The analytical modelling showed that a dramatic improvement in the performance of AlTiN in the 1 N test at 500 °C could be explained by the stress distribution in contact resulting in a change in yield location due to the high temperature mechanical properties. The increase in critical load with temperature on AlTiN and AlCrN is primarily a result of the changing stress distribution in the highly loaded sliding contact rather than an improvement in adhesion strength

A critical review on the numerical simulation related to Physical Vapour Deposition

Physical Vapour Deposition (PVD) is a process usually used for the production of advanced coatings regarding its application in several industrial and current products, such as optical lens, moulds and dies, decorative parts or tools. This process has several variants due to its strong evolution along the last decades. The process is commonly assisted by plasma, creating a particular low pressure and medium temperature atmosphere, which is responsible for the transition of atomic particles between the target and the parts to be coated into a vacuum reactor. Several parameters are directly affecting the deposition, namely the substrate temperature, pressure inside the reactor, assisting gases used, type of current, power supply, bias, substrate and target materials, samples holder and corresponding rotation, deposition time, among others. Many mathematical models have been developed in order to allow the generation of numerical simulation applications, trying to combine parameters and expect the corresponding results. Numerical simulation applications were created around the mathematical models previously developed, which can play an important role in the prediction of the coating properties and structure. This paper intends to describe the numerical simulation evolution in the last years, namely the use of Finite Elements Method (FEM) and Computational Fluid Dynamics (CFD).info:eu-repo/semantics/publishedVersio

A critical review on the numerical simulation related to Physical Vapour Deposition

Physical Vapour Deposition (PVD) is a process usually used for the production of advanced coatings regarding its application in several industrial and current products, such as optical lens, moulds and dies, decorative parts or tools. This process has several variants due to its strong evolution along the last decades. The process is commonly assisted by plasma, creating a particular low pressure and medium temperature atmosphere, which is responsible for the transition of atomic particles between the target and the parts to be coated into a vacuum reactor. Several parameters are directly affecting the deposition, namely the substrate temperature, pressure inside the reactor, assisting gases used, type of current, power supply, bias, substrate and target materials, samples holder and corresponding rotation, deposition time, among others. Many mathematical models have been developed in order to allow the generation of numerical simulation applications, trying to combine parameters and expect the corresponding results. Numerical simulation applications were created around the mathematical models previously developed, which can play an important role in the prediction of the coating properties and structure. This paper intends to describe the numerical simulation evolution in the last years, namely the use of Finite Elements Method (FEM) and Computational Fluid Dynamics (CFD).LAETA/CETRIB/INEGI Research Center- FLAD – Fundação Luso-Americana para o Desenvolvimento | Ref. 116/2018Fundação para a Ciência e a Tecnologia | Ref. UID/EMS/0615/201

Laser assisted micro-milling of titanium alloy

The interest in applying Additive Manufacturing (AM) technology has grown due to its ability to produce complex parts with high flexibility, serving as an alternative to conventional manufacturing processes. However, the poor surface quality and limited dimensional accuracy of AM parts often necessitate post-processing such as machining, grinding, and polishing. Titanium, specifically Ti6Al4V alloy, is frequently used in AM technology. This study compares the machinability of AM Ti6Al4V parts produced by Electron Beam Melting (EBM) with extruded Ti6Al4V parts, focusing on cutting forces, specific cutting energy, burr formation, and surface quality in the micro-milling process. Despite the higher hardness of EBM Ti6Al4V, no significant difference in cutting forces was observed at chip thicknesses between 7.4 μm and 37.3 μm. However, at chip thicknesses below 7.4 μm, EBM parts exhibited lower cutting forces and specific cutting energies, and finer surface roughness. Both materials formed continuous wavy-type burrs of comparable size during micro-milling. The study also underscores the significance of Laser-Assisted Machining (LAM) in reducing machining forces and increasing Material Removal Rate (MRR). Instead of the traditional LAM method, a pico-second laser (USPL) was used to pre-structure the Ti6Al4V parts, impacting uncut chip thicknesses during micro-milling. A kinematic model was developed to understand the influence of workpiece structuring on uncut chip thicknesses, identifying structure density and depth as critical parameters. Experimental tests showed a significant reduction in cutting forces with pre-structured workpieces, without notable changes in surface roughness. The orientation of structure lines relative to the helix angle affected the surface roughness. Pre-structuring led to controlled subsurface damage and less material removal during milling, resulting in better machinability

Machining of biocompatible materials: Recent advances

Machining of biocompatible materials is facing the fundamental challenges due to the specific material properties as well as the application requirements. Firstly, this paper presents a review of various materials which the medical industry needs to machine, then comments on the advances in the understanding of their specific cutting mechanisms. Finally it reviews the machining processes that the industry employs for different applications. This highlights the specific functional requirements that need to be considered when machining biocompatible materials and the associated machines and tooling. An analysis of the scientific and engineering challenges and opportunities related to this topic are presented

PVD Coatings’ Strength Properties at Various Temperatures by Nanoindentations and FEM Calculations Determined

Nanoindentation is usually applied on thin films at ambient temperatures for hardness determination. Recently, instruments for conducting nanoindentation at elevated temperatures have been developed facilitating measurements up to 700 oC. Both indenter and specimen, if necessary, are heated in an inert atmosphere to avoid film oxidations. In the described investigations, nanoindentations were conducted on cemented carbides and high speed steel specimens, coated with various films, up to 400 oC. The obtained results were subjected to statistical analysis to estimate their reliability. Moreover, the results were evaluated by appropriate FEM (Finite Element Method) algorithms for determining the coatings’ elasticity modulus, yield and rupture stress as well as hardness at various temperatures. The results reveal a non-linear temperature dependence of the coating properties

Micro-impact testing of AlTiN and TiAlCrN coatings

A novel micro-scale repetitive impact test has been developed to assess the fracture resistance of hard coatings under dynamic high strain rate loading. It is capable of significantly higher impact energies than in the nano-impact test. It retains the intrinsic depth-sensing capability of the nano-impact test enabling the progression of the damage process to be monitored throughout the test, combined with the opportunity to use indenters of less sharp geometry and still cause rapid coating failure. The micro-impact test has been used to study the resistance to impact fatigue of Al-rich PVD nitride coatings on cemented carbide. The impact fatigue mechanism has been investigated in nano- and micro-scale impact tests. Coating response was highly load-dependent. A Ti0.25Al0.65Cr0.1N coating with high H3/E2 performed best in the nano- and micro- impact tests although it was not the hardest coating studied. The role of mechanical properties, microstructure and thickness on impact behaviour and performance in cutting tests is discussed

Mini symposium on cutting and machining: 25 years of ESAFORM activity

This paper reports on the state of the art in the experimental and numerical investigations of cutting and machining processes. The contributions on the above-mentioned processes and published on the Proceedings of the European Scientific Association for material FORMing (ESAFORM) Conferences are highlighted. In particular, this literature review is an update of a previous one conducted in 2007, after ten years of the ESAFORM activities, and it confirms the crucial role played by the minisymposium on Machining and Cutting in this field. In fact, the research has been quite active even in these last fifteen years, as demonstrated by the number of contributions and their relevant scientific contents. As overall, this review shows as the minisymposium on Machining and Cutting, that has been organized since 2001 with no interruptions, has contributed to the scientific progress on the study of the material removal processes