PVD and CVD gradient coatings on sintered carbides and sialon tool ceramics

• Autorzy: Dobrzański L. A. , Staszuk M.
• Języki publikacji: EN

Abstrakty

EN

Purpose: The main objective of the work is to investigate the structure and properties of multilayer gradient coatings produced in PVD and CVD processes on sintered carbides and on sialon ceramics, and to define the influence of the properties of the coatings such as microhardness, adhesion, thickness and size of grains on the applicable properties of cutting edges covered by such coatings. Design/methodology/approach: The investigation studies pertaining to the following have been carried out: the structures of the substrates and coatings with the application of transmission electron microscopy; the structure and topography of coating surfaces with the use of electron scanning microscopy; chemical composition of the coatings using the GDOES and EDS methods; phase composition of the coatings using X-ray diffraction and grazing incident X-ray diffraction technique (GIXRD); grain size of the investigated coatings using Scherrer’s method; properties of the coatings including thickness, microhardness, adhesion and roughness; properties of the operating coatings in cutting trials. The models of artificial neural networks have been worked out which involve the dependencies between the durability of the cutting edge and properties of the coatings. Findings: Good adhesion of the coatings to the substrate from sintered carbides is connected with the diffusive mixing of the components of the coating and substrate. In the case of PVD coatings obtained on sialon ceramics, the highest adhesion to the substrate (Lc=53-112 N) has been demonstrated by the coatings containing the AlN phase of the hexagonal lattice having the same type of atomic (covalence) bond in the coating as in the ceramic substrate. The damage mechanism of the investigated coatings depends to a high degree on their adhesion to the substrate. The durability of cutting edges covered by the investigated coatings depends principally on the adhesion of the coatings to the substrate, and to a lesser degree on the other properties. Practical implications: While selecting a proper coating material on ceramic cutting edges, it is advisable to remember that the coatings having the same type of atomic bond as the ceramic substrate have higher adhesion to the substrate. Another relevant aspect of the research presented in the paper is the fact that the adhesion of the coatings contributes significantly to the durability of the cutting edge, whereas the microhardness of the coatings, their thickness and grain size have a slightly lower influence on the durability of the tool being coated. Originality/value: The paper presents the research involving the PVD and CVD coatings obtained on an unconventional substrate such as sialon ceramics. Furthermore, to define the influence of coating properties on the durability of cutting edges, artificial neural networks have been applied.

Słowa kluczowe

EN

working properties of materials; working properties of products; mechanical properties; PVD coatings; CVD coatings

PL

własności eksploatacyjne; właściwości materiałów; właściwości produktów; własności mechaniczne; powłoki CVD; powłoki PVD

• Wydawca: International OCSCO World Press
• Czasopismo: Journal of Achievements in Materials and Manufacturing Engineering
• Rocznik: 2010
• Tom: Vol. 43, nr 2
• Strony: 552--576
• Opis fizyczny: Bibliogr. 96 poz., rys., tab., wykr.

Twórcy

autor

Dobrzański L. A.

• Division of Materials Processing Technology, Management and Computer Techniques in Materials Science Institute of Engineering Materials and Biomaterials, Silesian University of Technology, ul. Konarskiego 18a, 44-100 Gliwice, Poland

autor

Staszuk M.

• Division of Materials Processing Technology, Management and Computer Techniques in Materials Science Institute of Engineering Materials and Biomaterials, Silesian University of Technology, ul. Konarskiego 18a, 44-100 Gliwice, Poland

Bibliografia

• [1] M. Adamiak, The structure and properties of TiN and Ti(C,N) coatings deposited in the PVD process on high speed steel. PhD thesis, Silesian University of Technology Library, Gliwice, 1997 (in Polish).
• [2] M. Arndt, T. Kacsich, Performance of new AlTiN coatings in dry and high speed cutting, Surface and Coatings Technology 163-164 (2003) 674-680.
• [3] M. Betiuk, T. Borowski, K. Burdyński, The (Ti,Al)N, (Ti,Al)C and (Ti,Al)CN multicompound coatings synthesis in low pressure of DC arc discharge, Engineering Materials 6 (2008) 674-678 (in Polish).
• [4] T. Burakowski, T. Wierzchoń, Engineering of metal surface, WNT, Warszawa 1995 (in Polish).
• [5] T. Burakowski, Transformation of superficial layers of areological system, Engineering Materials 6 (2008) 543-547 (in Polish).
• [6] T. Burakowski, Possibility of areology, Engineering Materials 5 (2006) 890-897 (in Polish).
• [7] S.I. Cha, S.H. Hong, B.K. Kim, Spark plasma sintering behavior of nanocrystalline WC-10Co cemented carbides powders, Materials Science & Engineering A351 (2003) 31-38.
• [8] Yin-Yu Chang, Da-Yung Wang, Characterization of nanocrystalline AlTiN coatings synthesized by a cathodic-arc deposition process, Surface and Coatings Technology 201 (2007) 6699-6701.
• [9] P. Cichosz, Cutting tools, WNT, Warszawa, 2006 (in Polish).
• [10] F. Čuš, M. Soković, J. Kopač, J. Balič, Model of complex optimization of cutting conditions. Journal of Materials Processing Technology 64 (1997) 41-52.
• [11] K. Czechowski, I. Pofelska-Filip, P. Szlosek, A. Fedaczyński, J. Kasina, B. Królicka, Chosen properties of hard layers deposited on ceramic material cutting inserts and their influence on the inserts durability, Engineering Materials 5 (2005) 261-264 (in Polish).
• [12] K. Czechowski, I. Pofelska-Filip, P. Szlosek, B. Królicka, J. Wszołek, Forming the functional properties of cutting inserts of composite oxide-carbide ceramics by nanostructural coatings deposited using the arc PVD method, Engineering Materials 5 (2006) 913-916 (in Polish).
• [13] D-Y. Wang, C-L. Chang, C-H. Hsu, H-N. Lin, Synthesis of (Ti,Zr)N hard coatings by unbalanced magnetron sputtering, Surface and Coatings Technology 130 (2000) 64-68.
• [14] L.A. Dobrzański, M. Adamiak, G.E. D’Errico, Relationship between erosion resistance and the phase and chemical composition of PVD coatings deposited onto high-speed steel, Journal of Materials Processing Technology 92-93 (1999) 184-189.
• [15] L.A. Dobrzański, M. Adamiak, Structure and properties of the TiN and Ti(C,N) coatings deposited in the PVD process on high-speed steels, Journal of Materials Processing Technology 133 (2003) 50-62.
• [16] L.A. Dobrzański, K. Gołombek, E. Hajduczek, Structure of the nanocrystalline coatings obtained on the CAE process on the sintered tool materials, Journal of Materials Processing Technology 175 (2006) 157-162.
• [17] L.A. Dobrzański, K. Gołombek, J. Kopač, M. Soković, Effect of depositing the hard surface coatings on properties of the selected cemented carbides and tool cermets, Journal of Materials Processing Technology 157-158 (2004) 304-311.
• [18] L.A. Dobrzański, K. Gołombek, J. Mikuła, D. Pakuła, Multilayer and gradient PVD coatings on the sintered tool materials, Journal of Achievements in Materials and Manufacturing Engineering 31/2 (2008) 170-190.
• [19] L.A. Dobrzański, K. Gołombek, Characteristic of nanocrystalline coatings obtained in cathode arc evaporation process onto sintered tool materials, Engineering Materials 3 (2006) 368-371 (in Polish).
• [20] L.A. Dobrzański, K. Gołombek, Gradient coatings deposited by Cathodic Arc Evaporation: characteristic of structure and properties, Journal of Achievements in Materials and Manufacturing Engineering 14/1-2 (2006) 48-53.
• [21] L.A. Dobrzański, K. Gołombek, Structure and properties of the cutting tools made from cemented carbides and cermets with the TiN + mono-, gradient- or multi (Ti,Al,Si)N+TiN nanocrystalline coatings, Journal of Materials Processing Technology 164-165 (2005) 805-815.
• [22] L.A. Dobrzański, J. Mikuła, Structure and properties of PVD and CVD coated Al2O3+TiC mixed oxide tool ceramics for dry on high speed cutting processes, Journal of Materials Processing Technology 164-165 (2005) 822-831.
• [23] L.A. Dobrzański, J. Mikuła, The structure and functional properties of PVD and CVD coated Al2O3+ZrO2 oxide tool ceramics, Journal of Materials Processing Technology 167 (2005) 438-446.
• [24] L.A. Dobrzański, D. Pakuła, E. Hajduczek, Structure and properties of the multi-component TiAlSiN coatings obtained in the PVD process in the nitride tool ceramics, Journal of Materials Processing Technology 157-158 (2004) 331-340.
• [25] L.A. Dobrzański, D. Pakuła, A. Křiž, M. Soković, J. Kopač, Tribological properties of the PVD and CVD coatings deposited onto the nitride tool ceramics, Journal of Materials Processing Technology 175 (2006) 179-185.
• [26] L.A. Dobrzański, M. Polok, M. Adamiak, Structure and properties of PVD coatings on tool steel for nitriding X37CrMoV5-1 to hot work steel, Proceedings of the Third Scientific Conference M3E’2005, Gliwice-Wisła 2005, 159-166 (in Polish).
• [27] L.A. Dobrzański, M. Staszuk, J. Konieczny, W. Kwaśny, M. Pawlyta, Structure of TiBN coatings deposited onto cemented carbides and sialon tool ceramics, Archives of Materials Science and Engineering 38/1 (2009) 48-54.
• [28] L.A. Dobrzański, M. Staszuk, J. Konieczny, J. Lelątko, Structure of gradient coatings deposited by CAE-PVD techniques, Journal of Achievements in Materials and Manufacturing Engineering 24/2 (2007) 55-58.
• [29] L.A. Dobrzański, M. Staszuk, M. Pawlyta, W. Kwaśny, M. Pancielejko, Characteristics of Ti(C,N) and (Ti,Zr)N gradient PVD coatings deposited onto sintered tool materials, Journal of Achievements in Materials and Manufacturing Engineering 31/2 (2008) 629-634.
• [30] L.A. Dobrzański, Forming the structure and surface properties of engineering and biomedical materials, Foresight of surface properties formation leading technologies of engineering materials and biomaterials, International OCSCO World Press, Gliwice, 2009. (in Polish)
• [31] L.A. Dobrzański, The modern tendency into range of development sintered tool materials, Mechanics 1 (1987) 21-31. (in Polish)
• [32] L.A. Dobrzański, Design and manufacturing functional gradient tool materials - dependence properties on technology and thickness of surface layers with a gradient of both chemical and phase composition manufactured on tool from different applications. Design and manufacturing functional gradient materials, The Polish Academy of Science, Cracow, 2007 (in Polish).
• [33] S. Dolinšek, J. Kopač, Acoustic emission signals for tool wear identification, Wear 225-229 (1999) 295-303.
• [34] S. Dolinšek, J. Kopač, Mechanism and types of tool wear; particularities in advanced cutting materials, Journal of Achievements in Materials and Manufacturing Engineering 19/1 (2006) 11-18.
• [35] Z. Dongli, Y. Dianran, X. Lisong, D. Yanchun, Characterization of nanostructured TiN coatings fabricated by reactive plasma spraying, Surface & Coatings Technology 202 (2008) 1928-1934.
• [36] L.A. Donohue, J. Cawley, J.S. Brooks, Deposition and characterization of arc-bond sputter TixZryN coatings from pure metallic and segmented targets, Surface and Coatings Technology 72 (1995) 128-138.
• [37] I. Dörfel, W. Österle, I. Urban, E. Bouzy, Microstructural characterization of binary and ternary hard coating systems for wear protection. Part I: PVD coatings, Surface and Coatings Technology 111/2-3 (1999) 199-209.
• [38] J.L. Endrino, V.H. Derflinger, The influence of alloying elements on the phase stability and mechanical properties of AlCrN coatings, Surface & Coatings Technology 200 (2005) 988-992.
• [39] G.S. Fox-Rabinovich, J.L. Endrino, B.D. Beake, A.I. Kovalev, S.C. Veldhuis, L. Ning, F. Fontaine, A. Gray, Impact of annealing on microstructure, properties and cutting performance of an AlTiN coating, Surface and Coatings Technology 201 (2006) 3524-3529.
• [40] C. Gautier, H. Moussaoui, F. Elstner, J. Machet, Comparative study of mechanical and structural properties of CrN films deposited by d.c. magnetron sputtering and vacuum arc evaporation, Surface & Coatings Technology 86-87/1 (1996) 254-262.
• [41] W. Gissler, P.N. Gibson, Titanium implantation into born nitride films and ion-beam mixing of titanium born nitride multilayers, Ceramics International 22 (1996) 335-340.
• [42] K. Gołombek: The structure and properties of sintered carbides and cermets tool coated in PVD process by anti-wear coatings. PhD Thesis, Silesian University of Technology Library, Gliwice 2001 (in Polish)
• [43] J.R. Groza, A. Zavaliangos, Sintering activation by external electrical field, Materials Science & Engineerin A 287 (2000) 171-177.
• [44] W. Grzesik, Z. Zalisz, S. Król, Tribological behaviour of TiAlN coated carbides in dry sliding tests, Journal of Achievements in Materials and Manufacturing Engineering 17/1-2 (2006) 181-184.
• [45] H. Hahn, P. Mondal, K.A. Padmanabhan, Nanostructured Materials 9 (1997) 603.
• [46] S. Hampshire, Silicon nitride ceramics - review of structure, processing and properties. Journal of Achievements in Materials and Manufacturing Engineering 24/1 (2007) 43-50.
• [47] Y. He, I. Apachitei, J. Jhou, W. Walstock, J. Duszczyk, Effect of prior plasma nitriding applied to a hot-work tool steel on the scratch-resistant properties of PACVD TiBN and TiCN coatings, Surface & Coatings Technology 201 (2006) 2534-2539.
• [48] P. Holubar, M. Jilek, M. Sima, Nanocomposite nc-TiAlSiN and nc-TiN-BN coatings: their applications on substrates made of cemented carbide and results of cutting tests, Surface and Coatings Technology 120-121 (1999) 184-188.
• [49] P. Holubar, M. Jilek, M. Sima, Present and possible future applications of superhard nanocomposite coatings, Surface and Coatings Technology 133-134 (2000) 145-151.
• [50] H. Holzschuh, Deposition Ti-B-N (single and multilayer) and Zr-B-N coatings by chemical vapor deposition techniques on cutting tools, Thin Solid Films 469-470 (2004) 92-98.
• [51] S. Jonsson, Trita-Mac 506, The Royal Institute of Technology, Div. Physical Mettalurgy, Stockholm, 1992.
• [52] A. Kloc-Ptaszna: Structure and properties of gradient carbide steel sintered onto groundmass of HS6-5-2 high speed steel. PhD Thesis, Silesian University of Technology Library, Gliwice, 2007 (in Polish).
• [53] J. Kopaþ, M. Sokoviü, S. Dolinšek, Tribology of coated tool in conventional and HSC machining, Journal of Materials Processing Technology 118 (2001) 377-384.
• [54] J. Kopaþ, Influence of cutting material and coating on tool quality and tool life, Journal of Materials Processing Technology 78 (1998) 95-103.
• [55] M. Kupczyk, Identification of damage and loss adherence were resistance coatings to edges machineable in adhesion test. Archive of Machine Technology and Automation 21/2 (2001) 231-251 (in Polish).
• [56] M. Kupczyk, Surface engineering. Wear resistant coatings for cutting edges, Poznań University of Technology Publishing House, Poznań, 2004 (in Polish).
• [57] T. Kurita, M. Hattori, Development of new-concept desk top size machine tool, International Journal of Machine Tools & Manufacture 45 (2005) 959-965.
• [58] W. Kwaśny, The structure and properties of coatings obtained in PVD process on sintered high speed steel. PhD Thesis, Silesian University of Technology Library, Gliwice, 2001 (in Polish).
• [59] T. Leyendecker, O. Lammer, S. Esser, J. Ebberink, The development of the PVD coating TiAlN as a commercial coating for cutting tools, Surface and Coatings Technology 49 (1991) 175-178.
• [60] Y.H. Lu, Z.F. Zhou, P. Sit, Y.G. Shen, K.Y. Li, Haydn Chen, X-Ray photoelectron spectroscopy characterization of reactively sputtered Ti-B-N thin films, Surface & Coatings Technology 187 (2004) 98-105.
• [61] K. Lukaszkowicz: Structure and properties of wear resistance and corrosion resistant PVD multilayer coatings. PhD Thesis, Silesian University of Technology Library, Gliwice 2001. (in Polish)
• [62] A. Michalski, Physical chemistry bases obtaining coatings from gas phase. Outhosue Publishing of Warsaw Technical University Oficyna, Warsaw 2000 (in Polish).
• [63] A. Michalski, PVD methods applied to deposition both hard and low-fusible material layers on machining tools, Metal science, Heat treatment 79 (1986) 18-23 (in Polish).
• [64] M. Michalski, D. Siemaszko, Impulsive plasma sintering of WC-12Co nanocrystalline carbides. Engineering materials 3 (2006) 629-631 (in Polish).
• [65] J. Mikuła, Structure and properties oxides tool ceramic on Al2O3 base from PVD and CVD wear resistance coatings. PhD Thesis, Silesian University of Technology Library, Gliwice, 2004 (in Polish).
• [66] C. Mitterer, P. Losbichler, F. Hofer, P. Warbichler, P.N. Gibson, W. Gissler, Nanocrystalline hard coatings within the quasi-binary system TiN-TiB2, Vacuum 50 (1998) 313-318.
• [67] T.P. Mollart, J. Haupt, R. Gilmore, W. Gissler, Tribological behaviour of homogeneous Ti-B-N, Ti-B-N-C and TiN/h-BN/TiB2 multilayer coatings, Surface and Coatings Technology 86-87 (1996) 231-236.
• [68] B.A. Movchan, K.Yu Yakovchuk, Graded thermal barrier coatings, deposited by EB-PVD, Surface and Coatings Technology 188-189 (2004) 85-92.
• [69] J. Musil, Hard and superhard nanocomposite coatings. Surface and Coatings Technology 125 (2000) 322-330.
• [70] B. Navinšek, P. Panjan, F. Gorenjak, Improvement of hot forging manufacturing with PVD and DUPLEX coatings, Surface and Coatings Technology 137 (2001) 255-264.
• [71] A.J. Novinrooz, H. Seyedi, M.M. Larijani, Microhardness study of Ti(C,N) films deposited on S-316 by the Hallow Cathode Discharge Gun, Journal of Achievements in Materials and Manufacturing Engineering 14/1-2 (2006) 59-63.
• [72] D. Pakuła, L.A. Dobrzański, K. Gołombek, M. Pancielejko, A. Křiž, Structure and properties of the Si3N4 nitride ceramics with hard wear resistant coatings, Journal of Materials Processing Technology 157-158 (2004) 388-393.
• [73] D. Pakuła, Structure and properties of PVD and CVD multilayer coatings resistant to abrasion on nitride ceramic tool Si3N4. PhD Thesis, Silesian University of Technology Library, Gliwice, 2003 (in Polish).
• [74] M. Pancielejko, W. Precht, Structure, chemical and phase composition of hard titanium carbon nitride coatings deposited on HS 6-5-2 steel, Journal of Materials Processing Technology 157-158 (2004) 394-298.
• [75] M. Polok, Structure and properties of PVD coatings deposited onto substrate from X37CrMoV5-1 steel heat treated and plasma nitride. PhD Thesis, Silesian University of Technology Library, Gliwice 2005 (in Polish).
• [76] W.M. Posadowski, Modern techniques of magnetron atomization, Electronics 4 (2006) 40-43 (in Polish).
• [77] W. Precht, E. Łunarska, A. Czyżniewski, Corrosion Resistance, Structure and Mechanical Properties of PVD, TiCxN1-x Coatings. Vacuum 47 (1996) 867-869.
• [78] W. Precht, Recent advances in hard and superhard anti-wear coating technology, Engineering Materials 3 (2006) 513-515 (in Polish).
• [79] L. Przybylski, Modern ceramic tool materials. Monograph 276, Technical University of Cracow, Cracow, 2000 (in Polish).
• [80] A.E. Reiter, V.H. Derflinger, B. Hanselmann, T. Bachmann, B. Sartory, Investigation of the properties of Al1-xCrxN coatings prepared by cathodic arc evaporation, Surface & Coatings Technology 200 (2005) 2114-2122.
• [81] S.H. Risbud, C-H. Shan, Fast consolidation of ceramic powders, Materials Science & Engineering A 204 (1995) 146-151.
• [82] H. Ronkainen, I. Nieminen, I. Holminen, K. Holmberg, A. Leyland, A. Matthews, B. Matthes, E. Broszeit, Evaluation of some titanium-based ceramic coatings on high speed steel cutting tools, Surface and Coatings Technology 49 (1991) 468-473.
• [83] D.M. Sanders, Review ion-based coating processes derived from the cathodic arc, The Journal of Vacuum Science and Technology 7/3 (1989) 2339-2345.
• [84] M. Soković, M. Bahor, On the inter-relationships of some machinability parameters in finish machining with cermet TiN (PVD) coated tools, Journal of Materials Processing Technology 78/1-3 (1998) 163-170.
• [85] M. Soković, J. Mikuła, L.A. Dobrzański, J. Kopač, L. Koseč, P. Panjan, J. Madejski, A. Piech, Cutting properties of the Al2O3 + SiC(w) based tool ceramic reinforced with the PVD and CVD wear resistant coatings, Journal of Materials Processing Technology 164-165 (2005) 924-929.
• [86] M. Staszuk, The structure and properties of PVD and CVD gradient coatings deposited on sialons and sintered carbides. PhD Thesis, Silesian University of Technology Library, Gliwice, 2009 (in Polish).
• [87] S. Stolarz, High-melting compounds and phases. Publication of Silesia, Katowice 1974 (in Polish).
• [88] D.G. Teer, J. Hampshire, V. Fox, V. Bellido-Gonzalez, The tribological properties of MoS2/metal composite coatings deposited by closed field magnetron sputtering, Surface and Coating Technology 94-95 (1997) 572-577.
• [89] J.A. Thornton, Journal of Vacuum Science and Technology A 4/6 (1986) 3059-3065.
• [90] V.V. Uglov, V.M. Anishchik, S.V. Zlotski, G. Abadias, The phase composition and stress development in ternary Ti-Zr-N coatings grown by vacuum arc with combining of plasma flows, Surface & Coatings Technology 200 (2006) 6389-6394.
• [91] S. Veprek, A.S. Argon, Towards the understanding of mechanical properties of super- and ultrahard nanocomposites, Journal of Vacuum Science and Technology B 20 (2002) 650-664.
• [92] S. Veprek, S. Reiprich, A concept for the design of novel superhard coatings, Thin Solid Films 268 (1995) 64-71.
• [93] S. Veprek, New development in superhard coatings: The superhard nanocrystalline-amorphous composites, Thin Solid Films 317 (1998) 449-454.
• [94] B.G. Wendler, W. Pawlak, Low friction and wear resistant coating systems on Ti6Al4V alloy, Journal of Achievements in Materials and Manufacturing Engineering 26/2 (2008) 207-210.
• [95] Z. Werner, J. Stanisławski, J. Piekoszewski, E.A. Levashov, W. Szymczyk, New types of multi-component hard coatings deposited by ARC PVD on steel pre-treated by pulsed plasma beams, Vacuum 70 (2003) 263-267.
• [96] M. Wysiecki, Contemporary Tool Materials, WNT, Warszawa, 1997 (in Polish).