Diamond-like carbon (DLC) films deposited by cathodic vacuum arc evaporation (CVAE) have attracted worldwide interest from research groups and industry since the beginning of the 1990s. Hydrogen-free amorphous carbon (a-C) coatings were first deposited by CVAE about two decades after the first description of hydrogenated a-C coatings (a-C:H) deposited by glow-discharge techniques. This paper highlights the development and broad potential of hard a-C coatings deposited by direct (DCVAE) and filtered (FCVAE) cathodic arc evaporation, including pulsed arc. DLC films offer a wide range of exceptional physical (optical, electrical), chemical (interaction with media), mechanical (hardness, elastic modulus), biomedical and tribological properties. Monolithic tetrahedrally-bonded hydrogen-free coatings (ta-C) provide the highest hardness, while various softer a-C coatings are also useful in some applications. Many film properties such as electrical conductivity and surface energy can be modified by alloying with elements such as H, N, Si, B, F, P and metals. Recent research and industrial solutions for generating DLC coatings by CVAE of carbon-based cathodes are described, and hybrid methods using metal cathodes and gas-phase sources are discussed. Coatings containing additional elements and having complex architectures are also discussed, and selected properties for various coating types are presented. The number of industrial applications of ta-C and a-C coatings continues to increase, mainly for tribological coatings to reduce wear and friction. Various applications of coatings deposited by CVAE are described, including data hard disks, engine parts, razor blades, valve seals, decorative coatings, cutting and forming tools, biomedical products and others.

60 years of DLC coatings: Historical highlights and technical review of cathodic arc processes to synthesize various DLC types, and their evolution for industrial applications

In the present contribution, numerical and experimental methodologies concerning orthogonal cutting are proposed in order to study the dry cutting of an aeronautic aluminium alloy (A2024-T351) The global aim concerns the comprehension of physical phenomena accompanying chip formation according to cutting velocity variation For the numerical model, material behaviour and its failure criterion are based on the Johnson–Cook law The model proposes a coupling between material damage evolution and its fracture energy A high-speed camera was used to capture the chip formation sequences The numerical results show that the chip–workpiece contact and the tool advancement induce bending loads on the chip Consequently, a fragmentation phenomenon takes place above the rake face when the chip begins to curl up The computed results corroborate with experimental ones The numerical results predict the residual stress distribution and show high values, along the cutting direction, on the machined workpiece surface

Numerical and experimental study of dry cutting for an aeronautic aluminium alloy (A2024-T351)

Ti1−xAlxN films and/or their alloys are employed in many industrial applications due to their excellent mechanical and thermal properties. Synthesized by plasma-assisted vapor deposition, Ti1−xAlxN is reported to crystallize in the cubic NaCl (c) structure for AlN mole fractions below 0.4–0.91, whereas at larger Al contents the hexagonal ZnS-wurtzite (w) structure is observed. Here we use ab initio calculations to analyze the effect of composition and Al distribution on the metal sublattice on phase stability, structure, and elastic properties of c-Ti1−xAlxN and w-Ti1−xAlxN. We show that the phase stability of supersaturated c-Ti1−xAlxN not only depends on the chemical composition but also on the Al distribution of the metal sublattice. An increase of the metastable solubility limit of AlN in c-Ti1−xAlxN from 0.64 to 0.74 is obtained by decreasing the number of Ti–Al bonds. This can be understood by considering the Al distribution induced changes of the electronic structure, bond energy, and configuration...

Influence of the Al distribution on the structure, elastic properties, and phase stability of supersaturated Ti1- xAlxN

The use of aluminum alloys in manufacturing industry has increased significantly in recent years. This is because primarily to their ability to combine lightness and strength in a single material. Concomitant to this growth, the machining of aluminum alloys has enormously increased in volumetric proportions—so that the chip volume represents up to 80 % of the original volume of the machined material in certain segments of the industry, like aerospace. In this context, knowledge of the characteristics of machinability of aluminum alloys is essential to provide industry and researchers with information that allows them to make the right decisions when they come to machining this fantastic material. The purpose of this review is to compile relevant information about the characteristics of machinability of aluminum alloys into a single document.

Machining of aluminum alloys: a review

The current review aims to provide an overview on the research performed with vanadium containing nitride hard coatings. Such coatings were synthesised with the objective of reducing the friction at high temperature via self-adaptation of the coating while still providing a high level of wear resistance. The lubricating effect is based on the formation of vanadium oxides with weakly bonded lattice planes and low melting temperature. The review focuses on aspects regarding the synthesis, structure and properties of these coatings and also includes a discussion on possible future developments and further improvements of the coating design.

Vanadium containing self-adaptive low-friction hard coatings for high-temperature applications: A review

A 3 μm thick superlattice structured TiAlN/VN coating has been deposited by the steered cathodic arc/unbalanced magnetron sputtering technique. The coating has been tested in dry high-speed milling of aluminium alloys Al7010-T7651 and AlSi9Cu1 and the performance compared to that of the diamond-like carbon (DLC) coated, TiAlCrYN coated and uncoated tools. In milling the Al7010-T7651 alloy, TiAlN/VN and DLC coated tools showed comparable performance, outperforming TiAlCrYN coated and uncoated tools by a factor of 2.3 and 3.5, respectively. In the case of milling AlSi9Cu1, the DLC coatings failed to produce any lifetime improvement, TiAlCrYN showed ∼ 65% longer lifetime thus rendering TiAlN/VN as the best performing coating with 100% longer lifetime compared to that of the uncoated tools. The tests further showed that TiAlN/VN reduces the cutting forces and improves the surface finish. Scanning electron microscopy of the cutting edge carried out after the cutting tests showed that the TiAlN/VN coating significantly reduces metal transfer and built-up edge formation. © 2006 Elsevier B.V. All rights reserved.

TiAlN/VN superlattice structured PVD coatings: A new alternative in machining of aluminium alloys for aerospace and automotive components

A low-friction and wear resistant TiAlN/VN multilayer coating with TiAlN/VN bilayer thickness 3 nm has been grown by using the combined cathodic arc etching and unbalanced magnetron sputtering deposition on high speed steel tools for dry cutting of aluminium alloys. In this paper, in-lab and industrial high speed milling tests have been performed on an aerospace aluminium alloy 7010-T7651. The results show that the TiAlN/VN coated tools achieved lower cutting forces, lower metal surface roughness, and significantly longer tool lifetime by three times over the uncoated tools as a result of the low friction and eliminated tool-metal adhesion. Under the same conditions, a TiAlN based multicomponent coating TiAlCrYN also increased the tool lifetime by up to 100% despite the high cutting forces measured.

/pdf/performance-of-nano-structured-multilayer-pvd-coating-tialn-26q1qtagay.pdf

Performance of nano-structured multilayer PVD coating TiAlN/VN in dry high speed milling of aerospace aluminium 7010-T7651

In order to address the industry driven interest in wear and associated mechanisms of coated tools during dry high speed machining applications, two commercially available physical vapour deposited (PVD) coatings were studied. These were PAIN based and had multilayered architectures deposited on to cemented carbide 8 min ball-nosed two flute end mills. Raman microscopy and SEM-EDX analysis were used to characterise the molecular and elemental species, respectively, present on the worn surfaces of tools after controlled lifetime tests milling into A2 HRC58 die steel. This was performed to gain a better understanding of tribochemical reactions that occur in the highly complex wear environment during milling. Cutting temperatures were estimated as greater than or equal to950degreesC, indicated by oxide phase transformations and corroborated by static oxidation studies. In addition, transfer layers of iron/steel and iron oxide species (FeO, Fe3O4, and Fe2O3), oxidation products of the coating (TiO2 and alpha-Al2O3), and spectral changes owing to deformation and stress state were observed as a consequence of wear. The high spatial resolution (2 mum), sensitivity to structural/chemical changes, and the non-destructive nature of the technique make Raman microscopy ideal for the study of wear on tools with complex geometry that cannot be readily studied by other techniques without difficult sample preparation.

Investigation of wear processes on worn tools using Raman microscopy

Investigation of High Power Impulse Magnetron Sputtering deposited nanoscale CrN/NbN multilayer coating for tribocorrosion resistance

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TiAlN/VN superlattice structured PVD coatings: A new alternative in machining of aluminium alloys for aerospace and automotive components

Performance of nano-structured multilayer PVD coating TiAlN/VN in dry high speed milling of aerospace aluminium 7010-T7651

Investigation of wear processes on worn tools using Raman microscopy

Investigation of High Power Impulse Magnetron Sputtering deposited nanoscale CrN/NbN multilayer coating for tribocorrosion resistance