Title DLC and DLC-WS2 Coatings for Machining of Aluminium Alloys
Authors Brzezinka, Tomasz L. , Rao, Jeff , Paiva, Jose M. , Kohlscheen, Joern , Fox-Rabinovich, German S. , Veldhuis, Stephen C. , ENDRINO ARMENTEROS, JOSÉ LUIS
External publication Si
Means Coatings
Scope Article
Nature Científica
JCR Quartile 2
SJR Quartile 2
JCR Impact 2.43600
SJR Impact 0.46300
Web https://www.scopus.com/inward/record.uri?eid=2-s2.0-85069765578&doi=10.3390%2fCOATINGS9030192&partnerID=40&md5=6b87ebfcce9886df461998a80d5a7c17
Publication date 15/03/2019
ISI 000464284800001
Scopus Id 2-s2.0-85069765578
DOI 10.3390/coatings9030192
Abstract Machine-tool life is one limiting factor affecting productivity. The requirement for wear-resistant materials for cutting tools to increase their longevity is therefore critical. Titanium diboride (TiB2) coated cutting tools have been successfully employed for machining of AlSi alloys widely used in the automotive industry. This paper presents a methodological approach to improving the self-lubricating properties within the cutting zone of a tungsten carbide milling insert precoated with TiB2, thereby increasing the operational life of the tool. A unique hybrid Physical Vapor Deposition (PVD) system was used in this study, allowing diamond-like carbon (DLC) to be deposited by filtered cathodic vacuum arc (FCVA) while PVD magnetron sputtering was employed to deposit WS2. A series of similar to 100-nm monolayer DLC coatings were prepared at a negative bias voltage ranging between -50 and -200 V, along with multilayered DLC-WS2 coatings (total thickness similar to 500 nm) with varying number of layers (two to 24 in total). The wear rate of the coated milling inserts was investigated by measuring the flank wear during face milling of an Al-10Si. It was ascertained that employing monolayer DLC coating reduced the coated tool wear rate by similar to 85% compared to a TiB2 benchmark. Combining DLC with WS2 as a multilayered coating further improved tool life. The best tribological properties were found for a two-layer DLC-WS2 coating which decreased wear rate by similar to 75% compared to TiB2, with a measured coefficient of friction of 0.05.
Keywords self-lubricating coatings; tungsten disulphide; DLC; SEM; EDS; XPS; milling; aluminium
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