Chapters authored
Wear Mechanism and Failure of Carbide Cutting Tools with Nanostructured Multilayered Composite Coatings
The aim of this work is to study physical and chemical properties of nanostructured multi-layered composite coating based on three-layered architecture, deposited to a carbide substrate, as well as to study the mechanism of wear and failure of coated carbide tools under the conditions of stationary cutting. The coating were obtained by the method of filtered cathodic vacuum arc deposition (FCVAD). Here, the microstructure of coating as well as its hardness, strength of the adhesive bond to the substrate, chemical composition and phase composition were investigated on a transverse cross-section of experimental samples. The studies of cutting properties of the carbide inserts with developed coatings was conducted on a lathe in longitudinal turning of steel C45 (HB 200). The analysis of mechanisms of wear and failure of coated tool was carried out, including the processes of diffusion and oxidation in the surface layers of the coated substrate. Tools with harder and less ductile coatings showed less steady kinetics of wear, characterized by sharp intensification of wear and failure in transition from “steady” to drastic wear, i.e., at the end of the tool life. The X-ray microanalysis showed a considerable increase in oxygen content in the transverse cracks in the coating.
Part of the book: Nanostructured Materials
Delamination and Longitudinal Cracking in Multilayered Composite Nanostructured Coatings and Their Influence on Cutting Tool Wear Mechanism and Tool Life
The wear and failure mechanism for multilayered nanostructured coatings has a number of significant differences from the one typical for monolithic single-layered coatings. In particular, while the strength of adhesion bonds at the “substrate-coating” boundary is important for monolithic coatings, then for multilayered nanostructured coatings, the strength of adhesion and cohesion bonds at interlayer boundaries and boundaries of separate nano-sublayers becomes of significant significance. Meanwhile, the delamination arising in the structure of multilayered nanostructured coatings can have both negative (leading to loss of coating uniformity and subsequent failure of coating) and positive influences (due to decrease of internal stresses and inhibition of transverse cracking). Various mechanisms of formation of longitudinal cracks and delaminations in coatings on rake tool faces, which vary based on the compositions and architectures of the coatings, are studied. In addition, the influence of internal defects, including embedded microdrops and pores, on the formation of cracks and delaminations and the failure of coatings is discussed. The importance of ensuring a balance of the basic properties of coatings to achieve high wear resistance and maximum tool life of coated metal-cutting tools is shown. The properties of coatings and the natures of their failures, as investigated during scratch testing and dry turning of steel C45, are provided.
Part of the book: Novel Nanomaterials