Professional Documents
Culture Documents
2 0 2 0;9(2):1389–1399
https://www.journals.elsevier.com/journal-of-materials-research-and-technology
Original Article
Junbo Liu, Ji Xiong ∗ , Zhixing Guo, Chengtao Qin, Ya Xiao, Qianbing You
School of Manufacturing Science and Engineering, Sichuan University, Chengdu, 610065, P.R. China
a r t i c l e i n f o a b s t r a c t
Article history: CVD coatings were deposited on the cermets and cemented carbides tools. Uncoated cer-
Received 15 September 2019 mets, coated cermets and cemented carbides tools were used for hardened AISI H13 steel
Accepted 23 November 2019 machining. Face-centered cubic structure of the cermets attribute to the direct growth of the
Available online 12 December 2019 TiN coatings. TiN and TiCN shows (2 0 0) preferred orientation on the cermets. The hexag-
onal closepacked structure of the cemented carbides make the TiN coatings nucleate first
Keywords: and then grow. TiN and TiCN shows (1 1 1) preferred orientation on the cemented carbides.
Cermets When the cutting speed reaches and exceeds 700 r/min, the coated cermets have the longest
Structure life. The excellent diffusion and adhension wear resistance at elevated temperature of the
Coatings coated cermets result a better surface quality of workpiece.
Cutting performance © 2019 The Authors. Published by Elsevier B.V. This is an open access article under the
CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
matching result in rough surface. Besides, with the ceramic 2.2. Coating process
tools, Suresh et al. [13] did some researches in the effect of cut-
ting parameters on tool wear when turned hardened AISI H13 All the cermets and cemented carbides substrates were
tool steel. The results revealed that cutting speed and depth ground and polished to the roughness of 0.2 m prior to coat-
of cut have a significant effect on feed force. Nose region is ing deposition. Then they were cleaned with alcohol. The films
the main region of tool wear which is easily broken due to the were deposited by CVD reactor (Acti-C280, China). Multilay-
brittleness of ceramics. Ng et al. [14] machined the AISI H13 ers including four films were deposited on the specimens.
steel by using PCBN tools and explored the effect of cutting From the interior to the exterior, the coating was TiN, MT-
speed on the machinability. PCBN tools exhibit good cutting TiCN,␣-Al2 O3 and TiN respectively. The nominal thickness of
performance at high cutting speed, but high price limits the the corresponding layer was about 0.5 m, 5.0 m, 6.5 m and
use on a large scale. 1.0 m.
Ti(C,N)-based cermets exhibit excellent thermal deforma- The reaction of TiN coatings was shown by the following
tion resistance, chemical stability, and oxidation resistance chemical reaction:
[15–17]. In addition, Ti(C,N)-based cermets show higher hard-
2TiCl4 (g) + N2 (g) + 4H2 (g) → 2TiN(s) + 8HCl(g)
ness, lower friction coefficient compared with the cemented
carbide, superior toughness than the ceramics and more cost- The TiN deposition temperature was 950 ◦ C, the partial
effective than the PCBN. Recent advances in Ti(C,N)-based pressures of TiCl4 , N2 , and H2 were 1.0 kPa, 16.0 kPa and
cermets manufacturing technology have attribute to a new 42.0 kPa. The deposition time for the inner and outer TiN layer
generation of high performance cermets tools. Thus, cermets was 0.5 h and 1 h.
is an attractive alternative used in the machining of hardened The reaction of MT-TiCN coating was shown by the follow-
AISI H13 steel. Besides, multilayer-coatings of hard refractory ing chemical reaction:
materials such as, Ti(C,N), TiN and Al2 O3 , are today used in
TiCl4 (g) + 3/2H2 (g) + 1/3CH3 CN(g) → TiC2/3 N1/3 (s) + 4HCl(g)
order to further enhance the performance of the cutting tool
insert [18]. In the machining of steel, the multilayer-coatings The MT-TiCN deposition temperature was 850 ◦ C, the par-
show a high chemical and thermal Stability [19]. Thus, in the tial pressures of TiCl4 , CH3 CN, H2 were 0.04 kPa, 0.02 kPa and
work, cermets cutting tools were prepared by traditional pow- 2.3 kPa. The deposition time was 4 h.
der metallurgy. Commercial cemented carbide tools used for The reaction of ␣-Al2 O3 layer was shown by the following
cutting hardened steel were compared as a control group. The chemical reaction:
multilayer TiN/Al2 O3 /TiCN/TiN CVD coatings were deposited
on the cermets and cemented carbides tools. Uncoated cer- CO2 (g) + H2 (g) → CO(g) + H2 O(g)
mets, coated cermets and cemented carbides tools were used
for hardened AISI H13 steel machining. Characteristics of 2AlCl3 (g) + 3H2 O(g) → Al2 O3 (s) + 6HCl(g)
the coatings and cutting performance with different cutting The coatings were deposited in the H2 S-AlCl3 -CO2 -H2 -Ar
parameters of the inserts were investigated. system. The deposition pressure was 0.02 kPa.The deposition
temperature is 1000 ◦ C. The deposition time was 4 h.
2. Experimental procedures
2.3. Cutting performance test
Table 3 – Parameters in the cutting performance test. PW-1700 apparatus using CuKɑ radiation (␥ = 1.54056 Å).
Young’s modulus, poisson’s ratio , nanohardness of the
Experiment Number Vc (r/min) Ap (mm) F (mm/r)
coatings, cermets, cemented carbides were measured by the
1 300 0.2 0.05 NanoTest Vantage (Micro materials, U.K.). The nanotest inden-
2 500 0.2 0.05 ter was pressed into the depth of 1/10 thickness of the
3 700 0.2 0.05 different layers to measure the corresponding nanohardness.
4 300 0.2 0.05
The thermal conductivity were measured by thermal con-
5 300 0.4 0.05
6 300 0.6 0.05
ductivity tester (DRE-2c, Xiangke, China). Thermal expansion
7 300 0.2 0.05 coefficient were tested by hot expand coefficient measure
8 300 0.2 0.07 instrument (ZRPY-1400, Xiangke, China). Heat capacity were
9 300 0.2 0.09 tested by heat capacity tester (TF-BRA, Nanjing Nanda Wanhe
Technology Co., Ltd., China). Archimedes method was used
(Yunnan Machine Tool Factory, China). The cutting parameters to measure the density by precision electron balance model
(feed rate, cutting speed and depth of cut) were listed in the BSA124S (Beijing Sarturius Co., Ltd., China). The properties
Table 3. The flank wear VBB value was evaluated by the VMS- of the inserts materials, coatings and workpiece were listed
3020 F image measuring instrument (Wanwei, China). Flank in Table 4. The adhesion level of the TiN/Al2 O3 /TiCN/ TiN
wear VBB value was measured every 2 min. According to the coatings were measured by scratch test for coating adhesion
standard ISO 3685, when the cutting Flank wear VBB value use an automatic scratching instrument WS-2005. The acous-
reaches 0.3 mm, the tools are thought to be destroyed. tic emission (A.E.) signals were continuously recorded during
scratch testing. The adhension strength and nanohardness of
2.4. Characterization the coatings were listed in Table 5.
The microstructure, element distributions and the worn sur- 2.5. FEM analysis
face after cutting performance test were examined using
a scanning electron microscope (S-4800: Hitachi company, Numeral temperature filed analysis was conducted by Advant-
Japan) equipped with energy dispersive X-ray spectroscopy. X- Edge FEM (Beijing, China). Power Law Materials Model was
ray diffraction (XRD) experiments were conducted on a Philips used. The element meshes were divided by self-adaptive mesh
1392 j m a t e r r e s t e c h n o l . 2 0 2 0;9(2):1389–1399
Fig. 2 – The microstructure of the cutting inserts: (a) cermets, (b) cemented carbides.
technique. The minimum element edge length of chip bulk 3.2. Structure of the coatings
was 0.03966 mm. The minimum element edge length of cutter
edge was 0.03033 mm. The radius of refined region of cutter Fig.3 shows the cross-sectional morphology of the multilayer
edge was 0.14998 mm. TiN/Al2 O3 /TiCN/TiN CVD coatings on the cermets (Fig. 3a) and
cemented carbide (Fig. 3b).The total thickness of the coating
on the cermets and cemented carbides are 12.42 m, 11.28 m,
3. Results and discussion respectively. The columnar grain can be evidently seen in the
TiN/Al2 O3 /TiCN/TiN coatings, and the grain size is finer along
3.1. Microstructure of the cutting inserts with the substrate. Fig. 4 shows the X-ray diffraction patterns
of the multilayer coatings on the two substrates. The diffrac-
Fig. 2 shows the microstructure of the cutting inserts. Obvi- tion patterns shows the orientation of (0 1 2), (1 0 4), (1 1 1),
ously, typical core/rim structure of conventional cermets is (2 0 0), (1 1 6), and (2 2 0) planes. As for the TiN and TiCN
observed in the Fig. 2a. There exists two kinds of structures, coatings, the (1 1 1), (2 0 0), (2 2 0) orientations indicates a
one is the “black core-gray rim” structure and the other is face centered cubic structure. TiN and TiCN shows (2 0 0) pre-
the “white core-gray rim” structure. White cores are formed ferred orientation on the cermets while shows (1 1 1) preferred
mainly by undissolved WC during the sintering stage [20].The orientation on the cemented carbides. During the deposition
average grain size of core-rim phase is 1.8 m. In the Fig. 2b, procedure, the conditions (temperature, atmosphere, etc.) are
The white grains of irregular shape with angles are formed totally same for the two substrates. Thus, when the coating
mainly by WC while the dark grains of irregular shape are is deposited on the cermets and cemented carbides, the grain
(W,Ti)C solid solution. The cemented carbide shows an average size and the crystalline structure of the substrate may influ-
WC grain size of approximated 2.0 m and an average (W,Ti)C ence the grow of the coating on the substrate. The cermets
grain size of 1.3 m. in this research possess smaller grain size than the cemented
carbides, so there are more nucleation points in the cermets.
j m a t e r r e s t e c h n o l . 2 0 2 0;9(2):1389–1399 1393
Fig. 3 – The cross-sectional morphpology of the multilayer TiN/Al2 O3 /TiCN/TiN CVD coatings on the (a) cermets and (b)
cemented carbide.
Fig. 5 – The scratching response of the coatings on the two substrates at the load of Lc2: (a) cermets, (b) cemented carbides.
Fig. 6 – Flank wear VBB values of uncoated cermets, coated cermets and coated cemented carbides inserts with different
cutting speed: (a) 300 r/min, (b) 500 r/min, (c) 700 r/min.
finish and the stability of the machining process when the of the VBB is regarded as the end of the tool life during machin-
flank wear land width VBB value reach a certain level [26]. ing. As shown in Fig. 6–8, it can be seen that with the increase
Therefore the flank wear VBB value is used to evaluate the of the cutting speed (Fig. 6), depth (Fig. 7) and feed rate (Fig. 8),
cutting performance. According to ISO standard 3685, 0.3 mm the flank wear was accelerated. The protective effect of the
j m a t e r r e s t e c h n o l . 2 0 2 0;9(2):1389–1399 1395
Fig. 7 – Flank wear VBB values of uncoated cermets, coated cermets and coated cemented carbides inserts with different
depth of cut: (a) 0.2 mm, (b) 0.4 mm, (c) 0.6 mm.
Fig. 8 – Flank wear VBB values of uncoated cermets, coated cermets and coated cemented carbides inserts with different
feed rate: (a) 0.05 mm/r, (b) 0.07 mm/r, (c) 0.09 mm/r.
1396 j m a t e r r e s t e c h n o l . 2 0 2 0;9(2):1389–1399
Fig. 9 – Flank wear VBB values of uncoated cermets, coated cermets and coated cemented carbides inserts with different
cutting speed: (a) 900 r/min, (b) 1100 r/min.
Fig. 10 – The microstructure of the Flank wear of the (a) uncoated cemets, (b) coated cermets and the (c) coated cemented
carbides at the cutting speed of 1100 r/min, the cutting depth of 0.2 mm, and the feed rate of 0.05 mm/r.
CVD coating is obvious. The coated cermets has a longer tool the temperature. Owing to much higher metal composition in
life than the uncoated ones. On the one hand, compared with the cermet, the thermal conductivity value of the cermets is
the uncoated cermets, the surface of the coated ones possess higher than cemented carbide [27,28]. In this case, lower cut-
a higher hardness. Generally, the abrasion wear resistance of ting temperature of the coated cermets attributes to a longer
tools is determined by the hardness. Thus, the coated cermets work life. In Figs. 7 and 8, with the increase of depth of cut
show a better abrasion wear resistance. On the other hand, and the feed rate, the cutting force increase a lot. Because of
coatings reduce the diffusion of Fe from H13 steels to cermets a lower toughness, cracks iniate and propagate more easily in
which consists of Fe family elements, i.e. Ni and Co. Therefore, the coated cermets. Thus, the coated cermets show a shorter
coated cermets has a longer life than the uncoated ones. It is tool life than the coated cemented carbides.
also noted that the cutting speed has a dominant impact on As is discussed above, the coated cermets have a longer
the tool life. A larger cutting speed attributes to a higher tem- life than the coated cemented carbides when the speed reach
perature in the contact area. The elevated temperature causes 700 r/min. It seems that higher speed with small depth and
more severe thermal stress and reduction of the tool proper- feed rate is much more suitable for the coated cermets than
ties. Different from the Fig. 6a and 6b, when the cutting reaches the coated cemented carbides. Thus, in order to further deter-
700 r/min, the coated cermets show a better anti-wear proper- mine the high speed cutting behaviors of the coated cermets
ties than the coated cemented carbides as shown in the Fig. 6c. and coated cemented carbides, cutting performance test is
The increase of the speed gives rise to a drastic increase of conducted at the depth of 0.2 mm and feed rate of 0.05 mm/r,
j m a t e r r e s t e c h n o l . 2 0 2 0;9(2):1389–1399 1397
and the speed is 900 r/min and 1100 r/min. The results are
shown in Fig. 9. It demonstrates that the uncoated cermets
are destroyed easily. The coated cermets have the longest life.
3.4.3. Surface quality Fig. 11 – The main elements distribution tested by EDS
Fig.13 exhibits the workpiece surface of coated cermets mapping: (a) uncoated cemets, (b) coated cermets and the
and the coated cemented carbides at the cutting speed of (c) coated cemented carbides.
1100 r/min, the cutting depth of 0.2 mm, and the feed rate
of 0.05 mm/r. It is obvious that the quality of the work-
piece machined by coated cermets is better than the coated
cemented carbides [7]. This is attributed to the excellent dif- control group. The multilayer TiN/Al2 O3 /TiCN/TiN CVD coat-
fusion and adhesion wear resistance of the coated cermets ings were deposited on the cermets and cemented carbides
[26]. tools. Uncoated cermets, coated cermets and cemented car-
bides tools were used for hardened AISI H13 steel machining.
Characteristics of the coatings and cutting performance with
4. Conclusion different cutting parameters of the inserts were investigated.
The main conclusions of the study are summarized as follows:
In the work, cermets cutting tools were prepared by tra-
ditional powder metallurgy. Commercial cemented carbide (1) Face-centered cubic structure of the cermets attribute to
tools used for cutting hardened steel were compared as a the direct growth of the TiN coatings. TiN and TiCN shows
1398 j m a t e r r e s t e c h n o l . 2 0 2 0;9(2):1389–1399
Fig. 12 – The temperature distribution simulated by FEM: (a) uncoated cemets, (b) coated cermets and the (c) coated
cemented carbides.
Fig. 13 – The workpiece surface of coated cermets and the coated cemented carbides at the cutting speed of 1100 r/min, the
cutting depth of 0.2 mm, and the feed rate of 0.05 mm/r: (a) coated cermets, (b) coated cemented carbides.
(2 0 0) preferred orientation on the cermets. The hexagonal diffusion and adhension wear resistance at elevated tem-
close packed structure of the cemented carbides make the perature of the coated cermets result a better surface
TiN coatings nucleate first and then grow. TiN and TiCN quality of workpiece.
shows (1 1 1) preferred orientation on the cemented car-
bides. Coatings deposited on the cemented carbides are
thinner and denser than the cermets.
(2) With the increase of the three parameters (cutting speed, Conflict of interest statement
depth and feed rate), the flank wear is accelerated. The
coated cermets has a longer tool life than the uncoated We declare that we have no financial and personal rela-
ones. With the increase of depth of cut and the feed rate, tionships with other people or organizations that can
the cutting force increase a lot. Because of a lower tough- inappropriately influence our work, there is no professional or
ness, cracks iniate and propagate more easily in the coated other personal interest of any nature or kind in any product,
cermets. The coated cermets show a shorter tool life than service and/or company that could be construed as influenc-
the coated cemented carbides. ing the position presented in, or the review of, the manuscript
(3) At the depth of 0.2 mm and feed rate of 0.05 mm/r, entitled “Characteristics and cutting perfomance of the CVD
when the cutting speed reaches and exceeds 700 r/min, coatings on the TiCN-based cermets in turning hardened AISI
the coated cermets have the longest life. The excellent H13 steel”
j m a t e r r e s t e c h n o l . 2 0 2 0;9(2):1389–1399 1399