Textured and Solid Lubricant Based Tool Coatings: A Brief

Review

Uttakantha Dixita, Ramesh K. Gudurua*

a
Department of Mechanical Engineering, School of Technology, PD Energy University,
Gandhinagar, Gujarat, India

Abstract

The tools used in different manufacturing processes, such as, turning, milling, and drilling etc., experience a significant amount
of mechanical forces with rising temperatures during operation. They undergo various modes of damage and failures depending
on their chemistry/metallurgy and surface structures. Therefore, various types of hard, textured and solid lubricant based
coatings are usually deposited on their surface in order to improve hardness, wear resistance, thermal stability, and lubrication,
and thereby enhance their life span. Here, in this paper, we will provide a critical review on different tool coatings used along
with their texture geometries and solid lubricating properties. Initially we will provide an overview on the basics of the tool
coatings and their properties. Then, we will provide current status and future prospects of textured and solid lubricated tool
coatings.

Keywords: Solid Lubricants, Textured Coatings, Tool coatings, Wear Resistance, and Tribology.

1. Introduction
Machining/cutting is a material removal process from a workpiece in order to create a product with certain design.
The machining/cutting quality are usually measured in terms of end product as well as tool life. The materials
used to make cutting tools include cemented tungsten carbide (WC), high-speed steels, diamond, and boron
nitride, etc. Although each material has its own mechanical and tribological characteristics, cemented WC is the
most widely employed one in the industry, particularly for steel cutting applications due to the fact that cemented
WC is inexpensive and has a high hardness along with high boiling point [1]. Despite of such superior
characteristics, WC based tools undergo continuous failure due to poor shock and thermal resistance
characteristics. This has led to the development of several hard coatings for WC based cutting tools, with single
to multilayer structures. Many of these hard coatings have shown to extend the tool life up to ten times by slowing
down the wear phenomenon of the cutting tools as well as increasing the batch size of the work-pieces that can be
machined per tool [2]. The most often utilised coating deposition processes are physical vapour deposition (PVD)
and chemical vapour deposition (CVD) [3]. PVD and CVD coated tools were investigated by various researchers
for coating and tool mechanical properties, brittleness, coating-tool adhesion, cutting edge preparation, and their
influence on cutting performance. Techniques like gas flame spray, arc discharge plasma and vacuum deposition
were also employed to develop ceramic coatings on the steel substrates [4]. Plasma electrolytic oxidation (PEO)
based coatings were proven to be resistant in the corrosive and abrasive environments [5]. However, addition of
tool coating always adds up to increased costs of the tools. In contrast, recent advances in smart surface
engineering and coating technologies have opened up new avenues for minimizing the friction and wear in the
tools used for cutting, rolling, sliding, and rotating. Such coatings, in particular, can also fulfil the increasingly
multi-functional characteristics required for various tool applications [6]. Various studies have been conducted to
develop nano-composite based super-hard coatings for enhanced tool life [7].

*Corresponding author: Ramesh K. Guduru Telephone: +91 7337487497

Email address: Ramesh.Guduru@sot.pdpu.ac.in
In contrast, recent advances in smart surface engineering and coating technologies have opened up new avenues
for minimizing the friction and wear in the tools used for cutting, rolling, sliding, and rotating. Such coatings, in
particular, can also fulfil the increasingly multi-functional characteristics required for various tool applications
[6]. Various studies have been conducted to develop nano-composite based super-hard coatings for enhanced tool
life [7]. In recent years, the surface manufacturing technologies like laser texturing, laser-glazing, and shot-
peening have shown promising potentials with enhanced machining performance and increased tool life. Surface
texturing of tools has attracted a lot of attention through surface modification while reducing the friction and
improving the lubrication. Combining the surface texturing with coatings is also one possible technique for
improving tribological performance under severe conditions. Combining of tool texture with solid lubricant
coatings can be adopted in two ways. First, the coatings themselves can be textured, where the smaller contact
area of the textured coatings may result in less wear through removal of wear debris and extend the service life of
the tools. This method is commonly used to create hard and wear resistant coatings. Secondly, the coatings can
also be applied on prior textured substrates/tools while enabling the surface textures to store and re-supply the
solid lubricant material to the contact or extend the life of the textured features of the tool surface [8].

Recently, J. Liu et al., [9] provided a review on thermally assisted surface hardening techniques, such as, warm
shot peening, warm laser shock peening, ultrasonic surface rolling processing and ultrasonic nanocrystal surface
modification etc. Following the concept of minimum quantity lubrication (MQL) conditions, Pradhan et al. [10]
have introduced micro and nano textures on the rake face of the cutting tool inserts with or without solid lubricant;
these tools are also known as self-lubricating tools. Rajsekara et al., [11] have reviewed nano structured coatings
as well as textured surfaces with feature size 10 nm or less. Machado et al. [12] highlighted the effect of texturing
on machining considering the chip formation, cutting forces, cutting temperature, lubrication, surface integrity,
and tool life, where coating thickness and substrate roughness were showed to play an important role in enhancing
the tribological properties of the tools.

Dry machining is also very much desirable to avoid the extra costs and environmental problems associated to
cutting fluids. High-speed machining of hardened steel has the ability to produce a machined surface of sufficient
quality to eliminate the need for finishing operations like grinding and polishing [13]. Thus to provide smooth
machining, friction is the parameter to be eliminated. In order to overcome harmful outcomes of liquid cutting
fluids, use of solid lubricants are proven to be a sustainable step. Solid lubricants are fine powders that can be
divided into chemically and physically active substances based on their structure. Solid lubricant coatings are
primarily used to control the friction and wear in rough application conditions (such as high vacuum, aerospace,
high-speeds, high loads, and very low or high temperatures), where the conventional materials and lubricants are
unable to deliver the desired levels of performance or durability [14]. Table 1 lists some of the most prevalent and
commonly used solid lubricants.

Table 1: Commonly used solid lubricants [8], [12], [14]–[17]

CHARACTERISTICS Structure- Chemically effective Chemically Physically effective Physically effective

effective with layer lattice effective with layer lattice without layer
with layer lattice structure without layer structure lattice
SOLID LUBRICANTS structure lattice structure structure
MoS2 /////////////////// ////////////////////////
Graphite ///////////////////
Zincpyrophosphate ///////////////////
Calcium hydroxide ///////////////////
Aluminium /////////////////////
Zinc Sulphide /////////////////////
Zinc Oxide /////////////////////
Calcium Fluoride /////////////////////
Polytetrafluoroethylene ////////////////////
(PTFE)

2. Layered, Textured and Solid Lubricated Coatings

2.1 Single Layer Coatings:
In 1969, a thin coating of TiN was deposited via CVD on the surface of a cemented WC cutting tool to extend the
life time, and later it was patented and commercialised [18]. Since the early 1970s, many successful thin coatings
of TiC, TIN, Al2O3, and their combinations with thickness in the range of 5 microns were deposited on the cutting
tools to improve wear life and/or cutting speed capabilities. CVD was used to create above coatings on the
cemented WC for most of the part. Similarly PVD coatings of TiN were also developed on HSS tools, and a
review was provided in the reference [19]. Prengel et al. [20] have deposited monolayer TiN, TiAlN and TiB2 on
WC-6 tool using PVD. The PVD coatings provided performance benefits in applications that required peck cutting
as well as finishing. In the early 1990’s graphite and MoS2 were also used as solid lubricants because of their
layered structure with weak interlayer bonding. These materials exhibited better lubrication properties when
compared to the other types of solid lubricants. In another example, Fullerene (C 60) [21] was also used as a solid
lubricant due to its low surface energy, high chemical stability, spherical shape, and weak intermolecular bonding,
along with high load bearing capacity. These C60 fullerene films were deposited on a polished Silicon wafer by
sublimation at a high vacuum. In late 1990’s, the ultra-tough coatings, such as, diamond-like-coatings (DLC) was
introduced. Salvadori et al. [22] have deposited DLC on Si surface along with hybrid-surface pre-treatment to
increase the diamond film nucleation, as well as adhesion to the WC-Co tool inserts.

2.2 Multilayer/Multicomponent Coatings:

To further obtain increased hardness and enhanced tool life in comparison to the single layer coatings, multi-
layered coatings were developed on the tools. These multilayer coatings can be broken down into three functional
layers in general. The bottom layer establishes coating/substrate adhesion; the middle layer transitions from the
bottom to the top layer, forming a link between the layers; and the hard top layer [23]. Figure 1 presents various
types of textured coatings adapted so far in the tool coatings [6].

SUBSTRATE SUBSTRATE SUBSTRATE

Figure 1: Coatings used on tools (a) Multilayer (b) Superlattices (c) Nano-composites [6]

2.2.1. Multilayer coatings

Coatings for cutting tools in the latest generation with multi-layered architecture ensure a dual nature of the
coating, in which coatings should not only improve the mechanical and physical characteristics of the cutting tool
material, but also reduce the thermo-mechanical effect on the cutting tool, which determines wear intensity [24].
For example, Prengel et al. [20] worked on different variants of TiAlN multilayer coatings deposited on WC-6
wt.% Co hardmetal inserts, which showed performance advantages over the mono-layer TiAlN coatings.
TiN/TiCN/TiAlN-multilayer coating was particularly determined to provide enhanced performance at high
speeds. Figure 2 shows the toughness enhancement mechanism in a multilayer coating. Palatnik [25] with
multilayers of metal coatings showed a significant improvement in the strength when compared to the
coating/layer thickness below 500 nm. Holleck and co-authors [26] introduced toughening approaches based on
multilayer architectures in their publications. The relevance of dispersing fracture energy and deflecting cracks at
interfaces in multilayer structures comprised of hard ceramic materials, such as TiC/TiB2 or TiN/(Ti(C,N)
materials is highlighted in their research. S. Wang and Du [27] have worked on composite coatings of MT-
Ti(C,N)+Al2O3 using CVD and showed better wear resistance during dry milling. Lin and co-authors [28], [29]
studied the improvement in tool life of cemented carbide inserts with a PVD-applied aluminium chromium nitride
(AlCrN) coating (named Alcrona). They have conducted a thorough investigation on the effect of microstructures
on wear progressions, such as, abrasive wear processes of AlCrN coated cemented carbide tool inserts during dry
and wet machining at very high cutting speeds. Figure 3 graphically shows the tool life under high speed
machining for dry and wet machining. Surface texturing at different face of the tool, such as, flank face or rake
face affects the tool wear, friction coefficient and cutting forces [30]. In an investigation performed by Zhao et
al. [31] during down end milling of Ti6Al4V alloy, the efficiency of surface texturing on the rake face, parallel to
the main cutting edge of uncoated (K10) cemented carbide tools of 10 mm diameter was studied. The textures
were created with a Nd: YAG laser with a width of 100 µm, a spacing of 100 µm, and a depth of 50 µm. The
machining tests were carried out using both conventional and nanofluids containing Fe3O4 nanoparticles with a
diameter of 80 µm, which were applied under MQL conditions.

Figure 2: Toughness enhancement in multilayer hard coatings [25]

Figure 3: Tool life under high machining for dry and wet cutting (Reproduced by permission [29], Copyright Elsevier, 2007)

2.2.2. Gradients, nanostructured and superlattices coatings:

Superlattices, nanoscale multi-layered coverings have been developed to improve the hardness and strength.
A very thin layer of less than 10 nm, which was thought to be able to inhibit the development of dislocations
while the difference in elastic modulus between the layers impedes the mobility of the dislocations, is a
critical element in the notion of superlattices. The disadvantage of superlattices is that if the resultant layers
do not follow the correct order, the influence of the nano levels in the superlattices can be lost [1]. Diamond
and its coatings, are the hardest known materials continue to draw a lot of attention for demanding
applications involving high tribological conditions. Similarly, DLC coatings have sparked attention for a
variety of industrial applications requiring high efficiency, performance, and dependability. Erdemir et. al.
[17] presented a complete review on current developments in the tribology of super-hard diamond and DLC
films, with a focus on their friction and wear mechanisms, which are critical to their exceptional tribological
performance under difficult tribological conditions. DLC films may have mechanical and tribological
properties that are comparable to crystalline diamond films, despite their amorphous nature. Mechanically,
 they can be made quite hard and stiff. In an investigation by Yang et. al. [32] polycrystalline TiN/CrN
superlattices with bilayer periods of 5.6 - 39 nm were deposited on a Ni-base alloy substrate by reactive
unbalanced magnetron sputtering. The superlattices were annealed at various elevated temperatures for a
certain period of time, in order to study the thermal stability of the coatings. Recently in 2017, Zhang et. al.
[33] investigated the effect of WS2 solid lubricant film and femtosecond laser texturing on the rake face of
PVD coated TiAlN on cemented carbide tools. First, a nanotextured coating was induced on the WC/Co
substrate tool with various processing parameters using femtosecond laser scanning, and then TiAlN film
was deposited on the nanotextured substrate surface using the cathode arc-evaporation technique without
using any interlayer. The nanotextured TiAlN coated surface's surface micro-topography and mechanical
properties were investigated. Selective Laser Melting (SLM) technique was applied to produce stainless
steel, on which machining tests without cutting fluid were done using the proposed tool, as well as a cutting
tool without laser pre-treatment for comparison. The results obtained shows that the femtosecond laser-
induced periodic structure on the WC/Co substrate considerably improved the TiAlN coatings adhesiveness,
and the critical load of the TiAlN coatings is increased from 57 to 73 N. Improved machining performance
of nanotextured tools in drying cutting SLM 316 L stainless steel was accomplished, resulting in a 10–20 %
reduction in cutting forces, a 10–15 % reduction in cutting temperature, and a high surface quality of the
machined workpieces at high cutting speeds [33].

2.2.3. Composite coatings:

Malshe et. al. [34] at the University of Arkansas have worked on developing a composite coating of cBN-
TiN on WC-Co tool using two-step process of deposition, i.e. electrostatic spray coatings (ESC) of cBN
particles followed by developing of TiN coating by chemical vapour infiltration (CVI). An scanning electron
microscopy (SEM) image of the same is shown in Fig. 4. The reliability of the coatings has been examined
using Taguchi. The plots between various parameters were obtained using MINITAB software. Their results
showed excellent CBN-to-TiN substrate adhesion. This composite coating was later patented by Malshe et.
al. [35] stating that one phase material can be withhold another phase particle resulting in textured composite
coatings.

Figure 4: SEM of ESC deposited cBN particulates on WC-Co tool (Reproduced by permission [34], Copyright
Elsevier, 2003)

Malshe and his group [36] have worked on MoS2 and ZnO as solid lubricant to deposit it on a sample flat
geometry with sub-microns and nano-sized particles. Their investigation concluded that particle size plays
an important role in coating uniformity and powder transfer efficiency. Since nano-sized particles are prone
to cluster formation, nano-sized ZnO deposition showed cluster deposition whereas micro-sized MoS2 and
ZnO showed discrete type of deposition. The investigation concluded that nano-sized particulate coating
provide less friction when compared to micro-sized coating.

3 Conclusions
During this review, various coatings and their effect on tool life have been considered. Following to the
textured coatings, the article also review the advantage of using solid lubricants in enhancing tool life and
eliminating the conventional coolants. Solid lubricants are responsible for the proper and efficient operation
of a variety of tribological systems. Solid lubricants include large structural materials, soft metals, diamond
and DLC films. Their use is likely to grow in the coming years, owing to the fact that future tribosystem
working conditions are becoming increasingly demanding, and liquid and grease-type lubricants are
 unsuitable due to the environmental issues. The majority of solid lubricants used in modern applications are
manufactured as thin solid coatings on sliding surfaces. For the deposition of adhesive solid lubricant films
on a variety of substrates, including metallic, ceramic, and polymeric types, several PVD and CVD processes
are adopted. These methods help in producing solid lubricant films in gradient, duplex, multiplex, nano-
structured, and composite forms, leading to improved performance and durability in the hostile
environments. The tool coating and tool surface texturing present effective solutions to increase the tool life
and enhance machining process outputs during dry cutting. Dry cutting is better than wet cutting for TiAlN
coating inserts under high cutting speed (around 200–400 m/min) [11]. In dry milling of ductile cast irons,
and wet turning of Inconel 718, TiAlN alternating multilayer coated tools outperform TiAlN monolayer or
TiN/TiCN/TiAlN-multilayer coated inserts [25].

Acknowledgments

The authors would like to acknowledge the financial support from Science and Engineering Research Board
(SERB) Department of Science and Technology (DST, DO/PDEU/R&D/2021/SERB/RGVK/RO063),
India.

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