Surface and Coatings Technology 113 (1999) 286292

New hard/ lubricant coating for dry machining k

V. Deringer*, H. Bra ndle, H. Zimmermann
Balzers Ltd., FL-9496 Balzers, Liechtenstein Received 1 May 1998; received in revised form 10 December 1998; accepted 23 December 1998

Abstract Environmental and economic considerations have emphasized the trend for more dry machining. Advanced wear-resistant coatings with increased oxidation resistance such as PVD TiAlN oer an advantage for dry machining of cast iron and alloyed steel. Although some important cutting operations are still not possible without coolants, further possibilities for dry drilling and tapping of steels are enabled by the recent approach using tools with hard coating layers topped with a lubricant layer. The combination of hard/soft coating layers allows improved chip ow with a lowered coecient of friction and reduced cutting force. In this work, the hard/soft coating consists of a low-internal-stress TiAlN (hard layer) and WC/C ( lubricant layer) of medium microhardness and low coecient of friction. Both coating types are produced economically and reproducibly in one production scale PVD coating system. Recent performance data from eld tests will be presented. 1999 Published by Elsevier Science S.A. All rights reserved.
Keywords: Dry machining; Hard layer; Lubricant layer; TiAlN; WC/C

1. Introduction Today, dry machining is one of the most discussed topics related to production engineering. The motivation for this technology is a strong ecological and economical reason. The use, maintenance and disposal of coolant lubricants entail enormous costs. Investigations show that the costs for using a coolant lubricant are many times higher than, for example, the tool costs [1]. The benets of cooling lubricants in machining processes are the reduction of friction in the toolworkpiece contact ( lubrication eect), removal of chips from the cutting area (ushing eect), transport of thermal energy dissipated in the contact zone (cooling eect) as well as cleaning and anti-corrosive eects [2]. Today, mainly in Germany, there is a strong tendency to move away from the use of conventional amounts of cooling lubricants (emulsion: 3004000 l h1) in machining. Minimal lubrication is the new slogan. Using this technique, only 670 ml h1 of coolant lubricant are used for the manufacture of the same part [1,3]. The
Paper presented at the 25th International Conference on Metallurgical Coatings and Thin Films, 2730 April 1998, San Diego, CA, USA. * Corresponding author. Tel.: +41-75-388-5330; fax: +41-75-388-5413; e-mail: dev@si.blazers.net.
k

preconditions for this technology are research activities, which are concentrated on the adoption of cutting conditions as well as on the development of new drilling tools with improved properties for dry machining by optimizing manufacturing technologies, by alloying of cutting materials of sucient toughness and high hot hardness, by adapting drill tool geometries and nally by coating of the tools [4]. In dry cutting operations, tests have shown that the lifetime of tools could be increased by using a tool that is coated by a combination of a hard and lubricant layer. Mainly, in dry machining conditions for materials like alloys of aluminium or steel, positive results could be achieved [5,6 ].

2. Hard coating TiAlN is an evolutionary development of the widely used hard coating material TiN. TiAlN can only be produced using plasma processes where it is deposited as a metastable crystallographic phase. Based on dierent parameters such as the composition of the target material, evaporation rate, plasma ionization parameters, etc., titanium can be substituted by aluminium to dierent levels [79]. TiAlN coatings are mainly deposited through evapo-

0257-8972/99/$ see front matter 1999 Published by Elsevier Science S.A. All rights reserved. PII: S0 2 5 7- 8 9 7 2 ( 9 9 ) 0 0 00 4 - 3

V. Deringer et al. / Surface and Coatings Technology 113 (1999) 286292

287

ration of TiAl target material using the reactive gas nitrogen. Today, the basic evaporation methods for depositing TiAlN coatings are cathodic arc evaporation and magnetron sputter deposition. Comparing these two methods, the plasma produced by arc evaporation has a higher ionization level than the plasma that is created by a magnetron sputter source. Due to this eect, sputtered TiAlN coatings typically have an open and columnar structure. However, high-ionization TiAlN coatings show a dense ion plating structure plus a porefree and uniform interface, which is benecial for good adhesion [9]. In Fig. 1, the compressive stress of TiAlN coatings as a function of the microhardness is presented. In this work, the deposition of a TiAlN coating with lowinternal-stress type was chosen. This type of TiAlN coating, with a relatively high adhesion, is preferred for machining with lower cutting forces. Machining of material with a lower tensile strength and higher elongation, i.e. long chips, is possible. Process parameters that lead to an internal stress of the coating of approximately 2 GPa were chosen. The chemical composition of the TiAlN coating is about Ti/Al=0.6/0.4 (as measured by EDX measurements).

1000 HK , and the internal stress is about 1 GPa. 0.01 TEM investigations showed that the WC/C coating consists of an amorphous carbon matrix, which is honeycombed with nanocrystalline WC grains (1020 nm). In dry-sliding tests (e.g. pin-on-disc) WC/C coatings exhibit very low values of wear on the coated surface and on the uncoated counterface, even after a considerable testing time (see Fig. 2). The reason for this low amount of wear is the low coecient of friction and the smoothening of the surface during sliding due to the lamellar microstructure of the WC/C coating. This lamellar structure, consisting of alternating carbon-rich and WC-rich phases, is created during coating deposition due to substrate rotation and orientational relationship with the dierent sputtering targets [10].

4. Deposition technique and experimental conditions 4.1. Deposition technique Until now, most of these combination layers hard coating+lubricant coating have been deposited in two dierent coating devices. However, innovative equipment has now been designed to allow for a higher coating productivity. A standard arc production machine was re-designed into a hybrid plant, as shown schematically in Fig. 3. With this system, it is possible to use arc and sputter sources simultaneously. This was the optimal conguration for developing a new coating consisting of a TiAlN hard layer and on top of a WC/C lubricant layer. A simple plug and play solution to eciently change from an arc to a sputter process mode could be realized. The advantage of this machine is the

3. Lubricant coating Beside the commercially obtainable MoS coatings, 2 other low-friction coatings such as DLC or tungsten carbide/carbon coatings are available. Balzers has specialized on low friction coatings deposited by reactive magnetron sputtering of tungsten carbide targets. Typically, the hardness of this WC/C coating is about

Fig. 1. Compressive stress in dependence of the microhardness of deposited ( Ti,Al )N coatings.

288

V. Deringer et al. / Surface and Coatings Technology 113 (1999) 286292

Fig. 2. Pin-on-disc result for a typical WC/C coating.

Fig. 3. Schematic illustration of the deposition chamber used for lm deposition by PVD.

possibility of depositing mixed or graded transition layers by a programmed sequence from cathodic arc to magnetron sputter evaporation. This feature was used in forming a specic interlayer between the hard layer and the lubricant layer for improving the adhesion of the lubricant layer. From an economic point of view, this is a strong advantage, requiring only one heating and etching cycle for the deposition of two dierent layers, and contact of the tools with the atmosphere between the deposition of the two layers is obviated. 4.2. Characterization of deposited coatings The coating was characterized and analysed using a standard scanning electron microscopy (CamScan 404) of fracture cross-section of coated, cemented carbide inserts. Chemical compositions were determined by

energy-dispersive X-ray ( EDX ) analysis. The X-ray diraction measurements were carried out in a Siemens Diraktometer D500 using a Cu X-ray tube. Standard q/2q investigations were performed on dened steel substrates. These steel substrates were also used for measuring the internal stress of the coating, applying a three-point-bending method. Ball craters were made on the coated surfaces to assess the interface appearance, the presence of weak or brittle interfaces, coating thickness and nally wear quantication. Knoop hardness tests were performed at 50 g for the hard layer and 10 g for the lubricant layer. Pin-on-disc tests were performed using a 3 mm-diameter uncoated steel ball (100Cr6) sliding on a coated steel ring ( 35 mm, 100Cr6) using a CSEM tribometer with a circular track of 14 mm, a velocity of 0.35 m s1 and a load of 30 N.

V. Deringer et al. / Surface and Coatings Technology 113 (1999) 286292

289

The coating was also deposited on to high-speed steel drills ( 6 mm) for testing under dry (compressed air/1 bar) conditions. The cutting conditions were: drilling depth of 15 and 25 mm; cutting speed of 20 m min1; rotary speed of 1061 min1; feed of 0.12 mm rev1. The testplates ( X210Cr12) were annealed (~1000 N mm2). Additionally, high-speed-steel-tap drills ( 8 mm) have been coated for testing under dry conditions. The test used a cutting speed of 15 m min1 and a feed speed of 746 mm min1. The testplates (42CrMo4) were annealed (~1000 N mm2), and the holes were predrilled dry.

5. Results and discussion The deposition of the hard/ lubricant coating by a combined cathodic arc evaporation and magnetron sputtering resulted in a dense adherent hard coating having a functional layer for machining plus a softer low friction layer for chip transportation and torque reduction during the machining process. Fig. 4(a) is a scanning electron microscopy picture of a typical fracture cross-section of such a hard/ lubricant coating. This coating was deposited on to a polished cemented carbide insert. Next to the substrate is the TiAlN-hard layer which corresponds to our lowinternal-stress TiAlN coating followed by a thin specic interlayer. Finally, the top layer is a low-friction tungsten carbide/carbon ( WC/C ). In Fig. 4(b), a ball crater of this hard/ lubricant coating on a coated polished tempered steel sample is presented. Again, the structure of the coating can be

seen, the TiAlN hard coating is followed by a small interlayer (white stripe) and the low-friction WC/C layer of medium hardness. The generation of the crater by Calotest is also a qualitative adhesion test, especially for the adhesion of the lubricant layer with the hard layer. No pitting or peeling o of the lubricant layer in the area of the interlayer can be detected. The drill tests on some standard high-speed steel drills coated with the hard/ lubricant layers were conducted dry. Compressed air of 1 bar was used to blow away forced out chips at the workpiece surface. This avoided any wear attack of the drill through hardened and deformed chips lying on the top of the workpiece, and additionally a side tilt of the drill during the test could be prevented. However, it must be mentioned that this high-speed steel drill is not suitable for dry drilling in reference to its geometry. Normally, drills for dry machining have very special geometries such as open utes, conical diameters, etc. and are made of a certain grade of cemented carbide having a sucient toughness and a high hot hardness [1113]. In spite of the handicap of these unoptimized high-speed steel drills, only the inuence of the coating and not of the tool itself could be evaluated. Fig. 5 shows the results of a dry (compressed air) drilling test. In this case, the drilling depth was 15 mm, corresponding to 2.5 diameter of the drill. This test presents the relative performance of drills coated on the one hand with only a hard and wear-resistant coating and on the other hand with a combined hard/ lubricant coating. The performance data are normalized to the thickness (per micron) of the hard layer. These results show a systematic increase in the lifetime of the tool due to the presence of the low-friction WC/C top layer.

Fig. 4. (a) SEM fracture cross-section of a hard/ lubricant coating deposited on to a cemented carbide substrate; (b) ball crater of a hard/ lubricant coating deposited on to a tempered steel substrate.

290

V. Deringer et al. / Surface and Coatings Technology 113 (1999) 286292

Fig. 5. Performance of hard coated and hard/ lubricant coated high-speed steel drills (drilling depth: 2.5 diameter of the drill ).

Another dry drilling test was done where the drilling depth was increased to 25 mm (corresponding to 4 diameter of the drill ). In this test, the high-speed steel drills were subjected to a much higher cutting stress. The results in Fig. 6 show the spindle power of the cutting machine in relation to drill lifetime for two dierent coated drills. The upper graph shows the progress of the spindle power of a standard TiAlN coated drill, and the lower graph shows the progress of the spindle power of a hard/ lubricant coated drill. It can be seen that the TiAlN-coated drill has a large number of deections in the spindle power curve during its lifetime, whereas the hard/ lubricant coated drill has a very

smooth curve. This indicates a much lower stress condition of the tool during its application. For a better illustration, the spindle power curve as a function of the drilling depth of one hole (Hole No. 80) is presented separately in two inset diagrams. Up to a drilling depth of 15 mm, no signicant dierence in the level of the spindle power is observed, which means that the stress on both drills is still similar. However, at a greater drilling depth up to 25 mm, the spindle power of the pure TiAlN-coated drill increases greatly. This reects the fact that the chips have to be pushed out along the ute of the drill with a greater force. Due to a certain roughness of the hard coating

Fig. 6. Performance of a (Ti,Al )N coated and a hard/ lubricant coated high-speed steel drill (drilling depth: 4 diameter of the drill ). Inserts show the curve of the spindle power of one hole (No. 80).

V. Deringer et al. / Surface and Coatings Technology 113 (1999) 286292

291

Fig. 7. Schematic illustration of a possible mechanism on the role of the low-friction coating during a machining application.

on the ute, the chips cannot slide easily on this surface, and so the torque on the drill increases. On the contrary, due to the eect of a lubricant layer, the chips can glide along the ute much more easily. Thus, a real benecial eect of the lubricant top layer can be realized. We oer a possible mechanism on the role of the low-friction coating during this drilling application. This eect is illustrated in Fig. 7. Before machining, the combination of a hard and a lubricant coating exists where the lubricant layer must have a certain thickness approximating the roughness of the surface of the tool. During machining, the chips slide along this surface.

The lubricant WC/C coating that is deposited on exposed chip contact areas is removed early in the operation and will partially be pushed into the depressed areas. As a result, the surface will be planed, and additionally, lubrication grooves will be formed. This eect plays an important role mainly during the running-in period in the tribological wear mechanism. If a machining system with a minimal lubrication is used, this lubricant coating gives the tool good emergency running properties, which means that in the presence of minimal coolant, the lubricant coating further inhibits sticking and welding of the work material as it works by itself as a lubrication system in the regions not accessed by the coolant [14]. This theory is supported by the results shown in Fig. 8(a)(c). In Fig. 8(a), scanning electron microscopy pictures of the cutting face of a tap after several progressive passes during dry cutting show the wear of one tooth of a tap. The dark areas represent the TiAlN coating, and the white areas represent the WC/C coating. It can be seen that after ve threads, the lubricant coating has been removed in the area of the cutting

Fig. 8. Wear of a hard/ lubricant coated tap after (a) ve threads (b) 20 threads and (c) 1000 threads.

292

V. Deringer et al. / Surface and Coatings Technology 113 (1999) 286292

edge, whereas in the area of the ute, it is still available. Similar behaviour is apparent after the cutting of 20 threads [Fig. 8(b)]. Finally, after 1000 threads, it can be seen that there is still WC/C in the ute, mainly within the grinding marks of the tool [Fig. 8(c)]. It must be mentioned that in this application, the chips are pushed out in front of the tool cutting edge. Additionally, a strong crater wear in the areas of the cutting edge is recognizable.

production scale PVD coating system in a single process is of practical importance.

References
[1] F. Klocke, K. Gerschwiler, VDI Berichte 1375 (1998) 13. [2] K. To nsho, A. Mohlfeld, T. Leyendecker, H.G. Fuss, G. Erkens, R. Wenke, T. Cselle, M. Schwenck, Surf. Coat. Technol. 9495 (1997) 603. [3] E. Schillo, J. Steibl, VDI Berichte 1375 (1998) 113. [4] T. Cselle, A. Barimani, Surf. Coat. Technol. 7677 (1995) 712. [5] T. Cselle, New Directions in Drilling, Dry and Near-dry Machining Will Impact High Productivity Drilling in the Next Decade, Manufacturing Engineering, SME, Dearbron, MI, 1995. [6 ] R. Dubach, H. Curtins, H. Rechberger, Surf. Coat. Technol. 9495 (1997) 622. [7] G. Hakansson, J.E. Sundgren, D. McIntyre, J.E. Greene, W.D. Mu nz, Thin Solid Films 153 (1987) 55. [8] H. Holleck, Z. Werkstotech 17 (1986) 334. [9] H.G. Prengel, A.T. Santhanam, R.M. Penich, P.C. Jindal, K.H. Wendt, Surf. Coat. Technol. 9495 (1997) 597. [10] M. Berger, EUROME3 4 (1997) 13. [11] H. Zimmermann, PVD-beschichtete Schneidstoe fu r moderne Zerspanungsanwendungen, Ph.D. thesis, Aachen University of Technology, Verlag Mainz, Aachen, 1998. [12] T. Cselle, M. Schwenck, H. Ku hn, VDI Berichte 1375 (1998) 175. [13] D. Kammermaier, Charakterisierung von bina ren und terna ren Hartstoschichten anhand von Simulations- und Zerspanungsuntersuchungen, Fortschritt Berichte VDI, Reihe 2: Fertigungstechnik, 271, VDI, Dusseldorf, 1992. [14] W. Hockauf, H. Pro ll, R. Ba uerle, G. Eisenbla tter, W. Rehbein, VDI Berichte 1375 (1998) 135.

6. Conclusion The deposition of a hard/ lubricant coating on cutting tools seems to be a very interesting alternative to reduce the enormous amounts of cooling emulsion in metal cutting and to work with minimal or no lubrication in a number of applications. Possible elds of use may include machining of alloyed steel, aluminium alloys and cast iron. Specic application areas will be drilling (deep holes) and tapping and perhaps milling of aluminium alloys. Additionally, dry forming and materials that are dicult to machine, such as magnesium alloys, titanium alloys, stainless steel, etc., could be amongst the range of uses. Aside from the proven functionality of the TiAlN/WCC hard/ lubricant coating, the economic advantage in depositing the combined coating in one