DLC and DLC-WS2 coatings for machining of aluminium alloys

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dc.contributor.authorBrzezinka, Tomasz L.
dc.contributor.authorRao, Jeff
dc.contributor.authorPaiva, Jose M.
dc.contributor.authorKohlscheen, Joern
dc.contributor.authorFox-Rabinovich, German S.
dc.contributor.authorVeldhuis, Stephen C.
dc.contributor.authorEndrino, José L.
dc.date.accessioned2019-09-02T09:36:51Z
dc.date.available2019-09-02T09:36:51Z
dc.date.issued2019-03-15
dc.description.abstractMachine-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 ~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 ~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 ~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 ~75% compared to TiB2, with a measured coefficient of friction of 0.05.en_UK
dc.identifier.citationBrzezinka TL, Rao J, Paiva JM, et al., (2019) DLC and DLC-WS2 coatings for machining of aluminium alloys. Coatings, Volume 9, March 2019, Article number 192en_UK
dc.identifier.cris23256589
dc.identifier.issn2079-6412
dc.identifier.urihttps://doi.org/10.3390/coatings9030192
dc.identifier.urihttps://dspace.lib.cranfield.ac.uk/handle/1826/14496
dc.language.isoenen_UK
dc.publisherMDPIen_UK
dc.rightsAttribution 4.0 International*
dc.rights.urihttp://creativecommons.org/licenses/by/4.0/*
dc.subjectself-lubricating coatingsen_UK
dc.subjecttungsten disulphideen_UK
dc.subjectDLCen_UK
dc.subjectSEMen_UK
dc.subjectEDSen_UK
dc.subjectXPSen_UK
dc.subjectmillingen_UK
dc.subjectaluminiumen_UK
dc.titleDLC and DLC-WS2 coatings for machining of aluminium alloysen_UK
dc.typeArticleen_UK

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