Cutting Performance and Wear Behavior of AlTiN- and TiAlSiN-Coated Carbide Tools During Dry Milling of Ti-6Al-4V

doi:10.1007/s40195-020-01010-6

Abstract

Abstract:

Machining, especially dry machining of titanium alloys, has been one of the most significant challenges for carbide cutting tools. In this study, aluminum-rich AlTiN coating, as well as TiAlSiN nanocomposite coating, were successfully employed for dry milling of Ti-6Al-4V alloy with high efficiency and long tool life. At the cutting speeds of 150 m/min and 200 m/min, the tool life of the TiAlSiN-coated tool exceeds that of AlTiN-coated tool by 32 and 66%, respectively. The wear modes for both coated tools include the uniform flank wear, smooth wear, chipping, coating and substrate flaking, crater and notch wear, and the wear mechanisms include adhesion, diffusion, oxidation and crack. Among them, the wear mechanism is dominated by the adhesion and oxidation wear. As compared with AlTiN coating, TiAlSiN coating exhibits better mechanical properties and oxidation resistance, which contribute to a better cutting performance, fewer thermal cracks and smaller and uniform workpiece chips during the dry milling of Ti-6Al-4V alloy.

Key words: Cutting performance, Wear behavior, Ti-6Al-4V, AlTiN coating, TiAlSiN coating

Jie Liu, Shui-Sheng Zhu, Xin Deng, Jian-Ye Liu, Zhong-Ping Wang, Zhi Qu. Cutting Performance and Wear Behavior of AlTiN- and TiAlSiN-Coated Carbide Tools During Dry Milling of Ti-6Al-4V[J]. Acta Metallurgica Sinica (English Letters), 2020, 33(3): 459-470.

Figures/Tables 18

Fig. 1 Photograph of vertical high-speed milling machine

Table 1 Chemical composition of Ti-6Al-4V alloy (wt%)

Table 2 Physical and mechanical properties of Ti-6Al-4V alloy

Table 3 Tool geometry and milling parameters

Table 4 Chemical composition and mechanical properties of the coatings

Fig. 2 SEM fracture cross sections of AlTiN- and TiAlSiN-coated tools

Fig. 3 XRD patterns of AlTiN and TiAlSiN coatings

Table 5 Lattice parameters and grain sizes of AlTiN and TiAlSiN coatings

Fig. 4 Flank wear of AlTiN- and TiAlSiN-coated tools as a function of cutting length at different cutting speeds

Fig. 5 Cutting length of AlTiN- and TiAlSiN-coated tools at different cutting speeds

Fig. 6 Flank wear images of AlTiN and TiAlSiN tools at cutting speed of 200 m/min

Fig. 7 SEM micrographs of the worn rake face of AlTiN-coated tool at cutting speed of 200 m/min: a high magnification of the rake face showing smooth wear and coating flaking, b crater and notch wear, c chipping and flaking, d coating flaking

Fig. 8 SEM micrographs of the worn rake face of TiAlSiN-coated tool at cutting speed of 200 m/min: a smooth wear and coating flaking, b crater and chipping, c micro-chipping, d coating flaking

Fig. 9 SEM micrographs and AES linescans on the cross sections of coated tools after a cutting length of 20 m at the cutting speed of 200 m/min: a cross-section position of coated tools, b flank and rake faces of AlTiN-coated tool, c flank and rake faces of TiAlSiN-coated tool, d AES linescan of the worn flank face of AlTiN-coated tool, e AES linescan of the worn flank face of TiAlSiN-coated tool

Fig. 10 Magnification cross sections of a AlTiN, b TiAlSiN-coated tools

Fig. 11 XPS spectra of the worn rake face of AlTiN-coated tool after a cutting length of 20 m at the cutting speed of 200 m/min: a XPS detect area on the rake face, b Al 2p, c Ti 2p, d O 1s

Fig. 12 XPS spectra of the worn rake face of TiAlSiN-coated tool after a cutting length of 20 m at the cutting speed of 200 m/min: a Al 2p, b Ti 2p, c O 1s, d Si 2p

Fig. 13 Chip shapes and magnified micrographs after a cutting length of 20 m at the cutting speed of 200 m/min: a, c, e TiAlSiN-coated tool, b, d, f AlTiN-coated tool

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