TiAlSiN涂层刀具高速干车削钛合金磨损机理研究北大核心

TiAlSiN涂层硬质合金刀具材料力学性能较好,探究了TiAlSiN涂层刀具高速干切削钛合金的磨损机理,为改善刀具切削性能、提高加工效率提供指导。采用TiAlSiN涂层硬质合金刀具对TC4钛合金进行高速干车削试验,研究两种切削速度(v=80、120 m/min)下刀具的磨损机理。结果表明:TiAlSiN涂层刀具前刀面主要磨损机理为粘结磨损和氧化磨损,在高速时(v=120 m/min)还存在扩散磨损;TiAlSiN涂层刀具后刀面主要磨损机理为粘结磨损、氧化磨损和磨粒磨损;刀具在v=80 m/min时切削效果更好,切削速度越高,刀具磨损越严重。     

PVD涂层刀具高速铣削CoCrMo合金的性能研究

目的为了提高涂层硬质合金刀具的切削性能,研究了物理气相沉积PVD法制备的涂层硬质合金铣刀在高速干式环境下的铣削性能。方法采用阴极电弧技术制备了TiN、TiAlN以及TiAlSiN涂层硬质合金铣刀刀头,通过一同沉积涂层的硬质合金圆片,间接测量得出涂层的显微硬度、厚度和平均摩擦系数,并以CoCrMo合金为切削对象,进行了PVD涂层与无涂层刀具高速铣削下的对比试验。结果TiAlSiN显微硬度最高达3800HV,摩擦系数达0.3,TiAlN涂层平均膜厚为2μm,间接测得TiN、TiAlN以及TiAlSiN涂层的结合力依次为60、58、42N。在三者的切削性能中,TiAlSiN涂层的切削性能比TiAlN和TiN涂层的好,同等切削参数时,TiN刀具的高速铣削时间最短,TiAlSiN涂层的平均磨损值为0.1895,TiN的平均磨损值为0.3047。结论涂层中添加Al、Si,极大地提高了刀具的使用性能,改善了刀具切削过程中的耐磨性、红硬性,极大地延长了刀具的使用寿命。TiAlSiN涂层的硬度高,耐磨损性好,切削性能好,适合高速铣削加工。     

不同弧电流对AlCrBN涂层结构和性能的影响

目的 提高涂层刀具在高速工况下的切削寿命。方法 利用电弧离子镀技术在高速钢试样块和刀具表面制备不同弧电流（60、80、100 A）的AlCrBN涂层。采用扫描电镜（SEM）、X射线衍射仪（XRD）、X射线光电子能谱（XPS）、轮廓仪、洛氏压痕仪、划痕仪、显微硬度计、球盘摩擦磨损试验仪和切削试验对涂层的微观结构和性能进行研究分析。结果 AlCrBN涂层的物相成分为固溶的fcc-(Cr,Al)N相以及少量的CrB2和fcc-BN相。随着AlCrB靶弧电流由60 A增至100 A,表面粗糙度Sq值由197 nm增至208 nm,Sa值由107 nm增至113 nm;显微硬度由3574HK0.05先增至3890HK0.05,再降至3209HK0.05;结合强度Lc2由57 N增至63 N,再降至55 N,均呈现先增后减的趋势。不同弧电流制备的AlCrBN涂层的磨损率依次为0.69×10-15、0.38×10-15、0.84× 10-15 m3/(N?m),涂层的磨损机理均为磨粒磨损、粘着磨损和氧化磨损。切削结果显示,AlCrBN涂层刀具在切削速度VC为60 m/min和191 m/min条件下的切削寿命均高于AlCrN涂层刀具,且80 A条件下制备的AlCrBN涂层刀具切削寿命均最长,分别为9 m和6 m。切削速度60 m/min条件下的磨损机理：初期为磨粒磨损,中期为磨粒磨损和粘着磨损,后期为粘着磨损。切削速度191 m/min条件下的磨损机理：初期和中期为磨粒磨损和粘着磨损,后期为粘着磨损。结论 AlCrBN涂层刀具与AlCrN涂层刀具相比,切削性能更加优越,并且80 A条件下制备的AlCrBN涂层的综合性能最优。     

物理气相沉积(Ti,Al)N涂层刀具的切削性能

涂层已成为提高刀具切削性能的重要手段。对上海工具厂镀膜机制备的（Ti，Al）N涂层性能分析发现，其表面硬度达到32GPa，高于TiN的24GPa；同时，涂层表面生长良好。在试验室进行的干式切削试验表明，（Ti，Al）N涂层切削过程中磨损小于TiN涂层，切削寿命高于TN涂层；（Ti，Al）N涂层适合高速切削，分析了（Ti，Al）N涂层适合高速切削的主要原因。     

基于计算机数值模拟的TiAlSiN涂层刀具切削性能研究

为研究TiAlSiN涂层对硬质合金刀具切削性能的影响,采用DEFORM-3D有限元分析软件进行切削仿真试验,模拟了TiAlSiN涂层与未涂层硬质合金刀具在相同切削条件下切削钛合金时的切削温度、切削力;并比较了不同膜厚的TiAlSiN涂层对刀具切削性能的影响。试验结果表明:TiAlSiN涂层具有低的摩擦系数,可以有效地减小切削力,3μm的TiAlSiN涂层刀具比未涂层刀具以及厚度为6μm的涂层刀具切削力小,但切削温度最高;6μm厚的刀具涂层切削温度最低,但切削力较大。     

TiAlN,TiAlSiN涂层的制备及其切削性能

目的研究TiAlN及TiAlSiN涂层的微观结构及力学性能,以及硬质合金涂层刀具切削SUS304不锈钢的切削性能及磨损行为。方法采用阴极电弧离子镀技术在硬质合金试片及铣刀上分别制备纳微米TiAlN及TiAlSiN涂层。通过X射线荧光测量系统测量涂层的厚度,用扫描电镜(SEM)观察涂层表面形貌,用能谱仪(EDAX)分析涂层元素成分,用X射线衍射(XRD)分析涂层晶相结构,用纳米压痕仪表征涂层硬度,用洛氏硬度计定性测量涂层结合力,通过高速铣削试验探究涂层刀具的切削性能及磨损行为。结果 TiAlN及TiAlSiN涂层的厚度分别为3.32μm和3.35μm,表面致密、光滑,高分辨率(20 000×)下观察到涂层表面有液滴、针孔及凹坑存在。Si元素促进了Ti N(200)晶相的生长,晶粒尺寸减小,硬度增加。TiAlN及TiAlSiN涂层的显微硬度分别为29.6 GPa及37.7 GPa,结合力分别满足VDI-3198工业标准的HF3和HF1等级。在130 m/min的高速切削条件下,TiAlSiN涂层刀具寿命约为未涂层刀具的5倍,TiAlN涂层刀具的1.5倍。结论 Si掺杂制备的TiAlSiN涂层具有高的硬度及良好的抗粘附性,更适用于不锈钢材料的高速切削加工。     

钛合金切削用Ti_(1-x)Al_xN涂层的制备及其切削性能研究

采用磁控溅射法制备了不同Al含量的Ti1-xAlxN涂层.经XRD,SEM,EDX和纳米压痕仪分析发现,Al含量在0.50~0.58(原子分数,下同)之间时,Ti1-xAlxN涂层为(111)择优生长的fcc结构.当Al含量增加到0.63时,涂层中有六方纤锌矿结构的Al N生成,涂层硬度降低.另外,随着Al含量的增加,涂层表面颗粒尺寸变大,涂层变疏松.钛合金切削实验表明,涂层刀具的磨损形式主要为黏结磨损和崩刃.在低速切削(65 m/min)时,Ti0.50Al0.50N涂层刀具的切削性能略好于无涂层刀具,并且都好于Ti0.42Al0.58N和Ti0.37Al0.63N涂层刀具.在高速切削(100 m/min)时,Ti0.50Al0.50N涂层刀具有最好的切削性能,其切削距离比无涂层刀具提高4倍多.这主要因为Ti0.50Al0.50N涂层表面致密、硬度高,在钛合金切削时形成的切屑瘤致密而整齐.     

梯度过渡层对硬质合金沉积类金刚石膜的耐磨性影响

目的分析不同类型的梯度过渡层对硬质合金沉积类金刚石涂层耐磨性能的影响,制备出能有效改善硬质合金减摩抗磨性能的类金刚石涂层。方法采用真空阴极电弧离子镀和等离子体增强化学沉积技术,在硬质合金基底上制备了Ti/TiC/DLC、Ti/TiN/DLC、Ti/TiN/TiNC/DLC和Ti/TiN/TiNC/TiC/DLC四种类型的Ti多元梯度过渡类金刚石涂层。通过GNEHM-150型洛氏硬度计和电子显微镜、MFT-4000多功能材料表面性能试验仪、纳米硬度测试仪,分别评价不同类型多元梯度过渡层对硬质合金类金刚石涂层的膜基结合强度、摩擦磨损性能及纳米硬度。结果 Ti/TiC/DLC、Ti/TiN/DLC、Ti/TiN/TiNC/DLC和Ti/TiN/TiNC/TiC/DLC四种类型涂层的膜基结合强度等级分别为HF3-HF4、HF5-HF6、HF1-HF2、HF1,对两种膜基结合强度较好的涂层(Ti/TiN/TiNC/DLC、Ti/TiN/TiNC/TiC/DLC)进行摩擦磨损检测,其摩擦系数分别为0.2、0.1,且经过60 min对摩,Ti/TiN/TiNC/TiC/DLC涂层仍未出现明显剥落。结论梯度过渡层的类型对薄膜的膜基结合强度、摩擦性能有较明显的影响,Ti/TiN/TiNC/TiC/DLC结构的涂层膜基结合强度最好,具有最低的摩擦系数,表现出了优异的减摩抗磨性能,可有效改善硬质合金表面的耐磨性能。     

多层梯度结构对TiAlSiN涂层摩擦磨损性能的影响

为提高304不锈钢耐磨损性能,采用磁过滤阴极弧等离子体沉积的方法制备TiAlSiN多层梯度涂层,研究多层梯度结构对涂层摩擦磨损性能的影响。采用扫描电子显微镜(SEM)、X射线衍射仪(XRD)、X射线光电子能谱仪(XPS)、纳米压痕仪和划痕仪等方法对涂层的表面形貌、物相结构以及力学性能进行表征,并通过MST-3001摩擦磨损试验仪测试不同结构涂层的摩擦磨损性能。结果表明:与TiAlSiN单层涂层相比,TiAlSiN多层梯度涂层具有更高的结合力和韧性;两种涂层的摩擦因数和磨损率都远小于304不锈钢,其中TiAlSiN多层梯度涂层具有比单层涂层更低的磨损率,磨损率由2.6×104μm3/(N·m)降至8.5×103μm3/(N·m),降低了67.8%,TiAlSiN多层梯度涂层磨痕表面光滑致密,主要磨损机制为轻微粘着磨损、磨粒磨损和氧化磨损的协同作用。     

纳米Al2O3/TiO2多层涂层的低温制备及其性能

采用原子层沉积技术(ALD)在200℃低温条件下将纳米Al₂O₃/TiO₂多层涂层沉积在硬质合金刀具表面。利用扫描电镜SEM、划痕测试仪和三向测力仪以及数控机床等设备,对不同形式的纳米Al₂O₃/TiO₂多层涂层刀具的涂层-基体结合力和切削性能等进行研究。结果表明,基于原子层沉积技术低温制备的纳米多层涂层刀具的涂层-基体结合强度高;涂层层数、涂层沉积顺序及涂层层厚比对纳米多层涂层刀具的切削力有不同程度的影响;纳米多层涂层刀具更适合高速切削,当切削速度大于2.33m/s时,纳米多层涂层刀具的切削力和摩擦因数呈下降趋势,表现出良好的切削性能,其中双层纳米涂层刀具的切削性能更好;在高速切削时,纳米多层涂层刀具表面摩擦因数比普通未涂层硬质合金刀具低,纳米Al₂O₃/TiO₂多层涂层能够有效改善刀具的黏结磨损,减少刀-屑粘黏现象和烫伤现象,能够改善刀具表面的耐磨损性能。     

Machining performance of Ti-Al-Si-N coated inserts

Ti-Al-Si-N quaternary coating has recently been developed for industrial applications due to its excellent machining performance. Here, we present a comparative research on Ti-Al-N single layer, Ti-Al-Si-N single layer, TiAlN-TiAlSiN bilayer and TiAlN/TiAlSiN multilayer coatings deposited onto cemented carbide substrates by cathodic arc evaporation. The incorporation of Si into the Ti-Al-N coating results in an increase in hardness and thermal stability due to the formation of nanocomposite nc-TiAlN/a-Si₃N₄, and thereby causes an improved performance during continuous cutting. However, the lower toughness and adhesive strength with a substrate reduce its cutting-life during milling. Further optimization of Ti-Al-Si-N coated inserts during milling can be obtained by a structure adjustment from the nanocomposite into TiAlN-TiAlSiN bilayer and TiAlN/TiAlSiN multilayer coatings, which causes an increase to 156% and 172% for the life-time of Ti-Al-Si-N coated inserts, respectively. Our results indicate that the machining performance of coatings containing Si in both continuous cutting and milling can be optimized by the structure design of the TiAlN/TiAlSiN multilayer, where the coating sustains a high hardness of the Ti-Al-Si-N coating combined with a good cohesive strength with the substrate similar to the Ti-Al-N coating.     

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

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.     

氮气分压对AlCrTiSiN超晶格涂层微观结构及力学性能的影响

超晶格涂层因具有优异的力学性能及抗氧化性能在刀具涂层工业中备受关注。采用多弧离子镀技术在高速钢表面制备了AlCrTiSiN涂层,研究了氮气分压对AlCrTiSiN涂层微观结构及力学性能的影响。利用X射线衍射仪(XRD)、扫描电子显微镜(SEM)和原子力显微镜研究了AlCrTiSiN涂层的微观结构;利用纳米压痕仪、划痕仪和磨损仪研究了AlCrTiSiN涂层的力学性能。结果表明:不同氮气分压的AlCrTiSiN涂层均由(Cr,Al)N相、(Ti,Al)N相和(Cr,Al)2N相以及非晶态的Si相和Si3N4相组成。与氮气分压为4Pa的涂层相比,氮气分压为2或3Pa的涂层具有更高的硬度、抗载荷能力和涂层-基体结合强度,以及更低的摩擦因数及磨损率。此外,45钢和铸铁切削试验表明:AlCrTiSiN涂层刀具较AlCrN涂层刀具有更好的切削性能,无涂层刀具具有最差的切削性能。     

碳膜刀具干式钻削Al-Si合金的切削性能及其减摩机制

采用非平衡磁控溅射离子镀技术制备碳膜,通过对刀具后刀面磨损曲线、切削力以及所加工孔精度的分析,证明高硬度低摩擦因数碳膜高速钢刀具在干切削条件下钻削铝硅合金时具有良好的切削性能。同时采用OM、SEM、XPS和EDS等方法对切削过程中碳膜的减摩效应进行探讨,证明碳膜改善刀具抗粘结能力的本质在于碳元素对铝硅合金的润湿性较差,而非在摩擦过程中生成碳转移膜。切削过程中碳膜的热稳定性越好,碳膜刀具的寿命就越长,一旦碳膜破坏,则刀具迅速发生粘结失效。     

Effect of ultrafine gradient cemented carbides substrate on the performance of coating tools for titanium alloy high speed cutting

Gradient cemented carbides usually used as substrate for coating tools, and the substrate has different gradient layer thickness and grain size, which would affect the cutting performance of the coating tools. In this study, different contents of Co and cubic carbonitride were added, the ultrafine gradient cemented carbides with different gradient layer thickness and grain size were prepared by one-step sintering, and then the CAT films (films containing Cr, Al and Ti, basically.) were deposited on alloy surface by Arc Ion Plating (AIP) in Ar gas atmosphere for titanium alloy high-speed cutting. The influence of Co and cubic carbonitride content on the microstructure of alloy and the cutting performance of coated tools was studied. The results show that the gradient layer thickness could be controlled by changing the Co and cubic carbonitride contents, and then affected the cutting performance. The coating tools enhanced cutting performance obviously by reducing the flank wear in the high-speed Ti-alloy cutting. A thinner gradient layer can be formed in alloys that with a lower Co addition, thus leading to tools chipping during high-speed cutting Ti-alloy. The wear resistance and the cutting performance of the tools could be improved by adding cubic carbonitride. The Co10Ti3-CAT coated tool has the best cutting performance. And the wear resistance of Co8Ti4-CAT coated tool can be increased by 50% compared to substrate.     

高能离子刻蚀前处理对AlTiSiN涂层切削性能的影响

目的提高AlTiSiN涂层与刀具基材的结合强度,降低涂层表面的粗糙度,减少切削过程中涂层的剥落,改善涂层刀具的切削寿命。方法采用离子源增强的多弧离子镀设备刻蚀清理基体材料,并制备AlTiSiN涂层。利用X射线衍射仪(XRD)、扫描电镜(SEM)、粗糙度仪、划痕仪和铣削实验探讨涂层沉积前不同Ar离子刻蚀清洗工艺对AlTiSiN涂层结构、膜基结合力和涂层表面形貌的的影响,探究不同刻蚀清洗工艺对涂层刀具切削机理和切削性能的影响。结果 AlTiSiN涂层的相结构主要由(Al,Ti)N固溶体相组成,涂层沿着基体呈现柱状生长。随着高能Ar离子刻蚀电流由40 A增加至100 A,涂层的表面粗糙度降低,Ra值由140 nm降至69 nm,Sq值由226 nm降至117 nm;涂层与基体之间的结合强度增加,Lc2由41 N增加至52 N;切削加工DC53模具钢结果显示,当清洗电流增加至100 A,涂层的剥落几率降低,涂层刀具的切削寿命增加,由11 m增加至23 m。结论高能离子刻蚀前处理过程可有效增加涂层与基体之间的结合强度,降低涂层表面粗糙度,进而提高涂层刀具的切削寿命。刻蚀清洗所用电流强度越大,清洗效果越好,刀具涂层切削性能提高越明显。     

TiAlSiN多元PVD涂层的研究

采用PVD方法在硬质合金基体上制备了不同成分与结构的TiAlN涂层和TiAlSiN涂层。研究了涂层的组织结构和物理性能,分析了Si元素掺杂在TiAlN基涂层中的作用机理及其对涂层性能的影响,并通过切削实验对涂层刀具的使用性能进行了验证。结果表明:在TiAlN基涂层中添加了Si元素获得了明显区别于TiAlN涂层的组织结构,Si元素以Si3N4非晶相形式包覆在TiAlN晶界,一方面起到了细化涂层晶粒尺寸提高涂层硬度的效果,另一方面还可以提高涂层的热稳定性能。切削实验表明,含Si元素的TiAlSiN涂层在许多应用条件下也表现出较TiAlN涂层更优异的使用性能。     

Structure and wear resistance of TiN and TiAlN coatings on AZ91 alloy deposited by multi-arc ion plating

In order to investigate the microstructure of TiN and TiAlN coatings and their effect on the wear resistance of Mg alloy, TiN and TiAlN coatings were deposited on AZ91 magnesium alloy by multi-arc ion plating technology. TiN and Ti70Al30N coatings were prepared on the substrate, respectively, which exhibited dark golden color and compact microstructure. The microstructures of TiN and Ti70Al30N coatings were investigated by X-ray diffractometry (XRD) and scanning electron microscopy (SEM). The micro-hardness and wear resistance of TiN and Ti70Al30N coatings were investigated in comparison with the uncoated AZ91 alloy. The XRD peaks assigned to TiN and TiAlN phases are found. The hardness of TiN coatings is two times as high as that of AZ91 alloy, and Ti70Al30N coating exhibits the highest hardness. The wear resistance of the hard coatings increases obviously as result of their high hardness.