硬质合金刀具高能离子源增强多弧镀AlCrTiSiN梯度涂层制备及性能研究

采用离子源增强的多弧离子镀新技术，在硬质合金刀具表面制备了不同含Si层梯度结构的AlCrTiSiN梯度涂层，并对涂层组织结构、残余应力、结合强度、摩擦磨损以及铣削和钻削加工灰铸铁性能进行了详细的研究。结果表明：不同含Si层梯度结构的AlCrTiSiN涂层主要由固溶的(Al,Cr) N、(Al,Ti) N相和非晶态Si₃N₄相组成。其中，含Si层梯度变化最缓和的G3(Gradient 3)涂层具有较高的结合强度，较低的残余压应力、摩擦因数和磨损率。铣削和钻削试验显示，涂层刀具的切削磨损机理主要表现为磨粒磨损和粘着磨损。G3涂层降低了磨粒磨损，其刀具的铣削和钻削寿命均最高，这主要得益于其含Si层的梯度设计、适当的压应力(-3.8 GPa)以及良好的膜基结合强度。研究结果表明，通过对含Si层进行梯度设计可显著提高涂层刀具的切削性能。

Study on Preparation and Properties of Gradient AlCrTiSiN Coated Cemented Carbide Tools Deposited by Ion Source Enhanced Multi-arc Ion Plating Technology

Ion source enhanced multi-arc ion plating technology is adopted to fabricate the AlCrTiSiN composite coatings with different Si gradient structures on the surface of cemented carbide cutters. The effects of Si gradient coating structures on the microstructure, residual stresses, adhesion strength, friction and wear properties, milling and drilling against gray cast iron are studied in detail. The results showed that AlCrTiSiN composite coatings with different Si gradient coating structures are comprised of solid solution (Al, Cr)N, (Al, Ti)N and amorphous Si₃N₄. Among all the coatings, the G3 (Gradient 3) coating with the most gentle Si gradient structure show higher adhesion strength, the lowest residual compressive stress and the lowest friction coefficient and wear rate. The wear mechanism of coated cutters is mainly characterized by abrasive wear and adhesive wear. G3 coating decreased the abrasive wear, and also the milling and drilling experiment results showed that the G3 coated tools show the best cutting performance, which is attributed to the gradient design of Si containing layer, proper residual compressive stress (-3.8 GPa) and higher adhesion strength. This result show that gradient design of Si containing coating could effectively improve the cutting performance of the coated cutter.