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Hard Protective Coatings on Tools and Machine Elements
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Hard Protective Coatings on Tools and Machine Elements

A topical collection in Coatings (ISSN 2079-6412). This collection belongs to the section "Tribology".

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Editor

Prof. Dr. Smolik Jerzy

E-Mail Website
Guest Editor
Surface Engineering Centre, Łukasiewicz Research Network – Institute for Sustainable Technologies, Radom, Poland
Interests: PVD coating; hybrid methods; plasma processes; thin coatings; advanced materials; nanomaterials
Special Issues, Collections and Topics in MDPI journals

Topical Collection Information

Dear Colleagues,

Surface engineering, and above all thin Hard Protective Coatings, are one of the greatest achievements that have ensured the development of modern technologies. The rapid pace of development of many modern industries observed in the last several decades was determined primarily by the possibilities of surface engineering. Thanks to new material and technological developments for the creation of thin functional coatings, tools and machine elements could be better adapted to work in increasingly difficult operating conditions, e.g. under high mechanical and thermal loads, intense abrasive wear or corrosive environmental impact. Modern, highly specialized production systems, using new technologies, strictly defined materials, and required quality of their products and production efficiency, expect in the area of surface engineering, specialized solutions for their production needs. Such expectations of enterprises force the design of strictly dedicated PVD coating material solutions and the technology of their production for specific application areas. The conducted market analyzes show that there is an increasing expectation of enterprises for the implementation of technological developments in the area of surface treatment, aimed at production needs, taking into account both the type of production, machine park and related process parameters, the type of tools used and the materials processed.

In the scientific literature and at conferences, we observe many interesting examples of increasing the durability of various types of tools (e.g. cutting tools, forming tools, casting molds), as well as improving the functionality and durability of various machine components, e.g. in the machinery, automotive and aviation industries.

Towards this goal, we are assembling a Special Issue of Coatings: “Hard Protective Coatings on Tools and Machine Elements” to encourage researchers to exchange their experiences and to provide them with a platform to publish their novel studies. In my opinion, the Special Issue will also be an excellent source of coating solutions for modern applications.

The theme of this Special Issue “Hard Protective Coatings on Tools and Machine Elements” broadly includes (but is not limited to):

  • novel anti-wear resistant coatings for machining difficult-to-cut materials (g. Inconel; titanium alloys, alluminium alloys and others);
  • protective coatings and hybrid layers for hot forging dies;
  • protective coatings for preassure casting moulds;
  • high wear resistance and low friction coatings in machine elements applications;
  • protective coatings with high temperature resistance in machine elements applications

Prof. Dr. Smolik Jerzy
Guest Editor

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Published Papers (10 papers)

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2024

Jump to: 2023, 2022, 2021, 2020

20 pages, 4689 KiB  
Article
A Tribological Study of CrN and TiBN Hard Coatings Deposited on Cobalt Alloys Employed in the Food Industry
by Joaquín A. Hidalgo-Badillo, Irma Hernández-Casco, Héctor Herrera Hernández, Orlando Soriano-Vargas, Alan D. Contla-Pacheco, Carlos O. González Morán, Jorge Morales Hernández and José de Jesús Agustín Flores Cuautle
Coatings 2024, 14(10), 1278; https://doi.org/10.3390/coatings14101278 - 7 Oct 2024
Viewed by 1040
Abstract
In this work, a comparative study of the tribological performance of two hard coatings, CrN/TiBN, was conducted for research purposes and industrial applications in food products, particularly for food packaging into cans using the double hermetic sealing process. CrN and TiBN coatings were [...] Read more.
In this work, a comparative study of the tribological performance of two hard coatings, CrN/TiBN, was conducted for research purposes and industrial applications in food products, particularly for food packaging into cans using the double hermetic sealing process. CrN and TiBN coatings were successfully deposited on a base-cobalt metal substrate of a CoCrW commercial alloy using physical vapor deposition by arc evaporation (AEPVD) technology to improve the tribological properties of the commercial alloy, including wear and corrosion resistance, lower coefficient of friction, and overall durability. This research focuses on conducting scratch and abrasion wear resistance tests in dry conditions; specifically, it pursues to evaluate the wear corrosion properties, known as tribocorrosion performance, on CrN/TiBN hard coatings. The experimental results show that the CrN coating (2.9 μm) is slightly thicker than the TiBN coating (2.7 μm), with a 47 N critical load. It also shows a lower coefficient of friction (CoF) in a dry environment, while the TiBN coating showed total detachment and a high coefficient of friction in a dry environment condition. Tribocorrosion testing in brine aqueous solution indicated that CrN coating shows a high friction coefficient with a higher open circuit potential value (Ecorr), and TiBN shows the lowest corrosion potential (Ecorr) and the lowest friction coefficient. This suggests that CrN could provide better corrosion protection for commercial cobalt alloys and improve tool performance during the food canning process in brine environments. Full article
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20 pages, 10749 KiB  
Article
A Simulation Study on the Effect of Filament Spacing on the Temperature Field Uniformity of an HFCVD System
by Cen Hao, Fuming Deng, Quanbin Du, Zhiyu Min, Qing Lei, Lei Wang and Liang Zhang
Coatings 2024, 14(10), 1266; https://doi.org/10.3390/coatings14101266 - 2 Oct 2024
Viewed by 560
Abstract
Hot-filament chemical vapor deposition (HFCVD) has become the most widely used ways of preparing diamond film-coated tools due to the simple equipment used, its convenient operation, and its low cost. In the production process of an actual factory, a large number of coated [...] Read more.
Hot-filament chemical vapor deposition (HFCVD) has become the most widely used ways of preparing diamond film-coated tools due to the simple equipment used, its convenient operation, and its low cost. In the production process of an actual factory, a large number of coated tools need to be prepared in batches. Factors such as the hot-filament arrangement often affect the uniformity of coating on tools, making the performance of the tools prepared in the same batch unstable. This article uses ANSYS R15.0 software software in the context of computational fluid dynamics (CFD) to calculate the temperature field in the HFCVD system, and study the effect of filament spacing on the uniformity of the temperature field of the surface of the substrate. It was found that when the distance between filaments was 14 mm, 10 mm, 10 mm, 8 mm, 8 mm, the temperature field on the surface of the substrate was the most uniform. The experiments are consistent with the results of the simulation, indicating that simulation research has practical significance. Full article
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2023

Jump to: 2024, 2022, 2021, 2020

23 pages, 11438 KiB  
Article
A Study on Using Magnetic Abrasive Finishing with a 6-Axis Robot to Polish the Internal Surface Finishing of Curved Tubes
by Zhenfeng Zhou, Xu Sun, Yanzhen Yang and Yongjian Fu
Coatings 2023, 13(7), 1179; https://doi.org/10.3390/coatings13071179 - 30 Jun 2023
Cited by 2 | Viewed by 1650
Abstract
This study proposed a new magnetic abrasive finishing (MAF) method, in which a 6-axis robot with a magnetic machining tool was used to polish the inner surfaces of curved tubes. We have also developed a magnetic machining tool jig, which can be fixed [...] Read more.
This study proposed a new magnetic abrasive finishing (MAF) method, in which a 6-axis robot with a magnetic machining tool was used to polish the inner surfaces of curved tubes. We have also developed a magnetic machining tool jig, which can be fixed at the front of the 6-axis robot, rotating freely and suitable for polishing the inner surfaces of curved tubes. In this study, we focused on investigating the machining parameters in the initial machining stage and precision finishing stage. Based on the characteristics of machining parameters, a multi-stage MAF process was conducted to obtain an inner surface with high quality and high efficiency. The experimental results showed that both the roughness Ra and Rz of inner surface in the initial machining stage significantly decreased with the increase in the mixed magnetic abrasives, to as low as less than 20 nm Ra in the precision finishing stage when the machining parameters were appropriately adjusted. In addition, the roughness Ra of inner surface could be further reduced to less than 10 nm Ra in the multi-stage MAF process. Finally, the magnetic flux density cloud map and the magnetic field line distribution map were analyzed in Ansys Maxwell. Full article
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2022

Jump to: 2024, 2023, 2021, 2020

16 pages, 8181 KiB  
Article
Study on Cutting Performance of Micro Groove Tool in Turning AISI 304 and Surface Quality of the Workpiece
by Zhenghong Liu and Jinxing Wu
Coatings 2022, 12(9), 1326; https://doi.org/10.3390/coatings12091326 - 12 Sep 2022
Cited by 6 | Viewed by 1592
Abstract
AISI 304 has high-tensile strength and excellent corrosion resistance, which is widely needed in the energy industry and equipment manufacturing industry. However, the tools for cutting AISI 304 are easy to wear and have short service life. In order to improve tool life, [...] Read more.
AISI 304 has high-tensile strength and excellent corrosion resistance, which is widely needed in the energy industry and equipment manufacturing industry. However, the tools for cutting AISI 304 are easy to wear and have short service life. In order to improve tool life, micro grooves are designed on the rake face of the tool for the machining of AISI 304. Through the single factor cutting experiment, it is found that under the same cutting parameters, the micro groove tool has less cutting depth resistance than the initial tool; the main cutting force and feed resistance are reduced by more than 15%. The shear energy is reduced by more than 13%; the surface roughness and the hardening degree of the workpieces are reduced. Through the durability test, it is found that the service life of the micro groove tool is 57% longer than that of the initial tool, and the abrasive wear, bonding wear, and oxidation wear of the tool are significantly less. Through cutting experiments and theoretical analysis, the cutting performance of the micro groove tool has been improved. Full article
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2021

Jump to: 2024, 2023, 2022, 2020

17 pages, 25198 KiB  
Article
Enhancing Wear Resistance and Cutting Performance of a Long-Life Micro-Groove Tool in Turning AISI 201
by Jinxing Wu, Lin He, Yanying Wu, Chaobiao Zhou, Zhongfei Zou, Gang Zhan, Tao Zhou, Feilong Du, Pengfei Tian, Zichuan Zou and Xiuhua Zhang
Coatings 2021, 11(12), 1515; https://doi.org/10.3390/coatings11121515 - 9 Dec 2021
Cited by 6 | Viewed by 2300
Abstract
Tool-chip friction increases cutting temperature, aggravates tool wear, and shortens the service life of cutting tools. A micro-groove design of the rake face can improve the wear performance of the tool. In this study, we used the finite element simulation “Deform” to obtain [...] Read more.
Tool-chip friction increases cutting temperature, aggravates tool wear, and shortens the service life of cutting tools. A micro-groove design of the rake face can improve the wear performance of the tool. In this study, we used the finite element simulation “Deform” to obtain the temperature field distribution of the tool rake face. The size of the micro-groove was determined by selecting a suitable temperature field combined with the characteristics of tool–chip flow in the cutting process, and the tool was prepared using powder metallurgy. The three-direction cutting forces and tool tip temperature were obtained by a cutting test. Compared with the original turning tool, the cutting force and cutting temperature of the micro-groove tool were reduced by more than 20%, the friction coefficient was reduced by more than 14%, the sliding energy was reduced and the shear energy was greatly decreased. According to the analysis of tool wear by SEM (scanning electron microscope) and EDS (energy dispersive X-ray spectroscopy), the crater wear, adhesive wear and oxidation wear of the micro-groove tool were lower than those of the original turning tool. In particular, the change in the crater wear area on the rake face of the original tool and the micro-groove tool was consistent with the cutting temperature and the wear width of the flank face. On the whole, the crater wear area and the change rate of the crater wear area of the micro-groove tool were smaller. Due to the proper microgroove structure of the rake face, the tool-chip contact area decreased, and the second rake angle of the tool became larger. Hence, the tool-chip friction, cutting forces, cutting energy consumption were reduced, tool wear was improved, and the service life of the micro-groove tool was five times longer than that of the original tool. Full article
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15 pages, 7581 KiB  
Article
Very High Cycle Fatigue Properties of 18CrNiMo7-6 Carburized Steel with Gradient Hardness Distribution
by Shaopeng Yang, Peifeng Cheng, Fangzhong Hu, Wenchao Yu, Chi Zhang, Kaizhong Wang and Maoqiu Wang
Coatings 2021, 11(12), 1482; https://doi.org/10.3390/coatings11121482 - 2 Dec 2021
Cited by 6 | Viewed by 3240
Abstract
As research of the high cycle fatigue of carburized gear steel could not meet the status quo of longer and longer service lives, research of very high cycle fatigue (VHCF) performance has become the focus of current research. The VHCF properties of case-hardening [...] Read more.
As research of the high cycle fatigue of carburized gear steel could not meet the status quo of longer and longer service lives, research of very high cycle fatigue (VHCF) performance has become the focus of current research. The VHCF properties of case-hardening steel 18CrNiMo7-6 after being carburized with gradient hardness distribution were investigated by means of ultrasonic fatigue tests. The results showed that the carburized specimens with a case hardness of 705 HV and core hardness of 530 HV showed VHCF phenomenon, and the fatigue lives continuously increased to even 109 cycles as the stress amplitude decreased to about 500 MPa. Observations of the fracture surfaces of the fatigue specimens showed that the fatigue crack initiation sites were located in the transition area with the hardness at about 580 HV. It was found that the transition area had low VHCF properties, since the core did not show VHCF phenomenon, and the case had a higher hardness. A fine microstructure was observed in the granular bright facet (GBF) area, and the stress intensity factor ΔKGBF was measured to be 3.04 MPam−1/2. The 109 cycles fatigue life was predicted based on the inclusion size, and the 1010 cycles fatigue life was 490 MPa based on the prediction model. Full article
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16 pages, 9096 KiB  
Article
Characterization and Parametric Optimization of Performance Parameters of DLC-Coated Tungsten Carbide (WC) Tool Using TOPSIS
by Ramakant Rana, R. S. Walia and Qasim Murtaza
Coatings 2021, 11(7), 760; https://doi.org/10.3390/coatings11070760 - 24 Jun 2021
Cited by 20 | Viewed by 3601
Abstract
In this work, we have deposited the diamond-like carbon (DLC) coating on the tungsten carbide (WC) tool insert using the thermal chemical vapor deposition (CVD) method. For the growth of DLC coating, sugarcane bagasse was used as a carbon precursor. Raman spectroscopy, a [...] Read more.
In this work, we have deposited the diamond-like carbon (DLC) coating on the tungsten carbide (WC) tool insert using the thermal chemical vapor deposition (CVD) method. For the growth of DLC coating, sugarcane bagasse was used as a carbon precursor. Raman spectroscopy, a field emission scanning electron microscope (FESEM), and X-ray diffraction (XRD) were used to confirm the presence of DLC coating on the tungsten carbide tool inserts. The hardness tests were also performed for inspecting the microhardness induced by the self-developed DLC coating on the tungsten carbide (WC) tool insert. To determine the optimum process parameters for the turning operation on an aluminum (6061) workpiece using a self-developed DLC-coated tungsten carbide (WC) tool insert, we have applied the technique for order preference by similarity to ideal solution (TOPSIS) methods. The process parameters considered for the optimization were feed rate, cutting speed, and depth of cut. Whereas chosen response variables were flank wear, temperature in the cutting zone, and surface roughness. TOPSIS is utilized to analyze the effects of selected input parameters on the selected output parameters. This study in this paper revealed that it was advantageous to develop the DLC coating on the tungsten carbide tool inserts for the machining applications. The results also revealed that a 0.635 mm depth of cut, feed rate of 0.2 mm/rev, and cutting speed of 480 m/min were the optimum combination of process parameters. Full article
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18 pages, 4924 KiB  
Review
Hard Protective Layers on Forging Dies—Development and Applications
by Jerzy Smolik
Coatings 2021, 11(4), 376; https://doi.org/10.3390/coatings11040376 - 24 Mar 2021
Cited by 5 | Viewed by 3328
Abstract
The article presents a summary of many years of activities in the area of increasing the durability of forging dies. The results of comprehensive research work on the analysis of the destructive mechanisms of forging dies and the possibility of increasing their durability [...] Read more.
The article presents a summary of many years of activities in the area of increasing the durability of forging dies. The results of comprehensive research work on the analysis of the destructive mechanisms of forging dies and the possibility of increasing their durability with the use of modern surface engineering methods are presented. Great possibilities in terms of shaping operational properties of forging dies by producing hybrid layers of the “Nitrided Layer + PVD Coating” (NL + PVD coating) type were confirmed. An analysis of changes in forging dies durability under various operating conditions was performed, i.e., forging—die—forging press—pressures. It has been shown that the variety of parameters of the forging process, including forgings’ geometry and weight, materials, precision, pressures applied, and, what is very important, quality of machines, makes it very difficult to compare the effectiveness of various PVD coating solutions in the process of increasing the durability of forging dies. Hybrid layers of the “NL + PVD coating” type create great possibilities in shaping the operational properties of tools and machine elements. However, in each application a precise diagnosis of the wear mechanism and the design of an individual PVD coating material solution is required. Full article
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9 pages, 11456 KiB  
Article
Electrochemical Nucleation and Growth Mechanism of Aluminum on AZ31 Magnesium Alloys
by Jinling Zhang, Yelei Li, Xiaomin Zhang, Yanchong Yu and Shebin Wang
Coatings 2021, 11(1), 46; https://doi.org/10.3390/coatings11010046 - 5 Jan 2021
Cited by 3 | Viewed by 2343
Abstract
In this study, the nucleation and growth kinetics behavior of aluminum (Al) were investigated in the Choline-chloride (ChCl)-urea deep eutectic solvent (DES) ionic liquids. The studies of cyclic voltammetric and chronoamperometry demonstrated that the electrodeposition process of Al was controlled by three-dimensional progressive [...] Read more.
In this study, the nucleation and growth kinetics behavior of aluminum (Al) were investigated in the Choline-chloride (ChCl)-urea deep eutectic solvent (DES) ionic liquids. The studies of cyclic voltammetric and chronoamperometry demonstrated that the electrodeposition process of Al was controlled by three-dimensional progressive nucleation and instantaneous nucleation. And the growth of nuclei is a diffusion-controlled process. The diffusion coefficient of Al ions was calculated at 343 K, that is, 1.773 × 10−10 cm2/s. The Al coating was obtained on the surface of the AZ31 magnesium alloy electrode under appropriate conditions. According to the surface morphology of the Al film, it could be inferred that the theoretical deposit thickness is similar to the actual thickness, and the apparent diffusion rate of Al ions is slower than the diffusion coefficient in the electrolytes. So, in the later deposition, lamellar Al along the diffusion direction were formed, and lamellar depleted Al zones existed around the big grain Al-rich region. Full article
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2020

Jump to: 2024, 2023, 2022, 2021

13 pages, 6085 KiB  
Article
Characterization and Wear Response of Magnetron Sputtered W–B and W–Ti–B Coatings on WC–Co Tools
by Joanna Radziejewska, Rafał Psiuk and Tomasz Mościcki
Coatings 2020, 10(12), 1231; https://doi.org/10.3390/coatings10121231 - 16 Dec 2020
Cited by 6 | Viewed by 2083
Abstract
In this work, α-WB2 and (W,Ti)B2 borides were applied as wear-resistant coatings to commercial WC–Co cutting inserts. Properties of coatings deposited by magnetron sputtering on WC–Co tools were studied. The crystal structure and chemical composition were analyzed. Vickers hardness and surface [...] Read more.
In this work, α-WB2 and (W,Ti)B2 borides were applied as wear-resistant coatings to commercial WC–Co cutting inserts. Properties of coatings deposited by magnetron sputtering on WC–Co tools were studied. The crystal structure and chemical composition were analyzed. Vickers hardness and surface roughness were determined and wear test in semi-dry conditions was performed. The W–B and W–Ti–B coatings deposited on WC–Co substrate were smooth and very hard. However, titanium alloy W-B films with Vickers hardness of 3630 ± 260 HV0.02 were characterized by lower adhesion to the substrate, influencing the wear mechanism. Turning tests carried out on 304 stainless steel showed that the W–B film caused less wear compared to uncoated insert. Moreover, when W–B coating was applied, flank wear was reduced by 30% compared to uncoated WC–Co insert. Additionally, coating prevented chipping of the edge during cutting under test conditions. The research shows that W–B film deposited by magnetron sputtering has great potential as a coating for cutting tools for difficult-to-cut materials. Full article
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