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  • 1.
    Fallqvist, Mikael
    Dalarna University, School of Technology and Business Studies, Materials Technology.
    Microstructural, Mechanical and Tribological Characterisation of CVD and PVD Coatings for Metal Cutting Applications2012Doctoral thesis, comprehensive summary (Other academic)
    Abstract [en]

    The present thesis focuses on characterisation of microstructure and the resulting mechanical and tribological properties of CVD and PVD coatings used in metal cutting applications. These thin and hard coatings are designed to improve the tribological performance of cutting tools which in metal cutting operations may result in improved cutting performance, lower energy consumption, lower production costs and lower impact on the environment.  In order to increase the understanding of the tribological behaviour of the coating systems a number of friction and wear tests have been performed and evaluated by post-test microscopy and surface analysis. Much of the work has focused on coating cohesive and adhesive strength, surface fatigue resistance, abrasive wear resistance and friction and wear behaviour under sliding contact and metal cutting conditions.

    The results show that the CVD deposition of accurate crystallographic phases, e.g. α-Al2O3 rather than κ-Al2O3, textures and multilayer structures can increase the wear resistance of Al2O3. However, the characteristics of the interfaces, e.g. topography as well as interfacial porosity, have a strong impact on coating adhesion and consequently on the resulting properties.  Through the deposition of well designed bonding and template layer structures the above problems may be eliminated.

    Also, the presence of macro-particles in PVD coatings may have a significant impact on the interfacial adhesive strength, increasing the tendency to coating spalling and lowering the surface fatigue resistance, as well as increasing the friction in sliding contacts.

    Finally, the CVD-Al2Ocoating topography influences the contact conditions in sliding as well as in metal cutting.

    In summary, the work illuminates the importance of understanding the relationships between deposition process parameters, composition and microstructure, resulting properties and tribological performance of CVD and PVD coatings and how this knowledge can be used to develop the coating materials of tomorrow.

  • 2.
    Fallqvist, Mikael
    et al.
    Dalarna University, School of Technology and Business Studies, Materials Technology.
    M’Sauobi, R
    Seco Tools.
    Andersson, J
    Seco Tools.
    Olsson, Mikael
    Dalarna University, School of Technology and Business Studies, Materials Technology.
    Mechanical and tribological properties of PVD-coated cemented carbide as evaluated by a new multi-pass scratch testing method2012In: Advances in Tribology, ISSN 1687-5915, E-ISSN 1687-5923, no 305209Article in journal (Refereed)
    Abstract [en]

    A new test method based on multipass scratch testing has been developed for evaluating the mechanical and tribological properties of thin, hard coatings. The proposed test method uses a pin-on-disc tribometer and during testing a Rockwell C diamond stylus is used as the “pin” and loaded against the rotating coated sample. The influence of normal load on the number of cycles to coating damage is investigated and the resulting coating damage mechanisms are evaluated by posttest scanning electron microscopy. The present study presents the test method by evaluating the performance of Ti0.86Si0.14N, Ti0.34Al0.66N, and (Al0.7Cr0.3)2O3 coatings deposited by cathodic arc evaporation on cemented carbide inserts. The results show that the test method is quick, simple, and reproducible and can preferably be used to obtain relevant data concerning the fatigue, wear, chipping, and spalling characteristics of different coating-substrate composites. The test method can be used as a virtually nondestructive test and, for example, be used to evaluate the fatigue and wear resistance as well as the cohesive and adhesive interfacial strength of coated cemented carbide inserts prior to cutting tests.

  • 3.
    Fallqvist, Mikael
    et al.
    Dalarna University, School of Technology and Business Studies, Materials Technology.
    Olsson, Mikael
    Dalarna University, School of Technology and Business Studies, Materials Technology.
    The influence of surface defects on the mechanical and tribological properties of VN-based arc-evaporated coatings2013In: Wear, ISSN 0043-1648, E-ISSN 1873-2577, Vol. 297, no 1-2, p. 1111-1119Article in journal (Refereed)
    Abstract [en]

    The influence of surface defects, i.e., droplets and craters, on the mechanical and tribological properties of arc-evaporated VxN coatings deposited on cemented carbide has been investigated in a scratching contact using a diamond stylus and a sliding contact using a stainless steel pin. Post-test characterisation using 3D optical surface profilometry and scanning electron microscopy was performed in order to investigate the mechanical and tribological response of the coatings. The results show that scratch induced coating cracking mainly is restricted to larger droplets showing a low interfacial bonding to the adjacent coating matrix. The influence of coating defects on the cohesive strength, i.e., the tendency to chipping of small coating fragments, was found to be relatively small. In contrast, the presence of defects may have a significant impact on the interfacial adhesive strength, increasing the tendency to spalling. In sliding contact, surface defects such as droplets and craters have a strong impact on the tribological behaviour of the coatings causing abrasive wear of the less hard counter material surface and material transfer to the coating, both mechanisms affecting the friction characteristics of sliding contact tribo systems.

  • 4.
    Fallqvist, Mikael
    et al.
    Dalarna University, School of Technology and Business Studies, Materials Technology.
    Olsson, Mikael
    Dalarna University, School of Technology and Business Studies, Material Science.
    The role of surface defects on the surface fatigue and tribological characteristics of VxN-PVD coatings in sliding contacts2010In: 14th Nordtrib Conference, Storforsen, 2010Conference paper (Other academic)
    Abstract [en]

    The influence of surface defects in arc-evaporated VxN PVD coatings on the adhesion, surface fatigue resistance, friction and wear characteristics has been investigated in a scratching contact using a diamond stylus and a sliding contact using a stainless steel pin. Post-test characterisation using scanning electron microscopy and 3D optical interferometric surface profilometry was performed in order to investigate the mechanical and tribological response of the coatings. The results show that surface defects such as droplets and craters show a strong influence on the tribological behaviour of the coatings causing abrasive wear of the counter surface and material pick-up on the coating surface. In contrast, the influence on the mechanical properties of the coatings, i.e. cracking behaviour, fatigue resistance, etc, was found to be relatively small and cracking seems to be restricted to larger droplets showing a low interfacial bonding to the adjacent coating matrix.

  • 5.
    Fallqvist, Mikael
    et al.
    Dalarna University, School of Technology and Business Studies, Material Science.
    Olsson, Mikael
    Dalarna University, School of Technology and Business Studies, Material Science.
    Andersson, Jon
    Msauobi, Rachid
    The influence of surface topography on the formation of build-up layers and wear of CVD-Al2O3 coatings2009In: Wear of Materials, Las Vegas, 2009Conference paper (Other academic)
    Abstract [en]

    During the last years it has become more and more obvious that the surface topography and surface texture strongly influences the performance of CVD and PVD coated cutting tools. As a result the interest for different types of pre- and post-surface treatments of the substrates and the deposited coatings has increased. In the present study the friction and wear characteristics of CVD a-Al2O3 coated cemented carbide exposed to different post-surface treatments, including grinding, wet and dry micro-blasting and polishing, have been investigated using modified scratch testing and pin-on-disc testing using , AISI 304 stainless steel, AISI A2 tool and steel reinforcing iron as counter materials. The influence of the coating surface topography/texture on the resulting friction characteristics, tendency to build up layer formation and prevailing wear mechanisms were identified by optical profilometry, FEG-SEM and EDX analysis. Based on the results obtained, the potential of pin-on-disc testing in the tribological characterisation of CVD coatings for cutting tool applications is discussed.

  • 6.
    Fallqvist, Mikael
    et al.
    Dalarna University, School of Technology and Business Studies, Materials Technology.
    Olsson, Mikael
    Dalarna University, School of Technology and Business Studies, Materials Technology.
    Ruppi, S
    Abrasive wear of textured-controlled CVD a-Al2O3 coatings2007In: Surface & Coatings Technology, ISSN 0257-8972, E-ISSN 1879-3347, Vol. 202, no 4-7, p. 837-843Article in journal (Refereed)
    Abstract [en]

    In the present study the wear resistance of some CVD alpha-Al2O3 coatings with different growth textures, i.e. <0001>, <10<(1)over bar>2> and <10<(1)over bar>4>, and a kappa-Al2O3 coating have been investigated using a micro-abrasion test with diamond particles as the abrasive medium. The results show that the softer kappa-Al2O3 coating shows a higher wear rate as compared with the textured alpha-Al2O3 coatings. Of the latter coatings, the 101¯4 textured a-Al2O3 coating shows the lowest wear rate while the <0001> and <10<(1)over bar>2> textured alpha-Al2O3 coatings show similar wear rate. Two different dominant wear mechanisms, i.e. micro cutting and micro chipping, were observed and the latter mechanism is believed to control the wear rate of the Al2O3 coatings investigated. The results obtained are discussed in relation to the dominant wear mechanisms of the coatings identified using scanning electron microscopy.

  • 7.
    Fallqvist, Mikael
    et al.
    Dalarna University, School of Technology and Business Studies, Materials Technology.
    Olsson, Mikael
    Dalarna University, School of Technology and Business Studies, Material Science.
    Ruppi, Sakari
    Abrasive wear of multilayer kappa-Al2O3-Ti(C,N) CVD coatings on cemented carbide2007In: Wear, ISSN 0043-1648, E-ISSN 1873-2577, Vol. 263, no 1-6, p. 74-80Article in journal (Refereed)
    Abstract [en]

    In the present study the wear resistance of kappa-Al2O3–Ti(C,N) multilayer CVD coatings with different multilayer structures (8, 15, 32 layers of kappa-Al2O3 separated by thin Ti(C,N) layers) have been investigated using a micro-abrasion and a cutting test. The results show that the wear rate of the kappa-Al2O3 multilayer coatings tend to decrease with decreasing layer thickness in the micro-abrasion test and decrease with increasing layer thickness in the cutting tests. The reason for this is mainly due to the difference in wear behaviour depending on temperature. The results obtained are discussed in relation to the dominant wear mechanisms of the coatings which have been identified using scanning electron microscopy and energy dispersive X-ray spectroscopy. The potential of the micro-abrasion test in the characterisation of thin CVD coatings for cutting tool applications is discussed.

  • 8.
    Fallqvist, Mikael
    et al.
    Dalarna University, School of Technology and Business Studies, Materials Technology.
    Ruppi, S
    Seco Tools.
    Olsson, Mikael
    Dalarna University, School of Technology and Business Studies, Materials Technology.
    Ottosson, M
    Uppsala Universitet.
    Grehk, Mikael
    Dalarna University, School of Technology and Business Studies, Materials Technology. Sandvik Materials Technology.
    Nucleation and growth of CVD α-Al2O3on TixOy template2012In: Surface & Coatings Technology, ISSN 0257-8972, E-ISSN 1879-3347, Vol. 207, p. 254-261Article in journal (Refereed)
    Abstract [en]

    The microstructure, phase and chemical composition of TixOy templates used to nucleate α-Al2O3 on Ti(C,N) coated cemented carbide have been elucidated using scanning electron microscopy, X-ray diffraction, Auger electron spectroscopy and Time-of-Flight Secondary Ion Mass Spectrometry. Further, the adhesive strength of the α-Al2O3–TixOy–Ti(C,N) interfaces was investigated using scratch adhesion testing.

    The present study confirmed that the as-deposited template consisted of a Ti4O7 phase which during subsequent deposition of the Al2O3 layer transformed to a Ti3O5 phase and that the grown Al2O3 layer consisted of 100% α-Al2O3. Furthermore, the results showed that the lowest interfacial strength within the multilayer structure was exhibited by the Ti(C,N)–TixOy interface and that the transformation of Ti4O7 to Ti3O5 in the template resulted in formation of pores in the Ti(C,N)-template interface lowering the interfacial strength even more. The use of surface analysis techniques such as Auger electron spectroscopy and especially Time-of-Flight Secondary Ion Mass Spectrometry enabled trace element analyses using depth profiling to characterise the thin interfacial layers in detail.

  • 9.
    Fallqvist, Mikael
    et al.
    Dalarna University, School of Technology and Business Studies, Materials Technology.
    Schultheiss, F
    Lunds Universitet.
    Olsson, Mikael
    Dalarna University, School of Technology and Business Studies, Materials Technology.
    M’Sauobi, R
    Seco Tools.
    Ståhl, J E
    Lunds Universitet.
    Influence of CVD Al2O3 coated tool surface micro topography on the tribological characteristics in metal cutting: part I2013In: Wear, ISSN 0043-1648, E-ISSN 1873-2577, p. 87-98Article in journal (Refereed)
    Abstract [en]

    The influence of surface micro topography of CVD α-Al2O3 coatings, deposited on cemented carbide inserts, on tribological characteristics in sliding contact and in metal cutting has been investigated using quenched and tempered steel as counter/work material. Pin-on-disc and turning tests were carried out and post-test characterization using 3D optical surface profilometry and scanning electron microscopy was performed in order to investigate the tribological response of the coatings. The results show that surface micro topography can have a significant impact on the tribological performance of Al2O3 coatings under initial and cutting contact conditions. For both kinds of tests the tendency for transfer of workpiece material strongly increases with increasing coating micro topography. In the pin-on-disc tests, a smooth coating surface significantly reduces the friction coefficient. In the turning tests the contact conditions at the flank face increase with decreasing micro topography. In contrast, no general conclusions can be drawn regarding the influence of coating micro topography on the contact conditions at the rake face. The resulting topography of the turned surface was found to increase with increasing coating topography.

  • 10.
    Schultheiss, F
    et al.
    Lunds Universitet.
    Fallqvist, Mikael
    Dalarna University, School of Technology and Business Studies, Materials Technology.
    M’Sauobi, R
    Seco Tools.
    Olsson, Mikael
    Dalarna University, School of Technology and Business Studies, Materials Technology.
    Ståhl, J E
    Lunds Universitet.
    Influence of CVD Al2O3 coated tool surface micro topography on the tribological characteristics in metal cutting: part II2013In: Wear, ISSN 0043-1648, E-ISSN 1873-2577, Vol. 298, p. 23-31Article in journal (Refereed)
    Abstract [en]

    The tribological conditions at the contact between the cutting tool and the chip are of great importance when analyzing the machining process. By knowing the contact conditions on the rake face of the cutting tool the wear on the clearance and rake face may be predicted in terms of size and type of wear. A certain value of the surface stresses is often thought of as leading to a higher wear rate of the cutting tool and thus a shorter tool life. In this article two different methods for experimentally measuring the contact condition on the clearance and rake face of the cutting tool are presented and illustrated with results obtained while turning AISI 4140. Results are also obtained in terms of how the surface roughness value of the cutting tool influences the contact condition. It was found that the tool surface topography may have a significant impact on the tribological performance during machining.

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