Investigating the supremacy of PVD S3p deposition over HiPIMS for AlTiN coating

Abstract

Dry machining of Duplex Stainless Steel 2205 (DSS2205) is a challenging task due to difficulties including high cutting temperatures, work hardening tendency and Built-up Layer (BUL) formation. Moreover, the high demand for DSS stresses improving machining productivity and quality. This study focuses on inspecting the supremacy of the PVD Scalable Pulse Power Plasma (S3p) coating deposition technique, which is rarely used for dry machining DSS, over High Pulse Impulse Magnetron Sputtering (HiPIMS) to deposit AlTiN coatings. A combination of evaporation and sputtering used for S3p dominated over HiPIMS. After a machining length of 6240 mm, the AlTiN (HiPIMS) coatings were unable to sustain the dry machining conditions, exhibiting faster tool wear rates than the AlTiN (S3p) coatings. As a result, AlTiN (S3p) exhibited a tool life of 8840 mm, 1.6 times higher than the AlTiN (HiPIMS) coating. The effect of decreasing tool life at any selected cutting speed was more severe at higher feed rates (0.19 mm/rev). The tool life decreased by 56%, 32% and 23% for the uncoated, AlTiN (HiPIMS) and AlTiN (S3p) tools, respectively. The surface roughness and cutting force were found to decrease by a notable 13% and 10%, respectively, due to the excellent properties of AlTiN (S3p) coatings compared to AlTiN (HiPIMS) coatings.

Keywords:

• AlTiN
• DSS2205
• dry machining
• HiPIMS
• S3p

Acknowledgments

The authors express gratitude to CemeCon, Germany, Balzer, Switzerland and SECO, India for providing timely support for tool and the coatings.

Ethical approval

The manuscript does not contain any clinical studies or patient data.

Disclosure statement

The authors declare that there is no conflict of interest and authors have full control of all the data included in manuscript and authors are agree to allow journal to review their data, if required.

Data availability statement

The raw/processed data required to reproduce these findings cannot be shared at this time as the data also forms part of an ongoing study. Moreover, the data can be made available as and when requested.

Additional information

Funding

The authors would like to thank the NEB and Department of Science and Technology (DST), Govt. of India for funding this project (Ref: 11/10/2015-NEB (G)/03 Dated 27/09/2017)