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A new generation cutting tool AIP coating SX series
In the past 10 years, the application of coating technology on cutting tools has been rapidly popularized, and coated tools have become an indispensable mainstream tool for cutting. At the same time, with the rapid development of cutting to high-speed cutting, strong cutting and dry cutting, higher requirements are placed on the performance of coated tools. This article provides an overview of the current state of tool coating technology, development trends, and the development of new coating technologies by Japan JFE Precision Co., Ltd. 1 Current status of cutting tool coating technology (1) Types of cutting tool coating technology Coating technology for cutting tools is mainly divided into two major categories: PVD (physical coating) and CVD (chemical coating). PVD is further divided into vacuum coating, cathode vacuum sputtering and ion plating. When the coating technology is used for cutting tools, the processing temperature of the CVD process is close to 1000 °C. For cutting tools with sharp cutting edges, this high temperature will reduce the hardness of the tool base and cause deformation and damage; vacuum coating and cathodic vacuum plating The main problem with the process is that the bonding strength of the coating to the substrate is low; ion plating can obtain a coating with a high bonding strength at a lower processing temperature, which is very suitable for use in a cutting tool. (2) Ion plating equipment and its special ion plating is a coating technology that forms a coating film by evaporating a metal material in a vacuum and ionizing it in a plasma to bombard it on a negatively biased product. . A variety of ion plating apparatuses have been developed in the past, and HSD (hot cathode) type and AIP (single arc/multi-arc ion plating) type are widely used in the industry. The difference between the two devices is mainly due to the different composition of the evaporation source. Since AIP type ion plating has the advantages of easily obtaining a multi-element coating and a multi-coating using a plurality of metals and a high bonding strength of a coating, it has become a mainstream equipment in recent years. A disadvantage of the AIP type is that there are molten particles from the evaporation source in the ion plating layer. The presence of such particles deteriorates the surface roughness of the plating layer, and if it falls off, it becomes a plating defect and becomes a starting point for corrosion and wear. In order to reduce such coating defects, the magnetic field control of the evaporation source is improved, and the precision cathode is used to greatly reduce the size and number of molten particles, which has a good effect on prolonging the tool life, and the device has been commercialized. (3) Types and characteristics of general AIP coatings Due to the difference in workpiece material and cutting conditions, the life of coatings varies greatly. Therefore, the applicable coating materials should be selected according to the cutting conditions and requirements to obtain the best quality and economy. benefit. For example, when it is mainly required that the cutting tool has excellent wear resistance, TiN, TiCN, TiAlN coating materials are mostly selected. In recent years, the use of TiAlN coating materials for coated cemented carbide tools has increased significantly; in the cutting of non-ferrous metals such as copper and aluminum, coated tools have also used CrN coating materials with good anti-stick properties. Examples; in the stamping die, TiCrN coating materials are mainly used; the most used coating material for injection molds is TiN, but in recent years, the proportion of CrN coating materials with excellent corrosion resistance and resin adhesion resistance is increasing. . At present, from the purpose of protecting the environment, users have stopped using chrome plating technology and replaced it with CrN coating materials. The tint and ZrN coatings are gold-tone, very aesthetically pleasing, and are used in decorative coatings. 2 Development trend of AIP coating for cutting tools (1) History of coating development Coatings used for cutting tools began with TiN coatings, and coating technology is widely used in many general-purpose products. Since strong cutting requires the use of coating tools with higher hardness and better wear resistance than TiN, TiCN and TiAlN coating materials have been developed. Due to the excellent properties of these coatings, their market has expanded rapidly. TiAlN coating has good oxidation resistance and is suitable for cutting of high hardness materials. TiCN coating has poor oxidation resistance, but has low frictional resistance and excellent anti-sticking performance. It is suitable for cutting of lower hardness materials. These two coatings have a tendency to be used separately around the HRC40. In recent years, the requirements for processing of heat-treated workpieces, high-hardness materials, and difficult-to-machine materials by cutting (or even dry cutting) have been increasing. In addition, the use of a coating material tool can cut the requirements from low hardness to high hardness. It is also very strong. In order to meet these requirements, it is being explored to develop coatings that are higher in grades than TiCN and TiAlN, and which are superior in wear resistance, oxidation resistance, and anti-sticking properties. It can be said that they have entered a new era of coating development. Japan JFE Precision Co., Ltd. has developed SX-2, which has excellent wear resistance and anti-sticking performance, SX-W for hard alloy tools and SX- for high-speed steel tools, which have significantly improved coating hardness and oxidation resistance compared to TiAlN coatings. H and other SX series coated tools are being commercialized. (2) Development trend of coating As mentioned above, TiAlN has been rapidly popularized in the cutting of high hardness materials. Since Al is added to TiN, the hardness and oxidation resistance of the coating are improved. The increase in coating hardness is due to the fact that the added Al does not destroy the cubic crystal structure of TiN and solid-melt into Al in the grain boundary. In recent years, attempts have been made to add a third trace element, continue to maintain the crystal structure, and further increase the proportion of Al. The improvement in oxidation resistance is due to the fact that Al is first oxidized on the surface of the coating to form a stable oxide (Al2O3), which acts as a protective layer. Thus, by solid-melting a plurality of elements in the crystallization, a part of the elements exerts a functional effect on the surface of the coating while obtaining a high-hardness coating layer, so that it is possible to obtain excellent characteristics. Therefore, there are many potentials for exploration in the development of coatings. 3 New generation AIP coated SX series (1) Basic design idea of ​​new coating The abrasion resistance of coating is the physical property measured at room temperature, reflecting only the wear resistance at room temperature. However, when the coated tool is actually used, its characteristics will inevitably change due to the softening and oxidation of the coating under high temperature cutting conditions. Table 3 shows the characteristics of some representative coatings at room temperature and elevated temperature. TiC and TiCN with high room temperature hardness will decrease in hardness at high temperatures. The high temperature hardness of the coating has a strong dependence on its chemical stability and oxidation resistance, and the properties of the resulting oxide itself also affect the wear resistance of the coating. The wear resistance test results of AlCrN coating show that the coating wear depth increases with the increase of temperature. However, the wear depth of the CrN coating at 700 ° C is much smaller than the wear depth of 500 ° C due to the improved wear resistance of the Cr oxide formed on the friction surface. When designing a coating for a coating tool used for high-hardness material cutting, dry cutting, etc., the bonding strength must be considered, and the high-temperature characteristics of the coating must be considered, especially the oxide formed to improve the oxidation resistance. effect. (2) Characteristics of SX series coatings JFE Precision Co., Ltd. of Japan developed SX-W coating for cemented carbide tools. Compared with TiAlN, the hardness and oxidation resistance of this coating material are greatly improved. The coating is coated on a cemented carbide end mill. When milling high hardness material (SKD11), the flank wear width is 1/3 of TiAlN coated end mill, the tool performance is greatly improved; milling low hardness For the material (50 carbon steel), the flank wear width is 1/2 of that of the TiAlN coated end mill. It can be seen that the SX series coating materials have a wide range of applications. “SX Prototyping†is a previously developed product with almost the same coating properties as SX-W coating at room temperature, but the cutting performance is not superior to TiAlN coating when milling high hardness and low hardness materials. It can be seen that the coating properties at room temperature are not in a simple proportional relationship with the cutting performance. Cutting tools require a comprehensive balance of coating characteristics. When cutting high hardness materials, oxidation resistance is one of the important characteristics; while cutting low hardness materials, the effect of oxidation resistance is reduced, and the influence of anti-sticking performance is increased. In addition, the balance between the hardness and toughness of the coating and the bond strength of the coating to the substrate is also very important. The way to achieve all of these elements at a high level is to conduct diversified, multi-layered research and development. SX-W and SX-H are a new generation of coatings that are diversified and multi-layered. Considering the difficulty in processing the material being machined, reducing the cost of cutting and protecting the environment, the importance of coating for cutting processing is becoming more and more important. The new generation of coating materials represented by SX-W will live up to expectations and play an important role. .