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THE DEVELOPMENT OF AN INDUSTRIAL PRODUCTION PROCESS FOR WC COATING FOR HS TOOLS AT LOW TEMPS & OF WEAR RESISTANT COATIN G & OPTIMISATION OF PVD PROCESS ON HSTOOLS

Objective

1 Development and optimization of new wear-resistant PVD coatings on differnet types of HSS tools. 2 Optimization double treatment of plasma nitriding and PVD process. 3 Development of an industrial low temperature CVD process for WC CVD equipment. 4 Jobshop comparisons between different coated HSS tools. 5 Application trials and jobshop comparisons between different coated hot-working steel tools. achievements to date Objectives 1-2: A Choice, characterization and classification of different new PVD mono and multilayer coatings. Objective 4: B Developing and setting-up of different machinability laboratory tests for the following tools: a) HSS Drills; b) HSS Form tools; c) HSS End mills. Objective 3: C Design and construction of a hot-wall CVD reactor. D Delivery, assembly and testing of CVD reactor. E W2C coating procedure for secondary security provisions.
The achievements of the research so far are:
choice, setting up and optimisation of different new physical vapour deposition (PVD) coatings;
developing and setting up of different machinability tests, optimisation of the machining cycle parameters for the different coated tools, setting up and organisation of different coated tools tested;
design and construction of a hot wall chemical vapour deposition (CVD) reactor W2C coating, optimisation of process parameters, secondary security provisions;
realisation and characterisation of different hot working steel tools, setting up and organisation of different application trials.

The aims of the project were to develop new monolayer and multilayer coatings with an industrial physical vapour deposition (PVD) process and to develop a chemical vapour deposition (CVD) process based on the already known tungsten carbide coatings. This latter process should have the following characteristics: uniform coating thickness, maximum operating temperature of 500 C, smooth surface coating, strong bonding between substrate and coating and be an environmentally clean process.
Titanium aluminium nitride and titanium hafnium nitride coatings have been developed and compared with standard titanium nitride coatings on drills, form tools and end mills. The titanium aluminium nitride is very good for drill tools and form tools but only at very high speed. The titanium hafnium nitride coating is better than the standard titanium nitride coating only for end mills.
Tungsten carbide layers have been made on a development scale at coating temperatures of less than 500 C. Great care is required over the control of the carbon source. Nickel (phosphide based) was found to be the most satisfactory interlayer to promote adhesion between steel and the tungsten carbide coating.
AN INITIAL OBJECTIVE OF THE PROJECT IS THE STUDY AND DEVELOPMENT OF NEW SINGLE AND MULTILAYER WEAR-RESISTANT COATING MATERIALS FOR SUBSTRATES OF HSS USING AN INDUSTRIAL PVD PROCESS. IN PARTICULAR NEW COATINGS WILL BE STUDIED FOR USE IN SPECIFIC APPLICATIONS AND WITH BETTER PERFORMANCE THAN STANDARD TIN COATINGS. THE COATINGS WILL BE PRODUCED WITH "PVD ARC EVAPORATION REACTIVE ION PLATING" RESEARCH EQUIPMENT, INITIALLY ON SAMPLES AND TOOLS MADE WITH DIFFERENT HSS MATERIALS (M2, M35, ASP30, ETC...)
THE AIM IS TO REALISE AND OPTIMIZE THE QUALITY OF THE LAYERS BY THE DOUBLE TREATMENT OF PLASMA NITRIDING AND PVD PROCESS ON DIFFERNENT HSS TOOLS.
THE COATING QUALITY WILL BE EXAMINED WITH LABORATORY QUALITY CONTROL AND THE COATINGS PRODUCED WILL BE OPTIMIZED WITH DIFFERENT MACHINABILITY TESTS ON DIFFERENT NEW COATINGS CLASSIFIED IN ACCORDANCE WITH THE MEASURED CHARACTERISTICS, AND THE OPTIMIZATION OF THE RESPECTIVE COATING CYCLES ON DIFFERENT HSS TOOLS.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

Consiglio Nazionale delle Ricerche (CNR)
Address
Via Frejus 127
10043 Orbassano Torino
Italy

Participants (4)

ARCHER TECHNICOAT LTD
United Kingdom
Address
Unit E Progress Road, Sands Industrial Estate
DORRENBERG EDEL
Germany
INNOVATIQUE
France
Metec Tecnologie
Italy
Address
Via Vinzaglio 14
10121 Torino