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Recent Advances, Applications and Challenges on Coated Tools for Machining...
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Recent Advances, Applications and Challenges on Coated Tools for Machining Processes

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 October 2023) | Viewed by 5265

Special Issue Editor

Dr. Gustavo F. Pinto

E-Mail Website
Guest Editor
1. ISEP - School of Engineering, Polytechnic Institute of Porto, 4249-015 Porto, Portugal
2. INEGI - Science and Innovation in Mechanical and Industrial Engineering, 4200-465 Porto, Portugal
Interests: manufacturing processes; CDV; PVD; coating; numerical simulation; material properties; microhardness; microstructures; hard coatings; wear, surface integrity
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

With globalization and technological evolution at a crazy speed, improving the characteristics of materials is essential to respond to new arising challenges. For the evolution of materials to keep up with the demand, it is very important to continue with studies on ways to create better advanced coatings, namely discovering new materials combinations, new multilayered structures, and graded coatings. Improving the characteristics of materials has been widely studied, as have coating techniques to offer combinations that in normal cases would not be possible in a single material. Thus, there are several interesting topics being developed every day. This Special Edition aims to bring together the latest advances through original and high-quality work, capable of disclosing new developments in coating processes and machining results.

Dr. Gustavo Filipe Pinto
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • manufacturing processes
  • CDV
  • PVD
  • coating
  • numerical simulation
  • material properties
  • microhardness
  • microstructures
  • hard coatings
  • wear, surface integrity

Published Papers (4 papers)

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Research

15 pages, 12672 KiB  
Communication
Hard and Highly Adhesive AlMgB14 Coatings RF Sputtered on Tungsten Carbide and High-Speed Steel
by Alexander M. Grishin and Vadim V. Putrolaynen
Materials 2023, 16(21), 6930; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16216930 - 28 Oct 2023
Viewed by 959
Abstract
We report a new industrial application of aluminum magnesium boride AlMgB14 (BAM) coatings to enhance the hardness of tungsten carbide ceramic (WC-Co) and high-speed steel tools. BAM films were deposited by RF magnetron sputtering of a single dense stoichiometric ceramic target onto [...] Read more.
We report a new industrial application of aluminum magnesium boride AlMgB14 (BAM) coatings to enhance the hardness of tungsten carbide ceramic (WC-Co) and high-speed steel tools. BAM films were deposited by RF magnetron sputtering of a single dense stoichiometric ceramic target onto commercial WC-Co turning inserts and R6M5 steel drill bits. High target sputtering power and sufficiently short target-to-substrate distance were found to be critical processing conditions. Very smooth (6.6 nm RMS surface roughness onto Si wafers) and hard AlMgB14 coatings enhance the hardness of WC-Co inserts and high-speed R6M5 steel by a factor of two and three, respectively. Complete coating spallation failure occurred at a scratch adhesion strength of 18 N. High work of adhesion and low friction coefficient, estimated for BAM onto drill bits, was as high as 64 J/m2 and as low as 0.07, respectively, more than twice the surpass characteristics of N-doped diamond-like carbon (DLC) films deposited onto nitride high-speed W6Mo5Cr4V2 steel. Full article
(This article belongs to the Special Issue Recent Advances, Applications and Challenges on Coated Tools for Machining Processes)
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Graphical abstract

24 pages, 9508 KiB  
Article
Study on the Micro-Abrasion Wear Behavior of PVD Hard Coating under Different SiC Abrasive Particles/Distilled Water Ratios
by Andresa Baptista, Gustavo F. Pinto, Vitor F. C. Sousa, Francisco J. G. Silva and Filipe Fernandes
Materials 2023, 16(8), 2939; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16082939 - 07 Apr 2023
Cited by 1 | Viewed by 1084
Abstract
Microscale abrasion has been intensively used to study the wear behavior o several hard coatings, enabling the observation of different wear mechanisms. Recently, a study arguing whether the surface texture of the ball could influence the dynamics of abrasive particles throughout the contact [...] Read more.
Microscale abrasion has been intensively used to study the wear behavior o several hard coatings, enabling the observation of different wear mechanisms. Recently, a study arguing whether the surface texture of the ball could influence the dynamics of abrasive particles throughout the contact was presented. In this work, the influence of the abrasive particles concentration able to change the texture of the ball was studied to understand its influence on the wear modes—rolling or grooving. Thus, tests were carried out using samples with a thin coating of TiN, deposited using the Physical Vapor Deposition (PVD) technique, and AISI 52100 steel balls etched over 60 s to induce a change in their texture and roughness were used. Three abrasive slurries were prepared with black silicon carbide (SiC) particles (average particle size of 4 μm) with different concentrations, 0.25, 0.35, and 0.45 g/cm3. The rotation speed used in the tests was 80 rpm and the normal loads applied in the study were 0.2 N and 0.5 N, and 1 N. After the wear tests, the coated samples and tracks on the surface of the balls were observed by SEM and 3D microscopy to understand the abrasive particle dynamics, evaluating the wear mode transition as well as the function of both applied load and slurry concentration. The tracks in the balls showed particles embedded on their surface. A lower concentration of abrasion was conducted to higher specific wear rate. Moreover, a predominant two-body wear mechanism was induced when the abrasive concentration was increased. There was an increase in the roughness of the scar and the surface of the balls with an increase in the abrasive particles’ concentration. Full article
(This article belongs to the Special Issue Recent Advances, Applications and Challenges on Coated Tools for Machining Processes)
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20 pages, 12411 KiB  
Article
Effect of the Granularity of Cubic Boron Nitride Vitrified Grinding Wheels on the Planar Technical Blades Sharpening Process
by Bartosz Zieliński, Krzysztof Nadolny, Wojciech Zawadka, Tomasz Chaciński, Wojciech Stachurski and Gilmar Ferreira Batalha
Materials 2022, 15(22), 7989; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15227989 - 11 Nov 2022
Cited by 1 | Viewed by 1378
Abstract
The most widely used method for shaping technical blades is grinding with abrasive tools made of cubic boron nitride (cBN) grains and vitrified bond. The goal of this work was to determine the effect of grinding wheel grain size (cBN grain number according [...] Read more.
The most widely used method for shaping technical blades is grinding with abrasive tools made of cubic boron nitride (cBN) grains and vitrified bond. The goal of this work was to determine the effect of grinding wheel grain size (cBN grain number according to FEPA standards: B126, B181 and B251), kinematics (grinding with the circumference, face and conical surface of the wheel) and feed rate (vf = 100; 150; 200 mm/min) on the effects of the grinding process evaluated by the cutting force of the blade after machining F, blade surface texture parameters (Sa, St, Smvr, Str, Sdq, Sdr and Sbi) as well as blade surface morphology. An analysis of output quantities showed that grinding wheels made of B181 cBN grains are most favorable for shaping planar technical blades of X39Cr13 steel in the grinding process. Full article
(This article belongs to the Special Issue Recent Advances, Applications and Challenges on Coated Tools for Machining Processes)
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22 pages, 8483 KiB  
Article
Effect of Pro-Ecological Cooling and Lubrication Methods on the Sharpening Process of Planar Blades Used in Food Processing
by Bartosz Zieliński, Krzysztof Nadolny, Wojciech Zawadka, Tomasz Chaciński, Wojciech Stachurski and Gilmar Ferreira Batalha
Materials 2022, 15(21), 7842; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15217842 - 07 Nov 2022
Cited by 3 | Viewed by 1345
Abstract
This work presents the results of an experimental study of the sharpening of planar technical blades used in the fish processing industry. Sharpening was carried out in the grinding process using several environmentally friendly methods of cooling and lubricating the machining zone (MQL [...] Read more.
This work presents the results of an experimental study of the sharpening of planar technical blades used in the fish processing industry. Sharpening was carried out in the grinding process using several environmentally friendly methods of cooling and lubricating the machining zone (MQL method, CAG nozzle, hybrid method that is a combination of MQL and CAG methods, as well as WET flooding method as reference). The purpose of the research was to determine the possibility of reducing the negative environmental impact of the sharpening process of technical blades by minimizing the expenditure of coolant. The application of the MQL method and the hybrid MQL + CAG method provided a very good realization of the lubricating function so that the share of friction of dulled cutting vertices against the workpiece surface is reduced, which manifests itself in the reduction of the grinding force and the correlated grinding power. In the case of grinding under cooled compressed air delivery conditions, the average cutting force was as much as 91.6% higher (F = 22.63 N) compared to the result obtained for the most favorable flooding method, demonstrating the insufficient quality of the blade shaped under such conditions. A comprehensive comparison of test results on grinding power gain, cutting force and surface texture suggests that the most favorable sharpening results were obtained using the environmentally friendly MQL method of cooling and lubricating the grinding zone. Full article
(This article belongs to the Special Issue Recent Advances, Applications and Challenges on Coated Tools for Machining Processes)
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