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The paper breaks the general concepts and shows that pore formation is possible in anodic aluminum barrier oxide by anodizing of pure Al, and also presents the results of electrochemical anodizing in boric acid and citrate buffer aqueous solutions of homogeneous binary alloys AlCu (4 wt.%), AlZn (3 wt.%) and AlAg (5.2 wt.% and 16.2 wt.%). Barrier anodizing allowed obtaining Al2O3 thin films doped with copper, zinc and silver. The anodizing behavior and the effect of anodic current density on the charge were studied, and scanning electron microscopy, X-ray photoelectron spectroscopy and Auger electron spectroscopy analyses were performed. The doped alumina thin films, which are a mixture of Al2O3, Cu2O, ZnO, Ag2O, AgO and promising double metal oxides CuAlO2, AgAlO2 and ZnAl2O4, are promising for use as resistive switching, photoelectron, mechanical, photo-thermoelectric and fluorescence materials; sensors; and transparent conductive and photocatalyst films. [ABSTRACT FROM AUTHOR]

Jet electrodeposition has the characteristics of rapid deposition with high current density, but faces the problem of tip discharge, which causes a decrease in coating surface uniformity and flatness. In this paper, scanning jet electrodeposition was adopted to optimize the tip discharge. The different nanoparticles were mixed as the reinforcing phase of Ni-Co alloy coating. Nano-CeO2/Nip mixed particles enhanced Nickel-Cobalt composite coatings on 304 stainless steel by scanning jet electrodeposition. The morphologies, texture orientation, microhardness, coating adhesion, and corrosion resistance of Ni-Co-CeO2/Ni composite coatings were characterized. The addition of nano-mixed particles (CeO2/Nip) changed the morphology of Ni-Co-CeO2/Nip composite coating from large cellular protrusion structures to fine granular structures and improved the uniformity of the composite coating. Compared with Ni-Co alloy coating, the microhardness increased from 467.8 to 524.7 HV, the adhesion between the substrate and the coating increased from 20.6 to 28.9 N, and the corrosion current density decreased from 2.413 × 10−5 to 5.598 × 10−6 A·cm−2 in Ni-Co-CeO2/Nip (4 g/L) composite coating, indicating that nano-mixed particles (CeO2/Nip) improved the mechanical properties and corrosion resistance of Ni-Co alloy coating in scanning jet electrodeposition. [ABSTRACT FROM AUTHOR]

A nickel-based copper alloy known as Monel-400 is extensively applied in many industries including aerospace, marine engineering, and nuclear power generation, owing to its exceptional characteristics such as extreme tensile strength and toughness, excellent corrosion resistance, and the ability to retain shape even at extremely high temperatures. Traditional methods of drilling Monel-400 alloy are difficult due to quick tool wear and poor surface polishing, resulting in expensive machining costs. In this study, a technique called heat annealing was implemented to externally heat-treat the Monel-400 alloy material before the drilling process. Cutting force, surface roughness, and tool wear were used as the responses to investigate the effect of heat annealing and the drilling parameters on the machinability of Monel-400. The results revealed that the cutting force (Fz) and surface roughness (Ra and Rt) could be reduced by 33%, 31%, and 25%, respectively, after annealing at 700 °C compared to the results of the drilled Monel-400 at room temperature. It can be observed that the maximum improvement can reach 42% of Fz, 35% of Ra, and 59% of Rt while annealing Monel-400 at 1000 °C. A significant reduction was observed in the tool wear for machining the annealed material, which minimized the tooling and overall machining cost. Regarding the effects of the drilling process on the considered responses, the results revealed that the spindle speed has a greater effect on the cutting force, whereas the feed rate has the most significant effect on Ra. The significance of the drilling input parameters on the outputs is determined by analysis of the main effect plots and surface plots. Subsequently, the multi-objective genetic algorithm (MOGA) is used to identify the optimal parametric conditions for minimizing the cutting force and surface roughness of the drilled holes. The optimized values achieved via multi-objective optimization are the cutting force, Fz = 388–466 N, and the surface roughness, Ra = 0.17–0.19 μm and Rt = 3–3.5 μm, respectively. [ABSTRACT FROM AUTHOR]

This paper presents the results of the investigation of a multilayer TiAlSiN/AlSiN coating. A novel coating architecture with a period consisting of nanocomposite sublayers of TiAlSiN and AlSiN was developed. We discovered that the combination of a harder sublayer with a more elastic one allows for obtaining a suitable combination of superhardness and enhanced toughness. The coating was deposited by cathodic arc technology. The EDS, XRD, and XRS analyses revealed that the nanocomposite structure is composed of TiAlSiN and AlSiN nanocrystallites, with sizes of 12–13 nm and 4–5 nm, respectively. The nanograin phase is incorporated in an amorphous Si3N4 matrix. The achieved structure causes the presence of four factors contributing to the hardness increase: nanocomposition, solid solution, refinement hardening, and the formation of many interfaces. An instrumented indentation test was used to investigate the mechanical properties. The developed coating possesses a superhardness of 49.5 GPa and a low elastic modulus of 430 GPa, resulting in an improved elastic strain resistance of 0.11, a plastic deformation resistance of 0.58 GPa, and an elastic recovery of 68%. These results imply that the developed coating combines high stability with mechanical degradation under external influence and provides an improved ability to absorb energy at deformation before fracture, and high elastic recovery. The investigation of the effect of the period modulation on the structure, composition, and mechanical properties of the nanocomposite multilayer TiAlSiN/AlSiN coating showed that the superhardness was due to the nanocomposite and solid solution hardening rather than the increased number of interfaces. The demonstrated combination of superhardness with high elasticity and improved toughness determines the developed nanocomposite TiAlSiN/AlSiN coating as very suitable for industrial applications such as high speed and dry machining. [ABSTRACT FROM AUTHOR]

The high chemical activity, low thermal conductivity, and high strength of titanium alloys lead to severe tool wear during cutting. The coating applied to the tool surface insulates the effect of heat and chemical reactions. TiAlSiN coating and AlCrN coating are two representative coatings with excellent properties in TiN-based and CrN-based applications, respectively. Three types of nanocoatings—TiAlSiN monolayer, AlCrN monolayer, and TiAlSiN/AlCrN multilayer—were prepared, and the microstructure, mechanical properties, oxidation resistance, diffusion properties with titanium alloy, and cutting performance of the coatings were investigated utilizing SEM, TEM, XRD, TGA, GD-OES, nanoindentation, and scratching instruments. The hardness, elastic modulus, and adhesion strength of TiAlSiN/AlCrN multilayer coatings are between TiAlSiN monolayer and AlCrN monolayer coatings, which meet the "law of mixtures". Adhesion strength is the primary condition for cutting applications and should have a minimum threshold value. Ti and N elements are the most significant in the diffusion between coatings and titanium alloys. The nitride coating containing Cr aggravates the loss of N in contact with the titanium alloy. In addition, multilayer structural coatings can lead to more severe diffusion than monolayer coatings due to their inherent interlayer defects. Although diffusion between titanium alloys and coated tools is more severe than with other workpiece materials, the main factor affecting tool cutting life is still the H3/E*2 value determined by the hardness and modulus of elasticity together. [ABSTRACT FROM AUTHOR]

Ti1-xAlxN coating is formed by replacing some Ti atoms in TiN with Al atoms, and their properties are closely related to Al content (0 < x < 1). Recently, Ti1-xAlxN-coated tools have been widely used in the machining of Ti-6Al-4V alloy. In this paper, the hard-to-machine material Ti-6Al-4V alloy is used as the study material. Ti1-xAlxN-coated tools are used for milling experiments. The evolution of the wear form and the wear mechanism of Ti1-xAlxN-coated tools are studied, and the influence of Al content (x = 0.52, 0.62) and cutting speed on tool wear are analyzed. The results show that the wear on the rake face changes from the initial adhesion and micro-chipping to coating delamination and chipping. Wear on the flank face varies from the initial adhesion and grooves to boundary wear, build-up layer, and ablation. The main wear mechanisms of Ti1-xAlxN-coated tools are dominated by adhesion, diffusion, and oxidation wear. Ti0.48Al0.52N coating protects the tool well and extends its service life. [ABSTRACT FROM AUTHOR]

Inconel 718 is considered the most widely adopted nickel-based superalloy, and drilling of this alloy is always challenging for researchers. Cemented carbide twist drills have been evaluated in the drilling of this alloy by changing the cutting environment or by varying the tool geometry. In the latter case, the cutting speed has been extended from 30 m/min to 60 m/min when drills are micro-textured or ground. In this study, contrary to cemented carbide twist drills, for the first time, inserts named stepped (central) and peripheral (wiper) are evaluated in the drilling of this alloy. The central insert is designed for balanced forces, while the peripheral is a wiper insert designed for better surface finish. Drilling experiments are conducted in flood cooling conditions with a 12 mm diameter twist drill equipped with novel stepped and wiper inserts at varying cutting speeds (25, 35, and 45 m/min) and feed rates (0.04, 0.06, and 0.08 mm/rev). At a cutting speed (Vc) of 25 m/min and feed rate (f) of 0.04 mm/rev, 25 holes are drilled with roughness (Ra) values ranging from 0.40 µm to 0.60 µm, which represents a significant increase in the number of holes per drill and improved surface finish over to previous work. The new inserts showed almost three-fold longer tool life compared to a standard drill bit at a higher Vc of 45 m/min and 0.04 mm/rev f with an Ra between 0.22 µm to 0.43 µm, which is deemed acceptable for aerospace applications. In addition, minimal surface and sub-surface defects were observed, eliminating the need for a post-drilling finishing operation; therefore, a one-step drilling operation was achieved. [ABSTRACT FROM AUTHOR]

Coatings are now frequently used on cutting tool inserts in the metal production sector due to their better wear resistance and heat barrier effect. Protective hard coatings with a thickness of a few micrometers are created on cutting tools using physical or chemical vapor deposition (PVD, CVD) to increase their application performance. Different coating materials are utilized for a wide range of cutting applications, generally in bi-or multilayer stacks, and typically belong to the material classes of nitrides, carbides, carbonitrides, borides, boronitrides, or oxides. The current study examines typical hard coatings deposited by PVD and CVD in the corresponding material classes. The present state of research is reviewed, and pioneering work on this subject as well as recent results leading to the construction of complete "synthesis–structure–property–application performance" correlations of the different coatings are examined. When compared to uncoated tools, tool coatings prevent direct contact between the workpiece and the tool substrate, altering cutting temperature and machining performance. The purpose of this paper is to examine the effect of cutting-zone temperatures on multilayer coating characteristics during the metal-cutting process. Simplified summary and comparisons of various coating types on cutting tools based on distinct deposition procedures. Furthermore, existing and prospective issues for the hard coating community are discussed. [ABSTRACT FROM AUTHOR]

Laser-Induced Thermionic Vacuum Arc (LTVA) provides a better way to produce uniform metallic thin films than the classical Thermionic Vacuum Arc (TVA) method. In Ti-doped chromium thin films produced using LTVA, the amorphous chromium is superimposed with small bcc chromium nanoparticles. These amorphous/crystalline structures with small crystallites induce lower roughness and electrical resistivity, reducing electron–phonon scattering and increasing charge transport across LTVA thin films. A significant shift in resistivity for the LTVA samples is observed due to electron scattering on the phonon–crystalline structures in the TVA samples which exhibit larger crystallites. Meanwhile, the wettability measurements reveal a higher contact angle, resulting in a lower surface free energy and consecutively lower dissociation energy for the LTVA-produced thin films than the TVA samples. [ABSTRACT FROM AUTHOR]

The ideal cutting-tool coating material is characterized by unique chemical and physical properties to achieve excellent cutting performance, a good thermal barrier effect, and a high-quality machined surface. Diamond-like carbon (DLC) coating, as a kind of cutting-tool coating material, has been used in cutting various materials due to its low coefficients of friction and thermal expansion, high hardness, and good chemical inert and thermal conductivity. This article mainly focuses on the modification methods for the DLC coating and their application in machining different materials. Firstly, the methods employed to improve the mechanical properties of DLC coating are reviewed and analyzed, including the multilayer structure design, transition layer, and doping other elements. Secondly, the machining performances of DLC-coated tools in the application of different materials are summarized. This review provides knowledge of modification mechanisms regarding DLC coating and its effects on mechanical properties. For machining different materials, it provides a reference to make a suitable selection and design of DLC coating to obtain better machining performance. [ABSTRACT FROM AUTHOR]