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Nano-composite (NCD) and multi-layered (MLD) diamond coatings were deposited on cemented carbide tools using hot filament chemical vapour deposition (HFCVD) techniques. Appropriate annealings were conducted on the examined diamond coatings in order to be characterized by the same level of residual stresses. The crystalline structure of the employed diamond coatings was investigated by conducting Raman spectra. Inclined impact tests at ambient and elevated temperatures were carried out for assessing their temperature-dependent fatigue strength. Moreover, the wear behaviour of diamond coated inserts was investigating in milling aluminum foam. Raman spectra were also conducted on the treated diamond coatings for capturing potential crystalline changes developed due to the exercised thermal and dynamic mechanical loads during cutting. According to the attained results, the coexistence of sp2– and sp3-bonded phases in the cases of MLD diamond coatings results in an accelerated wear development, despite their structure capability to decelerate the crack propagation. As a result, nano-crystalline diamond coatings characterized only by sp3-bonded phase exhibit an improved wear behaviour. The cutting performance of the NCD coated inserts is further improved due to the enhanced tribological properties of the NCD coatings.

The cutting performance of PVD coated tools can be significantly improved by appropriate pre- and post- treatments of the substrates and coated surfaces respectively. Substrate pre-treatments aim, among others, at improving the coating adhesion. In this way, lower coating loads develop during cutting leading to a decelerated wear evolution. Furthermore, the potential to increase the wear resistance of coated tools via micro-blasting is presented. Micro-blasting parameters such as of grain material, pressure, dry or wet etc., affect significantly the superficial coatings' hardness and brittleness and in this way their wear behaviour. To check the effectiveness of all these methods, innovative coating's characterization procedures providing information concerning the film and substrate properties as well as adhesion are applied, thus reducing the required experimentation time.