Tribological behavior of Al–6.5%, –12%, –18.5% Si alloys during machining using CVD diamond and DLC coated tools

Bhowmick, S.; Banerji, A.; Alpas, A.T.

doi:10.1016/j.surfcoat.2015.08.073

Cited by 45 publications

(23 citation statements)

References 29 publications

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“…The carbon-based coating offers high wear resistance as well as high hardness with low friction. [1][2][3][4] However, after extensive use in machining with high cutting speed, the cutting tool will experience significant wear 5 which subsequently leads to non-uniformed delamination of coating. A recent study by Pervaiz et al 6 has reported that metal cutting also contributes to environmental effect where it generates waste stream outputs in the form of worn cutting tool.…”

Section: Introductionmentioning

confidence: 99%

“…A de-coating process is deemed efficient and superior when it is able to remove the coating without inflicting damage to the substrate. 7,8 De-coating is usually carried out by means of a wet chemical process, an oftentimes challenging procedure due to (1) the stringent control necessary to regulate reactions between chemical solutions, and ensure no excessive corrosion occurs to substrates and no hazard is posed to operators, and (2) proper disposal procedures necessary in disposing the waste or residue after the de-coating process is completed.…”

Section: Introductionmentioning

confidence: 99%

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Laser de-coating of hard DLC coatings from tungsten carbide cutting tool

Hassan

Mativenga

Rajab

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Laser irradiation de-coating is a promising new approach for effective coating removal of cutting tools. While this method has demonstrated feasibility for conventional coatings, its use and efficacy on lubricant coating is however yet to be ascertained. This paper reports on the results of excimer laser de-coating of hard DLC from DLC-coated tungsten carbide (WC) substrates. A range of fluence and pulse was studied to evaluate the effectiveness of the de-coating process. Result shows that laser parameters of 7 J/cm2 fluence, 400 pulse and 25 Hz frequency were found to yield optimum results in removing hard DLC coating of 3.2 μm thickness from WC substrates. The experimental work indicated successful laser de-coating of hard DLC coating without noticeable damage to the WC substrate. The capability of this new de-coating process is significant in the aerospace industry as it could facilitate re-grinding and recoating of drills thereby improving economics of manufacturing. The process windows could also be applied in the removal of DLC from other cutting tools and applications.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Laser de-coating of hard DLC coatings from tungsten carbide cutting tool

Hassan

Mativenga

Rajab

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Today, industries around the world demand high strength-low weight materials to suit typical engineering applications. Aluminium-silicon alloy is one such material and is extensively used in automobile and aerospace industries due to its low thermal expansion coefficient and high wear resistance (Bhowmick et al, 2015;Kang et al, 2016). Globally, various advanced manufacturing techniques such as spray forming (Raju and Ojha, 2014), rheocasting (Ri et al, 2016), and thixocasting (Shafizadeh et al, 2017) are currently being used in foundries to produce Al-Si alloy castings with acceptable engineering properties.…”

Section: Introductionmentioning

confidence: 99%

Deformation and fracture characteristics of complex Al-Si alloy during high speed forging under different processing conditions

Khemraj

Jha

Ojha

2019

IJMPT

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The feasibility of bulk processing of complex Al-Si alloy (Al-18Si-2.5Cu-0.6Fe) has been demonstrated in the present work. Open and closed die forging experiments have been performed using solid cylindrical billets under different conditions of working temperatures, aspect ratios and interfacial friction between top-bottom dies and test samples. The results so obtained, have been critically analysed and discussed to explain the deformation and fracture behaviour of the above Al-Si alloy. Results reveal that due to the presence of hard silicon and intermetallic particles in the alloy, the open die forging of the test sample generates severe surface cracks during deformation under cold and hot processing conditions. However, the high speed closed die forging of above complex Al-Si alloy at elevated temperatures show encouraging results. The forged component so produced is free from surface cracks and possess improved engineering properties.

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“…Hard DLC is mainly used as protective coatings for metallic surfaces that have to withstand high friction, corrosion, and/or elevated temperatures [5][6][7]. Most commonly, DLC coatings are deposited by Chemical Vapor Deposition (CVD) [8,9] or magnetron sputtering [10], and have micrometer thickness 2-10 µm [11].…”

Section: Introductionmentioning

confidence: 99%

“…On the other hand, thick (micrometer) DLC coatings are susceptible to delamination and may require a buffer layer to enhance their adhesion to the metallic surface [6].…”

Section: Introductionmentioning

confidence: 99%

An Experimental Study on Nano-Carbon Films as an Anti-Wear Protection for Drilling Tools

et al. 2017

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Carbon thin films of 50-100 nm thickness were synthesized by Pulsed Laser Deposition in vacuum at different laser fluences from 2 to 6 J/cm 2 . The deposited films were characterized by Raman spectroscopy for compositional assessment, scanning electron microscopy for morphology/thickness evaluations, and X-ray reflectivity for density, thickness, and roughness determinations. The films were~100 nm thin, smooth, droplet-free, made of a-C:H type of diamond-like carbon. The mechanical properties of synthesized films were studied by nanoindentation and adhesion tests. The films that were obtained at low laser fluences (2, 3 J/cm 2 ) had better mechanical properties as compared to those synthesized at higher fluences. The mean values of hardness were around 20 GPa, while the friction coefficient was 0.06. The deposition conditions of carbon thin films that displayed the best mechanical properties were further used to coat commercial drills. Both uncoated and coated drills were tested on plates that were made of three types of steel: Stainless steel 304, general use AISI 572 Gr 65 steel (OL60), and AISI D3 tool steel (C120). All of the drill edges and tips were studied by optical and scanning electron microscopes. The coated samples were clearly found to be more resistant, and displayed less morphological defects than their uncoated counterparts when drilling stainless steel and OL60 plates. In the case of C120 steel, carbon coatings failed because of the high friction between drill and the metal plate resulting in tip edges blunting that occurred during processing.

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Tribological behavior of Al–6.5%, –12%, –18.5% Si alloys during machining using CVD diamond and DLC coated tools

Cited by 45 publications

References 29 publications

Laser de-coating of hard DLC coatings from tungsten carbide cutting tool

Laser de-coating of hard DLC coatings from tungsten carbide cutting tool

Deformation and fracture characteristics of complex Al-Si alloy during high speed forging under different processing conditions

An Experimental Study on Nano-Carbon Films as an Anti-Wear Protection for Drilling Tools

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