HiPulse technology - motivation Potential of technology Coating … · 2017. 9. 5. · HiPULSE technology is the answer on the demands of cutting tool market superior film properties

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Outline

• HiPulse technology - motivation

• Potential of technology

• Coating materials for Hardcoating service

• Cutting test results

• Conclusion


Motivation

• Requested properties on sputtered coatings for cutting tools: – dense coating morphology – higher hardness – lower residual stress – good adhesion – profitable coating deposition – higher thermal stability

Become possible with development of the new, innovative coating technology = HiPulse


Advantages of both technologies = HIPIMS

Arc high ionization large number of metal ions droplets

Sputtering lower ionization without metal ions extreme flexible smooth, without droplets

Motivation


Outline

• HIPIMS technology - motivation

• Potential of technology

• Coating materials for Hardcoating service

• Cutting test results

• Conclusion


HIPIMS = High Power Impulse Magnetron Sputtering

• HiPulse is a metal ion assisted PVD method • High ionization of target material

0 100 200 300 400 500 600 700 800 900

1000

0 5 10 15 20 25 30 35 40 45 50 time / ms

pow

er /

kW

HIPIMS Puls DC


Improved coating properties in comparison to conventional d.c. sputtering

• higher coating hardness at improved ductility (E module)

• optimized adhesion

• lower residual stress

• improved crystal structure

• denser coatings

• higher temperature and oxidation resistance


(Ti0,46Al0,54)N, 4x DC (Ti0,46Al0,54)N, 4x DC, 2x HIPIMS

Hardness: 34 GPa (+/- 4) Young‘s modulus: 377 GPa (+/- 14)

Hardness: 30 GPa (+/- 1,5) Young‘s modulus: 460 GPa (+/- 19)

Higher ductility at higher hardness

Coating properties


High performance coating materials for metal cutting Generations of coatings:

Super hard coating Supernitride Powernitride Hard coating

NEW


Coating module Coating material: HiPULSE 3 ± 1 µm Properties: Composition: (Al,Ti,Cr)N Coating structure: nanostructured Microhardness: > 30 GPa E-Modulus: 368 GPa Application temperature: 900°C Milling of materials difficult to machine (nickel based alloys, stainless steel) Cutting with coolant Dry cutting Hard cutting HSC HPC


Tool life increased by 65 %

• Application • material: X38CrMoV5-1, 1.2343, 50 HRC • tool: ball nose end mill, Ø 10 mm • operation: milling • parameter: vc= 190 m/min ft = 0,05 mm ap = 0,5 mm without coolant

• HARDCOATING solution • TiAlN, 3 µm: 380 min • HiPULSE 3 µm: 629 min

Milling of X38CrMoV5-1

TINALOX SN²

HIPIMS TINALOX SN²

0

100

200

300

400

500

600

700

tool

life

/min

HTL HiPulse: Case Study


Tool life increased 28 %

• Application • material: X5CrNi1810 (1.4301) tool: turning tool with insert CNMG1204 • operation: turning • parameter: vc= 200 m/min f = 0,25 mm/rev ap = 2,5 mm with coolant

• Hardcoating solution

• ALOX SN², 6 µm: tool life 7,6 min • HIPIMS ALOX SN², 6 µm: tool life 9,7 min

Turning of X5CrNi1810

0

1

2

3

4

5

6

7

8

9

10

Tool

life

(min

)

ALOX SN² HIPIMS ALOX SN²



Wear reduction of 50 %

• Application • material: Inconel 718 • tool: carbide end mill 12 mm, 4 tooth • operation: milling • parameter: vc= 40 m/min

ft = 0,1 mm ap = 4 mm ae = 2 mm milling distance: 3,5 m

• HARDCOATING solution • AlTiN, 3 µm: Flank Wear 0,1 • HiPulse, 3 µm: Flank Wear 0,053

Milling of Inconel 718

00.010.020.030.040.050.060.070.080.090.1

AlTiNHiPULSE

wea

r dep

th (m

m)



Coated end mill

Arc technology (competition)

HiPULSE- HSN2 CemeCon


Result milling (with coolant 113 m)

TiAlN - DC TiAlN - HiPULSE

HSN² - DC HSN² - HIPIMS

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HiPULSE technology is the answer on the demands of cutting tool market

superior film properties of HiPULSE compared to DC

+ improved adhesion

+ higher oxidation resistance

+ denser morphology

+ higher hardness/lower residual stress

increased efficiency of coating machine

outstanding cutting performance

+ wear resistance and tool life

+ surface quality

Conclusion

Slide Number 1Slide Number 2Slide Number 3Slide Number 4Slide Number 5Slide Number 6Slide Number 7Slide Number 8Slide Number 9HTL HiPulse: Case StudyHTL HiPulse: Case StudyHTL HiPulse: Case StudySlide Number 13Slide Number 14Slide Number 15

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HiPulse technology - motivation Potential of technology Coating … · 2017. 9. 5. · HiPULSE technology is the answer on the demands of cutting tool market superior film properties