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Current status and prospects of tool coating technology
Coating technology has become a major transformation in the machining industry. It involves applying a thin layer of refractory compounds onto the tool's substrate, which enhances its toughness and overall performance. This innovation has significantly improved processing efficiency, accuracy, and tool life while reducing costs, making coated tools a global focus.
**Current Status**
Since the introduction of the first generation of CVD-deposited TiC cemented carbide inserts in the late 1960s, coating technology has played a vital role in advancing cemented carbide tools. In the early 1980s, PVD-deposited TiN was successfully applied to high-speed steel tools, marking a breakthrough in their performance. Since then, coating technology has rapidly evolved, with more mature processes and broader applications. In Western industrialized countries, the proportion of coated indexable inserts increased from 26% in 1978 to 90% by 2005. Over 80% of tools used in new CNC machines are coated. Companies like Sandvik Coromant and Kennametal have over 85% coated inserts, and in the U.S., about 80% of carbide blades on CNC machines are coated. Similar trends are seen in Sweden and Germany, where coated turning tools exceed 70%. Japan and Russia are also leading in coating technology development. China started later but has made rapid progress, with many cities now having their own coating centers. While large Chinese tool manufacturers have coating machines, most are used for low-end products. Meanwhile, international coating companies have set up operations in China, taking advantage of the growing demand driven by advanced CNC technology and difficult-to-machine materials.
**New Developments in Coating Technology**
Throughout the evolution of CVD and PVD technologies, several key trends have emerged. Initially, the focus was on localizing coating equipment to meet market needs. Then, efforts shifted toward developing new coating components to improve processing efficiency. Finally, multi-layer coatings were introduced to provide comprehensive mechanical properties tailored for different applications such as cutting and drawing. Recent developments include:
1. **Diffusion of Film Materials**: Common materials like TiC, TiN, and Al₂O₃ have been replaced by advanced ternary coatings such as TiAlN, which can be adjusted for varying properties. Composite coatings, including TiN/NbN and TiN/CNx, enhance bonding strength and material compatibility. Multi-component coatings like TiAlN, TiAlCN, and CrSiN offer excellent wear resistance, low friction, thermal stability, and oxidation resistance.
2. **Soft Coating**: While early coatings focused on hardness, soft coatings like MoSâ‚‚, WSâ‚‚, and TaSâ‚‚ are now used for materials that cannot tolerate hard coatings, such as high-strength aluminum and titanium alloys.
3. **Nano-Coating**: Innovations in nano-coated tools allow for combinations of materials to meet specific performance needs. These coatings exhibit superior anti-friction, anti-wear, and self-lubricating properties, ideal for high-speed dry cutting. A representative example is an AlTiN/Si₃N₄ nanocomposite with a hardness of 45 GPa and thermal stability up to 1000°C.
PVD and CVD will continue to coexist due to their respective advantages. While PVD offers versatility, CVD remains superior for certain applications. Future developments may involve hybrid approaches, such as PCVD technology.
**Application of Coated Tools**
Coating technology is now widely used across industries, including machinery, electronics, aerospace, and food. It enables deposition on both metals and non-metals like ceramics, glass, and plastics. Its impact is evident in every sector of the economy, and it is commonly showcased at machine tool exhibitions worldwide.
**Key Considerations in Coating**
1. **Ideal Tool Material**: The base material must be of high quality, not just "qualified." Market inconsistencies require thorough inspection before selection.
2. **Hardness Inspection**: Proper heat treatment ensures the tool’s hardness is suitable for coating. For instance, high-speed steel tools below 65HRC or those above 68HRC may not benefit from coatings. Standards like JB/T8365-96 specify a minimum hardness of 2000HV for TiN-coated tools, but many market products fall short.
3. **Demagnetization Treatment**: Before coating, demagnetization is essential to avoid interference with the process.