目的 针对AlCrN/TiSiN涂层在高速干切削工况中切削温度高,刀具易发生氧化磨损的难题。提出“多层复合+预氧化”方法,利用电弧离子镀技术制备AlCrN/TiSiN涂层,并对涂层进行预氧化处理,在涂层表面原位形成稳定、致密的保护性氧化物薄层,制备出AlCrN/TiSiN/AlCrTiSiON多层复合涂层,阻止有害元素扩散,同时减少切削热向刀具传导,增强涂层的抗高温氧化性能和热稳定性,进而提升刀具涂层的抗氧化磨损和扩散磨损能力,提高刀具使用寿命和加工效率。方法 为验证预氧化处理对氧扩散行为的抑制作用并揭示其高温氧化失效机理,通过高温静态氧化实验、高温动态摩擦磨损实验和切削实验,对AlCrN/TiSiN/AlCrTiSiON涂层的高温氧化行为、高温摩擦学行为及切削性能进行评价。结果 经预氧化处理,涂层表面形成致密氧化物防护层,经不同温度的高温氧化实验,涂层中未生成新的氧化物相。随着氧化温度的升高,涂层硬度和弹性模量均呈先升高后降低的趋势,600 ℃高温氧化后涂层硬度达到最高值,为49.64 GPa。在高温摩擦实验中,随着摩擦温度的升高,AlCrN/TiSiN/AlCrTiSiON涂层中氧化物衍射峰强度提高,摩擦温度为700 ℃时,涂层磨损率降至最低值,为2.28×10-10 mm3/(N∙mm);摩擦温度为800 ℃时,涂层摩擦系数降至最低值,为0.63。经干铣削高硬淬火45钢试验,AlCrN/TiSiN/AlCrTiSiON多层复合涂层铣刀切削寿命是AlCrN/TiSiN涂层铣刀的3.46倍,铣削120 min时,AlCrN/TiSiN/AlCrTiSiON多层复合涂层铣刀切削温度比AlCrN/TiSiN涂层铣刀低68 ℃。结论 在纳米多层涂层表面制备预氧化防护层,可显著提升涂层在高温氧化环境下的结构稳定性,进而有效延长涂层刀具的服役寿命。
Abstract
To address the critical challenge of high cutting temperature and the consequent susceptibility of tools to oxidative wear when applying the AlCrN/TiSiN coating in high-speed dry cutting operations, this study proposes a "multilayer composite+pre-oxidation" strategy. Specifically, an AlCrN/TiSiN coating is deposited by arc ion plating, followed by a controlled pre-oxidation treatment. This process induces the in-situ formation of a stable, dense, and protective thin oxide layer on the coating surface, resulting in an AlCrN/TiSiN/AlCrTiSiON multilayer composite architecture. This functional oxide barrier serves a dual purpose: it impedes the inward diffusion of harmful elements such as oxygen into the underlying coating, while simultaneously reducing the conduction of cutting heat to the tool substrate. Consequently, this design significantly enhances the coating's high-temperature oxidation resistance and thermal stability, thereby bolstering its resistance to both oxidative and diffusion wear mechanisms. This ultimately leads to a substantial improvement in the tool's service life and machining efficiency.
To systematically verify the inhibitory effect of the pre-oxidation treatment on the oxygen diffusion behavior and to elucidate the underlying high-temperature oxidation failure mechanisms, a comprehensive evaluation is conducted. This evaluation integrates static high-temperature oxidation experiments, dynamic high-temperature friction and wear tests, and actual cutting experiments to assess the high-temperature oxidation behavior, tribological behavior, and cutting performance of the AlCrN/TiSiN/AlCrTiSiON coating. The experimental results demonstrate that the pre-oxidation treatment successfully generates a dense oxide protective layer on the coating surface. Crucially, following high-temperature oxidation experiments conducted across a range of temperatures, no new oxide phases are detected within the coating, indicating excellent phase stability. An analysis of the mechanical properties reveals that with increasing oxidation temperature, both the hardness and elastic modulus of the coating initially increase and then decrease. The coating achieves its peak hardness value of 49.64 GPa after oxidation at 600 ℃.
In high-temperature friction tests, the intensity of oxide diffraction peaks within the coating progressively increases with rising test temperature, indicating the formation of lubricious oxide phases that contribute to improved tribological performance. The minimum wear rate of the coating, measured at 2.28×10-10 mm3/(N·mm), is observed at friction temperature of 700 ℃. Furthermore, the minimum friction coefficient of 0.63 is obtained at 800 ℃. The effectiveness of this coating strategy is further validated through dry milling tests on hardened 45 steel. The results show that the tool life of the AlCrN/TiSiN/AlCrTiSiON multilayer composite coated milling cutter is 3.46 times longer than that of the conventional AlCrN/TiSiN coated cutter. After 120 minutes of continuous milling, the cutting temperature of the AlCrN/TiSiN/AlCrTiSiON multilayer composite coated cutter is measured to be 68 ℃ lower than that of the AlCrN/TiSiN coated cutter.
In conclusion, the fabrication of a pre-oxidized protective layer on the surface of a nanoscale multilayer coating significantly enhances its structural stability under high-temperature oxidizing environments, thereby effectively prolonging the service life of coated cutting tools.
关键词
电弧离子镀 /
AlCrN/TiSiN/AlCrTiSiON涂层 /
高温氧化行为 /
高温摩擦学行为 /
切削性能
Key words
arc ion plating /
AlCrN/TiSiN/AlCrTiSiON coating /
high-temperature oxidation behavior /
high-temperature tribological behavior /
cutting performance
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基金
京津冀基础研究合作专项（25JJJJC0019）; 天津市制造业高质量发展专项（25ZGSSSS00020）
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