Abstract
The paper proposes a classification of adaptive materials and coatings for tool purposes, showing the ability to adapt to external heat and power influences, thereby improving tool life. Creating a cutting tool made of composite powder high speed steels containing refractory TiC, TiCN, and Al2O3 compounds for milling 41CrS4 steel demonstrated the effectiveness of the adaptive materials. The tool material characteristics under the external loads’ influence and the surface layer adaptation to the heat–power exposure conditions were shown by the temperature field study using a semiartificial microthermocouple method (the level of fields is reduced by 20%–25% for 80% HSS + 20% TiCN), frictional interaction high-temperature tribometry (the coefficient of friction did not exceed 0.45 for 80% HSS + 20% TiCN at +20 and 600 °C), laboratory performance tests, and spectrometry of the surface layer secondary structures. Spectral analysis shows the highest spectrum intensity of TiC2 after 5 min of running in. After 20 min of milling (V = 82 m/min, f = 0.15 mm/tooth), dicarbide decomposes and transits to thermally stable secondary phase films of good lubricity such as TiO (maximum) and TiN (partially). There was an increase in tool life of up to 2 times (>35 min for 80% HSS + 20% TiCN), and a decrease in the roughness of up to 2.9 times (Ra less than 4.5 µm after 25 min of milling).
Highlights
It is necessary to design, create, and use innovative materials with an improved complex of physical, mechanical, and operational properties based on structural and tool materials, ceramics, and topocomposites to ensure improved performance of critical engineering products operating in difficult and variable conditions associated with the impact of increased thermal and power loads that cause high wear rates of contact surfaces
Creating a cutting tool made of composite powder high speed steels containing refractory TiC, TiCN, and Al2O3 compounds for milling 41CrS4 steel demonstrated the effectiveness of the adaptive materials
Among some known shape memory alloys used in mechanical engineering, an intermetallic compound based on titanium nickelide (Ni-Ti system) has the maximum thermal cyclic strength, but its hardness and heat resistance are insufficient for use as a material for the cutting part of the tool [66]
Summary
It is necessary to design, create, and use innovative materials with an improved complex of physical, mechanical, and operational properties based on structural and tool materials, ceramics, and topocomposites (materials with functional coatings) to ensure improved performance of critical engineering products (elements of aviation equipment, power plants, turbocompressors, metalworking tools, and others) operating in difficult and variable conditions associated with the impact of increased thermal and power loads that cause high wear rates of contact surfaces. Zekonyte et al [15] researched transition metal dichalcogenides (self-adaptive W–S–C coatings), which belong to a small family of solid lubricants with potential to produce an ultralow friction state using friction force microscopy These materials form well-oriented films on the sliding surface with a thickness of 10 nm with a decrease in friction coefficient when the load increases. The novelty of the work is research of adaptive coatings of HSS + TiC, TiCN, and Al2O3 additives systems under conditions of 41CrS4 steel milling at normal temperature and in the conditions of elevated temperatures (600 ◦C), classification of adaptive materials and coatings, and creating a cutting tool made of composite powder high speed steels containing refractory compounds.
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