Effect of PVD films wet micro-blasting by various Al2O3 grain sizes on the wear behaviour of coated tools

Abstract

Micro-blasting on PVD films has been documented, among others, as an efficient method for inducing compressive stresses, thus for increasing the coating hardness and potentially tool life of coated tools. Since contradictory results have been registered concerning the efficiency of wet micro-blasting on coated tools for improving the wear behaviour, the paper aims at explaining how this process can be successfully applied for post-treatment of PVD films. In this context, the employed conditions such as pressure and grain size affect significantly the wear resistance of the micro-blasted coated tools.In the described investigations, TiAlN coatings were post-treated through wet micro-blasting by Al2O3 abrasives of various grains' diameter. Abrasion mechanisms after micro-blasting were investigated by roughness measurements. Nanoindentations on micro-blasted film surfaces at various pressures revealed the influence of this process on coating superficial hardness. The related residual stress changes were estimated considering the film yield stress alterations, which were analytically determined, based on nanoindentation results. Nano-impact tests were conducted for investigating the effect of the developed film compressive stresses at certain micro-blasting pressures and grain sizes on the film's brittleness. To monitor film thickness and cutting edge radius changes of coatings subjected to micro-blasting, ball cratering tests and white light scans were carried out respectively. In this way, micro-blasting conditions for improving the film hardness, without revealing the substrate in the cutting edge region, were detected. Finally, the wear behaviour of coated and variously wet micro-blasted tools was investigated in milling of hardened steel.