Abstract
AlCrSiN films with optimized structure and various thickness were prepared by ion source-enhanced multi-arc ion plating technology on an M42 high-speed steel substrate and end-milling cutters in this work. The effects of different film thicknesses on the structure, properties, and cutting performance of the films were investigated. The results showed that the AlCrSiN films were comprised of a gradient multilayer structure including an AlCrN adhesion layer, two sequential AlCrSiN transition layers, and an AlCrSiN working layer. The main phase of the films was nanocrystalline (Cr, Al) N phase and amorphous Si3N4 phase as revealed by the TEM results. The AlCrSiN films with a thickness of 5.00 μm (T2) had lower surface roughness (~ 180 nm), higher adhesion (HF1) and toughness, better wear resistance, and superior cutting performance (14.0 m). The main wear mechanisms of the films during cutting were abrasive wear, adhesive wear, and oxidation wear. This study indicated that the improved adhesion and cutting performance of the coated tools could be obtained by designing the gradient multilayer structure and an appropriate film thickness.
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