2004 Mechanical strength improvement of electrical discharge machined

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ThinSolidFilms447–448(2004)258–2630040-6090/04/$-seefrontmatterᮊ2003ElsevierB.V.Allrightsreserved.doi:10.1016/S0040-6090Ž03.01062-9

MechanicalstrengthimprovementofelectricaldischargemachinedcementedcarbidesthroughPVD(TiN,TiAlN)coatings

B.Casas,A.Lousa,J.Calderon,M.Anglada,J.Esteve,L.Llanes*abaaba,´DepartamentdeCienciadelsMaterialsiEnginyeriaMetallurgica,ETSEIB,UniversitatPolitecnicadeCatalunya,Barcelona08028,Spaina`´`DepartamentdeFısicaAplicadaiOptica,UniversitatdeBarcelona,Barcelona08028,Spainb`´

AbstractElectricaldischargemachining(EDM)isanalternativeshapingrouteformanufacturingcomplexcomponentshapesofhardandbrittlematerialsasWC–Cocementedcarbides(hardmetals).However,itresultsinaheat-affectedsurfacelayerwithpoorsurfaceintegritythatoftenleadstomechanicaldegradationofthesematerials.Thisworkfocusesonassessingthefeasibilityofphysicalvapordeposition(PVD)ofhardcoatingsasatechniqueforimprovingsurfaceintegrityandmechanicalstrengthofEDMedhardmetals.Indoingso,theinfluenceofPVDofTiNandTiAlNcoatingsontheflexuralstrengthofcementedcarbidessubstratesshapedusingmulti-passsequentialEDMwasinvestigated.Forcomparisonpurposes,coatingeffectsonareferencesurfaceconditionattainedthroughgrindingandpolishingusingdiamondasabrasivewerealsoevaluated.ExperimentalresultsshowthathardcoatingdepositionmarkedlydecreasesthelesseningeffectofEDMonthefractureresistanceofhardmetals.However,noflexuralstrengthdifferencesbetweencoatedanduncoatedabrasive-machinedsamplesarediscerned.Themechanicalcharacterizationstudieswerecomplementedbydetailedfractographicexaminationandtheresultswereanalyzedbylinear-elasticfracturemechanics.Itisconcludedthat,althoughcoatedEDMedcementedcarbidesexhibitaneffectivelylargercriticaldefectsize,amechanicalstrengthimprovementisfinallyachievedbecauseanovercompensatingeffectascribedtobeneficialchangesonintrinsicseverity(nature)ofthecriticalflawandresidualstressstateatthesurface.ᮊ2003ElsevierB.V.Allrightsreserved.

Keywords:Electricaldischargemachining(EDM);PVD(TiN,TiAlN)coatings;Cementedcarbides;Mechanicalstrength

1.IntroductionOwingtotheiroutstandingcombinationofhardness,strengthandwearresistance,advancedceramicsarewidelyusedasstructuralcomponentsandwear-resistantparts(includingtoolsanddies)inanextensiverangeofengineeringfields.Manyoftheseapplicationsofteninvolveextrememechanicaldemandsatthesurface;hence,qualityandintegrityofsurfacefinishresultingfrommanufacturingprocessesmayhaveasignificantimpactonproductperformance.Fromthisviewpoint,alargenumberofstudieshavefocusedondocumentingandunderstandingsurfaceintegrity–mechanicalresponserelationshipsforthesematerials(e.g.Refs.w1,2x).However,theseeffortshavebeenmainlyconcen-tratedonhardmachining(i.e.grinding,honingandlapping)effectsandinformationconcerningnon-abra-*Correspondingauthor:Tel.:q34-934011083;fax:q34-934016706.E-mailaddress:luis.miguel.llanes@upc.es(L.Llanes).siveshapingprocessesisquitescarce.Thislackinknowledgeisofgreatinterestforapplicationswhereprecise,intricateandcomplexgeometriesareprimarydesignrequirementsand,therefore,non-traditionalmachiningroutesaremandatoryassurfaceshapingandfinishingprocesses.Thisworkfocusesonthestudyofsurfaceintegrityeffectsresultingfromelectricaldis-chargemachining(EDM),oneofthemostimportantabrasionlessmachiningmethodsforceramics.EDMisbasedonthethermalerosionofelectricallyconductivematerials(electricalresistivitythresholdval-uesrangingfrom100to300Vcmw3,4x).Itisgivenbymaterialremovalthroughseriesofcontrolledelectricalsparksoccurringbetweentoolandworkpiecew5x.BecauseEDMdoesnotinvolveanyphysicalcontactbetweenelectrodes,itcanbeperformedregardlessofthehardnessandstrengthofthework-materials.How-ever,thermalactionofEDMprocessisknowntoyieldarelativelypoorsurfaceintegrity,includingcraters,microcracksandunfavorableresidualstresses,ofthe259B.Casasetal./ThinSolidFilms447–448(2004)258–263machinedcomponents(e.g.Refs.w3,6x).Consequently,EDMofelectroconductiveceramiccomposites(ZrOyNbCw7x,AlOyCrCw8x,SialonyTiNw9x,WCyCo2332w6,10x,AlOyTiCw11x,SiNyTiCw11x,andAlOy

233423

TiCyMoyNiw12,13x)resultsinapronounceddecrease

offracturestrength,ascomparedtothereferencevaluesevaluatedformaterialsconventionallymachined,i.e.usingdiamondasabrasive.Althoughthisshortcominghasbeenreducedinrecentyearsbythedevelopmentofadvancedpulse-typegeneratorsandtheimplementationofmulti-stepsequentialEDM,asevaluatedbymeansofcontact-relatedparameterssuchasscratchresistancew14xandadhesionstrengthw15x,similarqualitative

improvementonothersurfacesensitiveproperties,i.e.fractureresistanceofhardandbrittleceramics,mayrequireadditionalactions.Amongthem,post-EDMsur-facetreatmentseitherbymechanicalmeans(ultrasonicmachiningandabrasiveblastingonceramiccompositesw11–13x)ormaterialsurfacedeposition(coatingson