Research Initiation Award: Multi-layer Composite Coatings for High Speed Machining

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The object of the project is to develop multilayer composite coatings on carbide tool inserts for high speed machining of steel and cast iron. Nonequilibrium processing using laser physical vapor deposition will be employed. A multitarget, high vacuum chamber with facilities to maintain selective environment and in- situ process the coatings has been designed and constructed. Titanium carbide will be deposited on tungsten carbide tool insert to form and initial adherent coating. Multilayer composite coatings will be developed. Laser parameters, thickness and number of the layers of the coatings will be optimized to achieve high quality coatings. The coatings will be characterized using modern analytical techniques to determine second phase formation, interdiffusion, segregation, and epitaxial nature of the interface. Mechanical properties of the coatings will be evaluated. The coated tools will be tested in high speed machining to determine the wear and failure mechanisms. The project should lead to the development of coatings for cutting tools with improved wear resistance which should allow increased productivity in machining.