Advertisement

Al2O3/ZrO2-8Y2O3 and (Cr,Ti)AlSiN tool coatings to influence the temperature and surface quality in friction-spinning processes

  • Wolfgang Tillmann
  • Alexander FehrEmail author
  • Dominic Stangier
  • Markus Dildrop
  • Werner Homberg
  • Benjamin Lossen
  • Dina Hijazi
Production Process
  • 21 Downloads

Abstract

Friction-spinning is an incremental forming process, which is accompanied by complex thermal and mechanical loads in the tool and the formed part. To influence the process temperature, two main process parameters, i.e. the rotation speed and the feed rate, can be adapted. With the objective to improve the tool performance and the quality of the workpiece, this study focuses on a coating concept for friction-spinning tools made of high speed steel (HS6-5-2C, 1.3343). Atmospheric plasma sprayed (APS) Al2O3 and ZrO2-8Y2O3 coatings serve as a thermal insulator, while physically vapor deposited (PVD) Ti16.7Al21.8Si7.9N and Cr18.7Al22.2Si7.5N films are applied to increase the hardness of the tools. In addition, duplex coatings, combining the APS and PVD technique, are synthesized to influence both the heat transfer and the tribological properties of friction-spinning tools. Subsequently, all coated tools are tested in a friction-spinning process to form flanges made of AW-6060 (AlMgSi—3.3206) tube materials. The tool temperatures are determined in situ to investigate the impact of the tool coating on the process temperature. Compared to an uncoated tool, the alumina and zirconia coatings contribute to a reduction of the tool temperature by up to half, while the PVD films increase the hardness of the tool by 20 GPa. Furthermore, it is shown that the surface quality of thermally sprayed or PVD coated tools is directly related to the surface roughness of the resulting workpiece.

Keywords

Friction-spinning Thermal barrier coating (Ti/Cr)AlSiN Duplex coating Process temperature Surface roughness 

Notes

Acknowledgements

The authors thank the German Research Foundation (DFG) within the cooperation project TI 343/122-1 and HO 2356/11-1 “Production and application of graded coating microstructures for the process of friction-spinning using PVD and thermal spray technology” for their financial support.

References

  1. 1.
    Homberg W, Lossen B (2013) Thermal assisted incremental forming of tubes and sheets with process-integrated heat generation. In: Functionally graded materials in industrial mass production, vol 2. Wissenschaftliche Skripten, AuerbachGoogle Scholar
  2. 2.
    Lossen B, Homberg W (2016) Friction spinning—twist phenomena and the capability of influencing them, vol 1769, pp 070001-1–070001-6.  https://doi.org/10.1063/1.4963454
  3. 3.
    Homberg W, Lossen B (2015) Friction-spinning—innovative opportunity for overcoming process limits in spinning processes. In: Tekkaya AE, Homberg W, Brosius A (eds) 60 excellent inventions in metal forming. Springer, Berlin, pp 149–154Google Scholar
  4. 4.
    Homberg W, Hornjak D (2011) Friction-spinning of tubular components-basic research on parameter influence and process design. In: Steel research international—special edition, 10th international conference on technology in plasticity, pp 548–553Google Scholar
  5. 5.
    Lossen B, Homberg W (2015) Friction-spinning—influence of tool and machine parameters on the surface texture. KEM 651–653:1109–1114.  https://doi.org/10.4028/www.scientific.net/KEM.651-653.1109 CrossRefGoogle Scholar
  6. 6.
    Lossen B, Andreiev A, Stolbchenko M et al (2018) Friction-spinning—grain structure modification and the impact on stress/strain behaviour. J Mater Process Technol 261:242–250CrossRefGoogle Scholar
  7. 7.
    Hess S, Lossen B, Biermann D et al (2014) Analysis of the surface roughness obtained in a friction spinning process based on empirical models. Int J Adv Manuf Technol 74(9–12):1655–1665.  https://doi.org/10.1007/s00170-014-6066-2 CrossRefGoogle Scholar
  8. 8.
    Lampke T, Meyer D, Alisch G et al (2011) Alumina coatings obtained by thermal spraying and plasma anodising—a comparison. Surf Coat Technol 206(7):2012–2016.  https://doi.org/10.1016/j.surfcoat.2011.09.006 CrossRefGoogle Scholar
  9. 9.
    Yu D, Wang C, Cheng X et al (2009) Microstructure and properties of TiAlSiN coatings prepared by hybrid PVD technology. Thin Solid Films 517(17):4950–4955.  https://doi.org/10.1016/j.tsf.2009.03.091 CrossRefGoogle Scholar
  10. 10.
    Tillmann W, Dildrop M (2017) Influence of Si content on mechanical and tribological properties of TiAlSiN PVD coatings at elevated temperatures. Surf Coat Technol 321:448–454.  https://doi.org/10.1016/j.surfcoat.2017.05.014 CrossRefGoogle Scholar
  11. 11.
    Kang MC, Je SK, Kim KH et al (2008) Cutting performance of CrN-based coatings tool deposited by hybrid coating method for micro drilling applications. Surf Coat Technol 202(22–23):5629–5632.  https://doi.org/10.1016/j.surfcoat.2008.06.130 CrossRefGoogle Scholar
  12. 12.
    Philippon D, Godinho V, Nagy PM et al (2011) Endurance of TiAlSiN coatings: effect of Si and bias on wear and adhesion. Wear 270(7–8):541–549.  https://doi.org/10.1016/j.wear.2011.01.009 CrossRefGoogle Scholar
  13. 13.
    Pawlowski L, Fauchais P (1992) Thermal transport properties of thermally sprayed coatings. Int Mater Rev 37(6):271–289CrossRefGoogle Scholar
  14. 14.
    Ravichandran KS, An K, Dutton RE et al (1999) Thermal conductivity of plasma-sprayed monolithic and multilayer coatings of alumina and yttria-stabilized zirconia. J Am Ceram Soc 82(3):673–682CrossRefGoogle Scholar
  15. 15.
    Limarga AM, Widjaja S, Yip TH (2005) Mechanical properties and oxidation resistance of plasma-sprayed multilayered Al2O3/ZrO2 thermal barrier coatings. Surf Coat Technol 197(1):93–102.  https://doi.org/10.1016/j.surfcoat.2005.02.087 CrossRefGoogle Scholar
  16. 16.
    Martan J, Beneš P (2012) Thermal properties of cutting tool coatings at high temperatures. Thermochim Acta 539:51–55.  https://doi.org/10.1016/j.tca.2012.03.029 CrossRefGoogle Scholar
  17. 17.
    Samani MK, Ding XZ, Amini S et al (2013) Thermal conductivity of titanium aluminum silicon nitride coatings deposited by lateral rotating cathode arc. Thin Solid Films 537:108–112.  https://doi.org/10.1016/j.tsf.2013.04.029 CrossRefGoogle Scholar
  18. 18.
    Riedl A, Schalk N, Czettl C et al (2012) Tribological properties of Al2O3 hard coatings modified by mechanical blasting and polishing post-treatment. Wear 289:9–16.  https://doi.org/10.1016/j.wear.2012.04.022 CrossRefGoogle Scholar
  19. 19.
    Holmberg K, Matthews A, Ronkainen H (1998) Coatings tribology—contact mechanisms and surface design. Tribol Int 31(1–3):107–120.  https://doi.org/10.1016/S0301-679X(98)00013-9 CrossRefGoogle Scholar
  20. 20.
    Kalin M, Jerina J (2015) The effect of temperature and sliding distance on coated (CrN, TiAlN) and uncoated nitrided hot-work tool steels against an aluminium alloy. Wear 330–331:371–379.  https://doi.org/10.1016/j.wear.2015.01.007 CrossRefGoogle Scholar
  21. 21.
    Ohnuma H, Nihira N, Mitsuo A et al (2004) Effect of aluminum concentration on friction and wear properties of titanium aluminum nitride films. Surf Coat Technol 177–178:623–626.  https://doi.org/10.1016/S0257-8972(03)00936-8 CrossRefGoogle Scholar

Copyright information

© German Academic Society for Production Engineering (WGP) 2019

Authors and Affiliations

  • Wolfgang Tillmann
    • 1
  • Alexander Fehr
    • 1
    Email author
  • Dominic Stangier
    • 1
  • Markus Dildrop
    • 1
  • Werner Homberg
    • 2
  • Benjamin Lossen
    • 2
  • Dina Hijazi
    • 2
  1. 1.Institute of Materials EngineeringTU Dortmund UniversityDortmundGermany
  2. 2.Forming and Machining TechnologyUniversity of PaderbornPaderbornGermany

Personalised recommendations