1999 Progress Report: Novel Nanocoatings On Cutting Tools For Dry Machining

EPA Grant Number: R825339
Title: Novel Nanocoatings On Cutting Tools For Dry Machining
Investigators: Komanduri, Ranga , Fehrenbacher, L.
Institution: Oklahoma State University - Main Campus , Technology Assessment & Transfer Inc
EPA Project Officer: Hahn, Intaek
Project Period: October 1, 1996 through September 30, 1999
Project Period Covered by this Report: October 1, 1998 through September 30, 1999
Project Amount: $180,000
RFA: Technology for a Sustainable Environment (1996) RFA Text |  Recipients Lists
Research Category: Sustainability , Pollution Prevention/Sustainable Development


The objectives of this project are: (1) development of new cutting tool materials based on novel multilayer nanocoating architectures of a solid lubricant/metal (e.g., MoS2/Mo, MoS2/W, WS2/W, TaS2/Ta) on cemented carbide tools by closed field unbalanced magnetron sputtering (CFUMS) process; and (2) use of the nanolayer-coated tools in dry machining, which makes it environmentally friendly manufacturing.

Progress Summary:

he project deals with the deposition of a few micrometers thick (1?5 mm) multiple nanocoatings of alternate lubricating and tough materials on cutting tools to enhance the tool life in dry machining. TA & T, Inc. was working on the deposition of the coatings by closed field unbalanced magnetron sputtering (CFUMS) process. Lack of adhesion appears to be a major problem. At Oklahoma State University, we are developing a pulse laser deposition (PLD) technique using a 193 nm excimer laser. We have conducted several coatings experiments to deposit MoS2 and tungsten or Molybdenum. Because of low substrate temperature, two problems were encountered: low deposition rates and lack of good adhesion. We have installed a high temperature (up to 950 C) heater to heat the substrate to promote adhesion. We also are using part of the laser beam to activate the surface and the remaining fraction to deposit the nanocoatings. We also found that by providing a magnetic field around the chamber, we can increase the deposition rate as well as improve the adhesion. The magnetic field seems to focus the deposition material more towards the tool substrates. This work will be intensified in the coming year and will include depositing alternate materials, such as MoS2/W, WS2/W, TaS2/Ta.

Future Activities:

Pulsed Laser Deposition (PLD) technique using the excimer laser at Oklahoma State University will be employed to deposit alternate lubricating/metal coatings on cutting tools. The rate of coating was found to increase significantly by depositing the coatings in a magnetic field. This work will be accelerated to provide multiple nanocoatings. The coatings will be characterized for adhesion and surface morphology. Candidate nanocoated tools will be used for dry machining of selected alloy steels and titanium alloys.

Journal Articles on this Report : 2 Displayed | Download in RIS Format

Other project views: All 5 publications 5 publications in selected types All 2 journal articles
Type Citation Project Document Sources
Journal Article Komanduri R. Tool materials. Encyclopedia of Chemical Technology, John Wiley & Sons, Inc., . 1997:390-455 R825339 (1999)
not available
Journal Article Kustas FM, Fehrehnbacher LL, Komanduri R. Nanocoatings on cutting tools for dry machining. CIRP Annals - Manufacturing Technology 1997;46(1):39-42 R825339 (1999)
not available

Supplemental Keywords:

nanocoatings, pulsed laser deposition (PLD), cutting tools, dry machining, environmentally friendly machining, green manufacturing., RFA, Scientific Discipline, Sustainable Industry/Business, cleaner production/pollution prevention, Environmental Chemistry, Physics, Sustainable Environment, Technology for Sustainable Environment, Economics and Business, Environmental Engineering, in-process changes, cleaner production, dry machining, waste minimization, waste reduction, environmentally conscious manufacturing, nanocoatings, cutting tools, alternative materials, chemical vapor deposition, coating processes, process modification, innovative technology, pollution prevention, nonocaotings, industrial innovations, source reduction

Progress and Final Reports:

Original Abstract
  • 1997
  • 1998
  • Final