A study on the machinability of advanced arc PVD AlCrN-coated tungsten carbide tools in drilling of CFRP/titanium alloy stacks

This study aims to investigate the effect of an aluminum chromium nitride (AlCrN) coating on tool wear and hole quality in the conventional drilling process of carbon fiber-reinforced plastic (CFRP) composites, titanium alloy (Ti), and CFRP–Ti stack workpieces popular in the aerospace industry. The...

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Bibliographic Details
Published in:Carbon Letters 2021-06, Vol.31 (3), p.497-507
Main Authors: Kim, Dave, Swan, Sam R., He, Bin, Khominich, Viktor, Bell, Eric, Lee, Seok-Woo, Kim, Tae-Gon
Format: Article
Language:English
Subjects:
Aerospace industry
Aircraft
Aluminum
Arc deposition
Carbide tools
Carbon
Carbon fiber reinforced plastics
Carbon fiber reinforcement
Chromium
Chromium nitride
Coatings
Composite materials
Cutting tools
Drilling
Drills
Heat resistance
Hole size
Machinability
Physical vapor deposition
Plasma acceleration
Productivity
Roundness
Silicon nitride
Stacks
Surface roughness
Titanium
Titanium alloys
Titanium base alloys
Tool wear
Tungsten
Tungsten carbide
Workpieces
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Summary:This study aims to investigate the effect of an aluminum chromium nitride (AlCrN) coating on tool wear and hole quality in the conventional drilling process of carbon fiber-reinforced plastic (CFRP) composites, titanium alloy (Ti), and CFRP–Ti stack workpieces popular in the aerospace industry. The advanced arc plasma acceleration (APA) method of physical vapor deposition (PVD) was used for all AlCrN coatings. The drilling experiments were conducted with uncoated drills as well as AlCrN-coated drills. When drilling CFRP only, the AlCrN coating was removed at the drill cutting edges and the margin area, which suggests the carbon fibers abraded the coatings. When drilling Ti only, the AlCrN-coated drill mitigated the Ti adhesion formation, which resulted in less tool wear. In addition, hole quality for both CFRP and Ti was improved when the coating was used versus the uncoated tool. The machinability of CFRP–Ti stacks in the drilling process was improved by utilizing the advanced AlCrN coating on the WC tool in terms of drilling forces and hole quality parameters such as average hole size, average hole roundness, hole surface roughness, and Ti exit burr height.
ISSN:1976-4251
2233-4998
DOI:10.1007/s42823-020-00180-8