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Diamond coatings will be widely used in the field of cutting
The **Abstract** states that tool coatings should not only enhance the tool's lifespan but also address the issue of reducing or eliminating cutting fluids, while offering self-lubricating properties. Diamond-like carbon (DLC) coatings have shown advantages in machining specific materials like AlTi and its composites. However, after years of research, it has been found that DLC suffers from high internal stress, poor thermal stability, and a catalytic reaction with ferrous metals, which can cause the SP3 structure to transition into SP2. This limits their application primarily to non-ferrous metals, thereby restricting broader use in machining processes.
In recent years, new developments have emerged. A type of DLC known as graphite-like coating (also referred to as SP2-based DLC) has demonstrated hardness up to 2040 GPa, without the catalytic effect on ferrous metals. It exhibits a very low friction coefficient and excellent moisture resistance, making it suitable for dry cutting. Its performance is superior to uncoated tools, with a significant increase in tool life. It is now viable for cutting steel materials, drawing considerable interest from both coating companies and tool manufacturers. Over time, this advanced DLC coating is expected to gain widespread application in the machining industry.
As material performance requirements continue to rise, various vapor deposition technologies have developed rapidly over the past few decades. These technologies not only meet mechanical performance needs—such as wear resistance, friction reduction, and corrosion protection—but also extend into fields like electromagnetic, optical, optoelectronic, thermal, superconducting, and biological applications. Surface engineering enhances the advantages of low-cost metal materials and plays a crucial role in developing new coating materials, showing great potential for future applications.
New demands are placed on cutting tools. Beyond extending service life, there is an increasing need to reduce environmental pollution during machining. As the machining industry advances, dry cutting is preferred wherever possible. When cutting fluids cannot be fully eliminated, they should contain only rust inhibitors and no organic compounds, significantly lowering recycling costs and environmental impact.
Milling cutters must also account for intermittent impact characteristics. Early coatings focused mainly on wear resistance, but the diverse working conditions of cutting tools determine the choice of coating materials. For example, turning and drilling require different approaches. Hardness remains a key factor in some applications. Titanium nitride, for instance, is a common coating with a relatively high friction coefficient (ranging between 0.4 and 0.6). During machining, frequent contact between the tool and workpiece generates substantial heat. To prevent tool overheating, deformation, and loss of accuracy, cutting fluids are typically used.