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New coating tools surpass international standards
The article discusses a groundbreaking advancement in coating technology for high-performance cutting tools, specifically the new Ti-Al-XN coating developed by Zhuzhou Diamond Tool. This innovative method utilizes vapor deposition to apply a thin layer of ultra-hard and wear-resistant Ti-Al-XN material onto the surface of high-strength tool substrates. By doing so, it significantly reduces tool wear, extends tool life, and enhances cutting speed—making it a major breakthrough in China's national projects focused on advanced CNC machine tools and manufacturing equipment.
This technology has successfully broken the long-standing monopoly held by foreign companies in the high-end tool coating sector. It not only improves the localization rate of premium coated tools but also provides a solid foundation for key industries like automotive and aerospace to boost production efficiency and reduce costs. For instance, Zhuzhou Diamond managed to cut the cost of machining a critical engine block component by 30%, while raising the localization rate of Chery Automobile’s engine processing tools from 20% to 47%. This is a significant step toward replacing imported tools and meeting urgent industrial demands.
Despite being a large country, China still faces challenges in catching up with international standards in CNC cutting tool technology, especially in the field of advanced coatings. However, the successful application of the Ti-Al-XN coating marks a turning point. It not only breaks foreign monopolies but also lays the groundwork for higher localization rates and better service for key industries, offering substantial economic and social benefits.
Tools are often referred to as the "machines that make machines." In this context, high-end carbide precision tools can be seen as the "diamonds" on the artwork of modern industrial civilization. Their brilliance comes from the ultra-thin, precision-coated layers that enhance their performance. Coated tools offer exceptional surface hardness, wear resistance, chemical stability, heat resistance, low friction, and low thermal conductivity. These properties stem from the coating acting as both a chemical and thermal barrier, reducing tool-workpiece interaction and extending tool life by 3 to 10 times, while increasing cutting speeds by 20% to 100%.
Today, over 80% of cutting tools are coated. As foreign firms dominate the high-end market, the importance of coating technology in China’s CNC machine tool initiatives has never been greater. Breakthroughs in this area have become a priority in multiple research programs.
Zhuzhou Diamond’s development of the Ti-Al-XN coating was no easy feat. Initially, they could only produce basic Ti-N and Ti-Al-N coatings. Through continuous learning and innovation, they eventually developed nano-structured Ti-Al-N coatings with improved performance, yet still fell short of industry needs. To address this, they formed a dedicated R&D team and leveraged specialized platforms to focus on developing next-generation high-performance coatings.
After extensive trials, they selected the optimal Ti-Al-XN coating, which offered higher oxidation resistance and hardness compared to Ti-Al-N, though its cutting performance remained similar. To understand why the results were not as expected, the team conducted detailed analysis using differential scanning calorimetry, examining phase structure evolution and spinodal decomposition at high temperatures. Their efforts led to the creation of an optimized nanocomposite multilayer coating, nc-TiAlN/Si3N4.
This new coating technology has already secured nine invention patents. The PVD coating products achieve a hardness above 40 GPa, delivering a superhard effect. Even after oxidation at 1100°C for 10 hours, the coating remains largely intact. After tempering at the same temperature, the hardness maintains over 40 GPa, with bond strength exceeding 90 N. Meanwhile, their self-developed CVD α-Al2O3 coating reaches 10 μm in thickness, with bond strength over 80 N, allowing cast iron machining speeds up to 500 meters per minute. These achievements match or even surpass international standards in similar products, marking a major milestone in China’s technological development.