Advanced ceramic multilayer coatings for increasing the tool life of cutting inserts: A hybrid CVD-PVD approach

The manufacturing sector faces significant challenges in efficiency, adaptability, and sustainability, with cutting tool performance being critical for both production processes and final product quality. The development of new multilayer coatings for cutting tools has become a constant concern in today's industrial landscape, driven by the need for enhanced tool life and improved machining efficiency in increasingly demanding applications. In this study, multilayer structures were designed with TiN (<0.3 μm)/TiCN (4 μm)/Al 2 O 3 (3 μm)/TiN (1 μm) base layers deposited via CVD, followed by AlCrN (4 μm) or AlCrN (3 μm) + ZrN (1 μm) applied via PVD-HiPIMS. The textured Al 2 O 3 intermediate layer exhibited a preferred (006) crystallographic orientation, typically associated with enhanced hardness of the CVD layer. Energy Dispersive X-ray Spectroscopy (EDS) and tribological tests demonstrated lower adhesion of workpiece materials and improved wear resistance for the hybrid coatings compared to conventional CVD coatings. Machining tests on AISI 316 stainless steel during a turning operation revealed that the hybrid-coated tools exhibited significantly better tool life compared to the CVD-coated tools (by 69.20%), considering a flank wear of VB = 0.134 mm as the end-of-life criterion. These results provide strong evidence that the hybrid CVD/PVD multilayer coating strategy significantly enhances cutting tool performance and longevity in demanding machining applications. • Hybrid CVD-PVD Approach: Development of advanced ceramic multilayer coatings using a combination of Chemical Vapor Deposition (CVD) and High-Power Impulse Magnetron Sputtering (HiPIMS)-based Physical Vapor Deposition (PVD) for enhanced tool life. • Optimized Crystallographic and Coating Properties: The study demonstrates the importance of crystallographic orientation and coating density in improving the wear resistance of cutting inserts, with a focus on TiN/TiCN/Al 2 O 3 /TiN multilayers. • Superior Tool Performance: Machining tests on stainless steel show a direct correlation between the new coatings and a significant increase in tool life, highlighting their potential to boost efficiency and durability in industrial applications.