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Surface & Coatings Technolog
Structural and mechanical property of Si incorporated (Ti,Cr,Al)N
coatings deposited by arc ion plating process
Kenji Yamamoto a,*, Susumu Kujime b, Kazuki Takahara b
a Materials Research Lab. Kobe Steel Ltd, 1-5-5 Takatsuka-dai Nishi-ku, Kobe, 651-2271 Hyogo, Japanb Advanced Products and Technologies Department, Machinery and Engineering Company, Kobe Steel Ltd, 3-1, 2-chome,
Shinhama Arai-cho Takasago, Hyogo 676-8670, Japan
Available online 27 September 2005
Abstract
(Ti,Cr,Al,Si)N coatings with different Al+Si fractions (0.6 and 0.65) were deposited by an arc ion plating (AIP) apparatus that is
equipped with the plasma-enhanced type arc cathode. The (Ti,Cr,Al,Si)N coatings were deposited under different substrate bias voltages
and effect of the deposition parameter on the composition, structure and mechanical properties was investigated. X-ray diffraction
measurements of the (Ti,Cr,Al,Si)N coating deposited under different substrate bias voltages revealed that formation of the hexagonal
phase (Wurzite structure) was only limited to a relatively low bias voltage range of 20 to 30 V. Above this bias voltage, the crystal
structure of the coatings was single-phased cubic rock-salt structure (B1 phase) independent of the bias voltage. Grain size of the
coating was calculated from the full width of half maximum (FWHM) of the X-ray diffraction peak and it was smaller than the one of
conventional (Ti,Al)N or (Ti,Cr,Al)N coating with a comparable Al fraction. The grain size estimated from the cross-sectional TEM
observation was less than 10 nm. From the TEM observation, the coating was compositionally homogeneous and there was no evidence
that the film had a phase separation such as Si-rich and -poor region. Hardness of the (Ti,Cr,Al,Si)N coating with Al+Si=0.6 was in
the range of 26 to 27 GPa independent of the substrate bias. (Ti,Cr,Al,Si)N coating with Al+Si=0.65 showed slight increase in
hardness from 24 to 27 GPa when the substrate bias was increased to more than 100 V. To evaluate the oxidation resistance, annealing
tests in the air at 1000 -C were conducted and surface SEM observations revealed that surface of the conventional (Ti,Al)N and
(Ti,Cr,Al)N was covered with coarse oxide grains enriched with TiO2. Whereas only a dense but very thin protective oxide layer was
observed in case of (Ti,Cr,Al,Si)N coating after the oxidation. These coatings were applied to the high-speed dry cutting tests against
hardened D2 steel (HRC 60) and the result clearly indicated better performance of (Ti,Cr,Al,Si)N compared to the conventional coatings
such as (Ti,Al)N and (Ti,Cr,Al)N.
D 2005 Elsevier B.V. All rights reserved.
Keywords: Si addition; (Ti,Cr,Al,Si)N; Cathodic arc; Al+Si ratio; Oxidation resistance
1. Introduction
High hardness and resistance to oxidation at elevated
temperatures have always been important criteria for hard
coatings particularly in dry cutting applications [1,2]. This is
mainly due to the requirement from the various industries to
machine harder work-pieces at higher cutting speeds. This
was the main reason in 1990s why TiN coating was replaced
0257-8972/$ - see front matter D 2005 Elsevier B.V. All rights reserved.
doi:10.1016/j.surfcoat.2005.08.025
* Corresponding author. Tel.: +81 78 992 5505; fax: +81 78 992 5512.
E-mail address: [email protected] (K. Yamamoto).
by (Ti,Al)N coating that had a higher hardness and was
more oxidation resistant [3,4]. But of course this was not the
end of ever-increasing demands from the industries to
improve the oxidation resistance and hardness for better
productivity and longer tool life.
Recently, much attention has been paid to Si containing
coatings such as (Ti,Si)N [5–12], (Cr,Si)N [13], (Ti,Al,-
Si)N [14–21] and other Si containing coating systems
[22,23]. These Si containing coatings have significantly
better oxidation resistance compared to the ones without Si
[5,14,20,23]. The role of Si in improving the oxidation
resistance is not yet fully clarified in many cases. Choi et
y 200 (2005) 1383 – 1390
K. Yamamoto et al. / Surface & Coatings Technology 200 (2005) 1383–13901384
al. reported, however, that preferential oxidation of Si was
observed after the oxidation test and this Si-rich oxide film
acted as a diffusion barrier for further oxidation [5], much
like in case of the preferential oxidation of Al in (Ti,Al)N
coating [2]. Also this Si containing (M,Si)N (M: metal)
system is known to form so-called ‘‘nano-composite’’
coatings [24,25]. In case of (Ti,Si)N system [6,11,12],
authors have reported rather small grain size (less than 10
nm) at the Si content of 10 to 20 at.%. Sometimes small
crystalline TiN grains surrounded by amorphous SiNx (a-
SiNx) matrix were observed [5,6] and this phase separation
was primarily considered as a basic mechanism of the
formation of the nano-composite. In the case of (Ti,Al,-
Si)N system [14,17], addition of Si resulted in refinement
of the grain size and formation of a-SiNx phase was
observed when coating contained a fairly large amount of
Si. (Ti,Al,Si)N coatings [14] containing relatively a small
amount of Si (a few atomic percent) consisted of single B1
cubic phase and there was no evidence of formation of
second phase such as a-SiNx. Only refinement of the grain
was observed in this case. Another interesting aspect of
(Ti,Al,Si)N system is change in the crystal structure cubic
(B1) to hexagonal (B4) depending on the Al+Si fraction.
Tanaka et al. [14] reported crystalline phase composition in
(Ti,Al,Si)N system and when Al+Si ratio exceeds 0.61 the
crystal structure changed from B1 single phase to B1+B4
mixed phase. This change in the crystal structure also
resulted in loss of the mechanical property where the
hardness decreased from at maximum 34 GPa to 25 GPa.
In (Ti,Al)N system, there are several reports indicating the
phase boundary of B1 and B4 is located around Al ratio of
0.6 to 0.7 [26,27]. Tanaka et al. reported that in case of the
coating containing no Si, it had B1 single phase at
equivalent Al+Si fraction. This implies that Si has
negative effect to maintain the B1 phase, which is usually
a harder and a preferred phase for wear resistant
applications [28].
In the previous paper [28], we reported properties of
(Ti,Cr,Al)N coating system with a high Al fraction of more
than 0.65. This (Ti,Cr,Al)N system was characterized by
high hardness more than 30 GPa and high oxidation
resistance compared to the conventional (Ti,Al)N coating.
Motivation of the present work is to improve the properties
of (Ti,Cr,Al)N coating further for better tribological
performance such as cutting operation. For this purpose,
the effect of Si incorporation on the structural and
mechanical properties of (Ti,Cr,Al)N coatings was inves-
tigated with different Al+Si fractions. Also cutting tests
were conducted in comparison with the conventional
(Ti,Al)N and (Ti,Cr,Al)N coating.
2. Experimental details
(Ti,Cr,Al,Si)N coatings with different Al+Si fractions
were deposited by a batch type cathodic arc ion plating
coater equipped with a plasma-enhanced cathode. Details
of the deposition equipment and the cathode can be found
elsewhere [28]. Two kinds of Ti–Cr–Al–Si targets were
prepared by a powder metallurgy process and used for the
deposition. Their compositions were Ti0.2Cr0.2Al0.55Si0.05(target A) and Ti0.15Cr0.2Al0.6Si0.05 (target B). Deposition
was conducted in the above-mentioned coater in pure N2
atmosphere at pressure of 2.7 Pa. WC-Co cutting inserts
(Mitsubishi Carbide SNGN120408), platinum foils (0.1
mmt) and WC-Co square end-mills (Mitsubishi Carbide 10
mmf, 6 flutes) were used as substrates. Prior to the
deposition, these substrates were Ar-ion-etch cleaned for 5
min at Ar pressure of 2.7 Pa. After the cleaning
procedure, arc was ignited and deposition was conducted
at arc current of 150 A and the substrate temperature was
regulated at about 500 -C. The substrate bias was varied
from 20 to 150 V to investigate the effect of substrate bias
on coating’s properties. The thickness of the coating layer
was about 3 Am for all samples unless mentioned.
The elemental composition of the coatings was
determined using energy dispersive X-ray (EDX) analysis
(Horiba EMAX), using ZAF correction and may contain
an error approximately 10% at maximum. Crystal
structure and preferred orientation of the coating was
determined with X-ray diffraction (XRD, Rigaku RINT-
200-PC) using Cu-ka radiation and the grain size was
calculated by the Scherrer’s equation using the full width
of half maximum (FWHM) of (111) diffraction peak of
the B1 phase [30]. Indentation hardness was measured
using a nano-indentation instrument (Elionix ENT-1100)
with a Berkovich type diamond indenter. The indenter tip
shape correction was conducted using the method
proposed by Sawa and Tanaka [31]. No thermal drift
correction was used, since this instrument was installed in
a thermally regulated chamber in which temperature drift
rate is less than 0.1 -C/10 s and one indentation
measurement took about 10 s. Microstructure, particularly,
to detect the possible existence of separated phase such as
a-SiNx, cross-sectional transmission electron microscope
observation (TEM: Hitachi) was used. Coatings deposited
on WC-Co inserts were cut out and thinned for TEM
observation using focused ion beam and micro-lifting
technique [32]. Oxidation tests were conducted by
annealing the coated platinum foil samples in atmosphere
(air) at 1000 -C for 30 min. After the oxidation tests,
surface morphology of the samples was investigated by
SEM. Depth composition profile of the oxide layer was
measured by an Auger electron spectroscopy (AES Perkin
Elmer PHI650) using Ar sputter for depth profile
measurements. Finally, cutting tests were conducted using
hardened AISI D2 cold working die steel (HRC 60) as a
work-piece. Cutting parameters were as follows: cutting
speed 150 m/min; feed 0.05 mm/flute; axial depth of cut
5 mm; radial depth of cut 0.1 mm; dry cut, air-blow only.
Flank wear of the cutting edge was measured after the
cutting length of 30 m.
K. Yamamoto et al. / Surface & Coatings Technology 200 (2005) 1383–1390 1385
3. Result and discussion
3.1. Composition and crystal structure
Composition of the coatings was slightly different from
the targets used for depositions. The coatings deposited
from both targets A and B had a few percentage less Al and
also a few percentage enriched Cr than the targets, while
other elements, Ti and Si, had almost the same composition
with the targets. Compositions of (Ti0.2Cr0.23Al0.53Si0.04)N
and (Ti0.14Cr0.22Al0.59Si0.05)N were obtained as the resulting
compositions of the coatings deposited from targets A and B
at the bias voltage of 70 V. This compositional deviation of
Al and Cr was more pronounced as the substrate bias was
increased. The decrease of Al composition corresponding to
the change in the substrate bias can be explained by the
preferential sputtering of Al which has a highest sputter
yield among the coating’s elements [28,33].
Fig. 1(a) shows X-ray diffraction patterns of (Ti,Cr,Al,-
Si)N coatings deposited from the targets A and B (hereafter
referred as coatings A and B) under various substrate biases.
At the substrate bias of 20 V, the diffraction pattern of the
coating B contained a weak diffraction peak from the
Fig. 1. (a) X-ray diffraction patterns of (Ti,Cr,Al,Si)N coatings with
different Al+Si fractions deposited under various substrate biases. Marks
(*) denote diffraction peaks from the substrate (WC-Co). (b) Result of de-
convolution of overlapping peaks located between the diffraction angle of
32- to 40-.
Fig. 2. Effect of the substrate bias voltage on (a) grain size and (b) position
of (111) diffraction peak of (Ti,Cr,Al,Si)N coatings with different Al+Si
fractions.
hexagonal B4 phase. This weak peak, as shown in Fig. 1(b),
can be clearly observed by a deconvolution of several
overlapping peaks between the diffraction angle from 32- to40-. This diffraction peak from the B4 phase was only
observed for coating B deposited at 20 V, and coatings A
and B deposited more than substrate bias of 20 V, only
diffraction peaks belonging to the B1 cubic phase were
observed. This bias (i.e. ion energy) induced transition in
crystal structure was also observed in (Ti,Cr,Al)N system
with a high Al fraction [28], yet the nature of this phase
transition is not clarified. The preferred orientation of the
coating changed from [111] to [100] as the bias was
increased for both coatings A and B. Fig. 2 shows the effect
of the substrate bias on the (a) grain size and (b) position of
(111) peaks. In case of coating A, the grain size was about
12 nm at the bias of 20 Vand decreased gradually as the bias
was increased. It reached, however, plateau when the bias
was increased for more than 50 V and the grain size became
a constant value of around 8 nm, whereas the grain size
showed nearly constant value of 8 nm for whole bias range
in case of coating B. Detailed discussion of the grain size
will be given in the Section 3.3.
The position of (111) peak was changed by the
substrate bias and it shifted toward lower diffraction angle
Fig. 3. Effect of the substrate bias voltage on (a) indentation hardness and
(b) elastic modulus of (Ti,Cr,Al,Si)N coatings.
Fig. 4. Indentation hardness – reduced modulus (E*) relationship of
(Ti,Cr,Al,Si)N and (Ti,Cr,Al)N coatings.
K. Yamamoto et al. / Surface & Coatings Technology 200 (2005) 1383–13901386
as the bias was increased. Two factors may influence the
position of (111) peak in this case; composition and
residual stress. As described at the beginning of this
section, the Al fraction decreased and Cr fraction increased
as the substrate bias was increased. This change in the
composition may induce the change in the lattice
parameter thus changing the position of (111) peak. The
lattice parameter of CrN and AlN is 0.414 and 0.412 nm
and nearly identical, however, and a few atomic percent
change of Al and Cr composition can induce the change in
diffraction angle of (111) peak smaller than 0.01-. There-fore, the observed change in the (111) peak position was
likely due to the change of residual stress that was induced
by the substrate bias (ion energy). Usually, PVD-deposited
coatings are in compressive stress and an increase in
compressive stress results in peak shift to smaller
diffraction angle. From this consideration, if we assume
the absolute value of the coating’s stress to be compres-
sive, the compressive stress increased as the substrate bias
was increased up to 50 V. More than this substrate bias,
the stress of the coating showed little change.
3.2. Mechanical property
Fig. 3 shows change in (a) indentation hardness and (b)
elastic modulus of coatings deposited under various biases.
Indentation hardness and elastic modulus of coating A
showed very little change over the whole bias range and
they were about 25 and 400 GPa. In case of coating B, both
indentation hardness and elastic modulus increased gradu-
ally as the bias was increased. This change in indentation
hardness of coating B probably relates to the bias induced
crystal structure change observed by the X-ray diffraction
measurements. The maximum indentation hardness of
coating B was approximately 27 GPa at highest substrate
bias of 150 V. These determined indentation hardness and
elastic modulus of coatings A and B were both lower than
the values of (Ti,Cr,Al)N coatings [28]. In case of
(Ti,Cr,Al)N coating, hardness was significantly low, less
than 20 GPa, at a lower substrate bias when the coating was
composed of mixture of B1 and B4 phase. However, the
maximum hardness of approximately 35 GPa was obtained
at the bias of 150 V. Incorporation of Si to the (Ti,Cr,Al)N
resulted in lower hardness and elastic modulus. However,
on the positive side these mechanical properties were more
insensitive to the deposition parameter and this is favorable
from the viewpoint of robustness of the deposition process.
Additionally, Tsui et al. [35] proposed that H3/E*2 gave
information on the resistance of the material to plastic
deformation, where H is the indentation hardness and E* is
reduced modulus E/(1�m2). Coatings with high H3/E*2
values are less likely undergo plastic deformation under
external force. Fig. 4 shows E*–indentation hardness
relationship for (Ti,Cr,Al,Si)N coatings and (Ti,Cr,Al)N
deposited under various substrate biases. Maximum hard-
nesses of both (Ti,Cr,Al,Si)N coatings were lower than the
ones of (Ti,Cr,Al)N coating. When compared at same E*,
however, (Ti,Cr,Al,Si)N coatings had higher indentation
hardness, thus higher H3/E*2 value.
3.3. TEM observation
Fig. 5 show (a) a high-resolution bright field TEM
image of (Ti,Cr,Al,Si)N (coating A), (b) an electron
diffraction (ED) pattern with an electron beam diameter
Fig. 5. (a) High-resolution TEM image of (Ti,Cr,Al,Si)N coating (Al+Si=0.6), (b) ED pattern with electron beam diameter of approximately 1000 nm and (c)
nano-ED pattern of area c.
K. Yamamoto et al. / Surface & Coatings Technology 200 (2005) 1383–1390 1387
of about 1000 nm, (c) an ED pattern of region c in the
TEM image. Coating A was deposited at the bias of 50 V
and substrate temperature of 500 -C. The TEM image
showed nano-crystalline nature of the (Ti,Cr,Al,Si)N coat-
ing. The grains were sized less than 10 nm and most of
them were as small as 5 nm, whereas the grain size of the
(Ti0.25Cr0.1Al0.65)N was about 12 nm [34]. The grain sizes
of (Ti,Si)N and (Ti,Al,Si)N coatings were reported by
several authors using mainly TEM [6,14,17,19]. Tanaka et
al. reported that the grain size of (Ti0.41Al0.59)N was
approximately 120 to 350 nm, whereas that of
(Ti0.42Al0.58Si0.03)N was 50 to 250 nm [14]. Parlinska-
Wojtan et al. [19] reported the effect of Al+Si content on
the grain size of (Ti,Al,Si)N coating with Al+Si content
ranging from 10 to about 50 at.% with comparable Si
content of about 4 to 6 at.% [14]. The reported grain size
showed strong correlation with the Al+Si content and it
was less than 10 nm when Al+Si content was more than
40 at.%. These two reports are quite controversial in the
absolute grain size, but they agree with each other on the
fact that Si has an effect to reduce the grain size. The ED
pattern with fairly large beam diameter (Fig. 5(b)) showed
that film only consisted cubic B1 phase and no other phase
like hexagonal B4 phase was observed. Additional ED
patterns were taken using nano-electron beam with beam
diameter was about 1 to 2 nm. Fig. 5(c) shows a typical
nano-ED pattern of a single crystal grain. Again only
diffraction spots corresponding to the B1 phase were
confirmed.
3.4. Oxidation resistance evaluation
Fig. 6 shows surface SEM images of different coatings
(a)–(d) as deposited and (a-1)–(d-1) after annealed in air
at 1000 -C for 30 min. Some macro-particles (MPs) were
observed on the surface of the as-deposited coatings. The
number of MPs was less for the coatings without Si. After
the oxidation tests, surface of coatings without Si (a-1),
(b-1) showed a coarse grain-like structure and a fine
needle-like structure was observed for the coatings
containing Si, (c-1) and (d-1). From the AES depth
profiles of sample (b-1) and (c-1) shown in Fig. 7(a) and
Fig. 6. SEM images of various nitride coatings as deposited, (a)– (d) and after the oxidation test at 1000 -C for 30 min in air (a-1)– (d-1).
K. Yamamoto et al. / Surface & Coatings Technology 200 (2005) 1383–13901388
(b), we can estimate that grain-like and needle-like
structure was corresponding to the formation of Ti- and
Al-rich oxide layer. Superior oxidation resistance of
Fig. 7. AES depth profiles of (a) (Ti0.25Cr0.1Al0.65)N and (b)
(Ti0.2Cr0.2Al0.55Si0.05)N after the oxidation test.
(Ti,Al)N coating is reportedly due to the formation of
protective Al2O3 layer by the outward diffusion of Al
atom [36]. This protective property is lost at higher
temperature when TiO2 layer is preferentially formed.
Because this TiO2 layer tends to develop vertical cracks
possibly due to the large difference in oxide to metal
volume ratio (Pilling–Bedworth ratio [37]). This means
that at 1000 -C rapid oxidation was taking place in the
coatings without Si. On the other hand, Al-rich protective
oxide layer was still formed on the surface of the
(Ti,Cr,Al,Si)N coatings as evidenced by the AES depth
profile, thus demonstrating the superior oxidation resist-
ance of the (Ti,Cr,Al,Si)N coatings. The oxide layer
thickness of the (Ti,Cr,Al,Si)N coating, as compared in
Fig. 6(a), was nearly 4 times thinner than (Ti,Cr,Al)N
coating. From the AES depth profile of (Ti,Cr,Al,Si)N
coating, the surface oxide layer has almost same
composition with the un-oxidized part and no specific
concentration or preferred oxidation was observed, such as
concentration of Si in the oxide layer reported by Choi et
al. [5]. The role of Si in improving the oxidation
resistance should be clarified to develop further and better
coating systems.
3.5. Cutting tests
High-speed dry cutting tests have been conducted against
hardened cold-working die steel (AISI D2, HRC 60) using
carbide end-mills. After the cutting length of 30 m, cutting
edge of the end-mill was observed using SEM and images
are shown in Fig. 8(a)–(c). The flank wear of the conven-
tional (Ti,Al)N coating was about 60 Am after 30 m of
cutting and also intensive sticking of the work-piece
material was observed. In case of (Ti,Cr,Al)N coating, the
flank wear was slightly less than (Ti,Al)N coating, it was 40
Am and no sticking was observed. Finally, the flank wear of
Fig. 8. SEM images of the worn cutting edge of (a) (Ti0.2Cr0.2Al0.55Si0.05)N, (b) (Ti0.25Cr0.1Al0.65)N and (c) (Ti0.5Al0.5)N coated end-mills after the cutting
length of 30 m.
K. Yamamoto et al. / Surface & Coatings Technology 200 (2005) 1383–1390 1389
(Ti,Cr,Al,Si)N coating was nearly one third of (Ti,Al)N and
half of (Ti,Cr,Al)N coating and also no sticking was
observed.
4. Summary
In this study, (Ti,Cr,Al,Si)N coatings with different
Al+Si fractions were deposited by cathodic arc method
and their properties were investigated in relation to the
Al+Si fraction and the substrate bias as an influencing
deposition parameter. Deposited (Ti,Cr,Al,Si)N coatings
had slightly less Al and enriched Cr fractions compared to
target compositions and the compositional difference
between coatings and target became larger as the substrate
bias was increased. (Ti,Cr,Al,Si)N coatings with the Al+Si
fraction of 0.6 had cubic B1 structure independent of the
substrate bias. But they had hexagonal B4 structure when
the Al+Si fraction was 0.65 and the substrate bias was 20
V. When the Al+Si fraction was 0.6, the grain size
decreased as the substrate bias was decreased from 14 to 8
nm. The grain size was almost constant value of 8 nm,
however, for the coatings with the Al+Si fraction of 0.65
independent of the substrate bias. The grain size was also
observed by TEM and it agreed with the results of the
XRD. The position change of (111) peak against the
substrate bias suggested that the compressive stress linearly
increased as the substrate bias was increased up to the
substrate bias of 70 V and it stayed constant for further
increase of the substrate bias. The indentation hardness and
elastic modulus was lower than the previously reported
(Ti,Cr,Al,Si)N coatings. In H –E* relationship, however,
(Ti,Cr,Al,Si)N coatings tended to have lower E* compared
to (Ti,Cr,Al)N coatings and this suggested that (Ti,Cr,Al,-
Si)N coatings, having lower H3/E*2 values, were likely
more resistant to plastic deformation. The oxidation
resistance of (Ti,Cr,Al,Si)N coating was much higher than
(Ti,Cr,Al)N coating that was evidenced by the fact that
oxide layer thickness was nearly 4 times thinner than
(Ti,Cr,Al)N coating. No concentration of specific element
was observed in the oxide layer and this left the
mechanism of high oxidation resistance of (Ti,Cr,Al)N
coating issue of future investigation. Finally, high-speed
dry cutting tests demonstrated that (Ti,Cr,Al,Si)N coating
was quite suitable for this purpose.
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