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Influence of the Crystal Structure of AlCrN on Tool Coating Properties and Wear in Dry Gear Hobbing

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Abstract:

Dry machining of gears demands advanced coating technologies to withstand high thermal and mechanical stresses. In this study, AlCrN coatings were deposited using the newly developed Focused Magnetron Sputtering (FMS) process and compared with conventional Cathodic Arc Evaporation (CAE)-AlCrN and boroncontaining CAE-AlCrBN coatings. XRD analysis showed that FMS produced a finegrained crystal structure with half the full width at half maximum (FWHM) of CAE-AlCrN. Stressoptimised deposition allowed a 60 % higher coating thickness with improved adhesion. Analogy gear hobbing tests (fly cutting tests) demonstrated that FMS-AlCrN had 52 % lower crater wear than CAE-AlCrN, while CAE-AlCrBN also improved crater wear resistance due to boroninduced grain refinement. However, both finegrained coatings exhibited increased flank wear compared to the coarse-grained CAE-AlCrN coating. The results show that FMS enables the production of dense, fine-grained coatings with superior adhesion and crater wear resistance, highlighting its potential for dry gear hobbing. Further optimisation of hardness and microstructure is required to balance crater and flank wear behaviour.

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Periodical:

Defect and Diffusion Forum (Volume 450)

Pages:

61-70

DOI:

https://doi.org/10.4028/p-LO2XLh

Citation:

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Online since:

April 2026

Authors:

Nils Paucke*, Martin Beutner, Andreas Lümkemann, Keith Thomas, Martin Učík, Hamid Bolvardi, Matthias Hackert-Oschätzchen

Keywords:

Crystal Structure, Dry Gear Hobbing, Fly Cutting Test, Wear

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Creative Commons CC BY 4.0

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* - Corresponding Author

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