Investigation of Surface Layer Condition of SiAlON Ceramic Inserts and Its Influence on Tool Durability When Turning Nickel-Based Superalloy

SiAlON is one of the problematic and least previously studied but prospective cutting ceramics suitable for most responsible machining tasks, such as cutting sophisticated shapes of aircraft gas turbine engine parts made of chrome–nickel alloys (Inconel 718 type) with increased mechanical and thermal loads (semi-finishing). Industrially produced SiAlON cutting inserts are replete with numerous defects (stress concentrators). When external loads are applied, the wear pattern is difficult to predict. The destruction of the cutting edge, such as the tearing out of entire conglomerates, can occur at any time. The complex approach of additional diamond grinding, lapping, and polishing combined with an advanced double-layer (CrAlSi)N/DLC coating was proposed here for the first time to minimize it. The criterion of failure was chosen to be 0.4 mm. The developed tri-nitride coating sub-layer plays a role of improving the main DLC coating adhesion. The microhardness of the DLC coating was 28 ± 2 GPa, and the average coefficient of friction during high-temperature heating (up to 800 °C) was ~0.4. The average durability of the insert after additional diamond grinding, lapping, polishing, and coating was 12.5 min. That is superior to industrial cutting inserts and those subjected to (CrAlSi)N/DLC coating by 1.8 and 1.25 times, respectively.