Ultrasonic Deposition of Carbon Nanotubes on Polycrystalline Cubic Boron Nitride Composites

Polycrystalline cubic boron nitride (PcBN) are super-hard materials with high hardness and excellent abrasive resistance, widely used in cutting tools for precision machining of automotive and aerospace parts; however, their brittle properties make them prone to premature failure. Coatings are often...

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Main Authors: Manuela Pacella, Sina Saremi-Yarahmadi, Luciano Lamberti
Format: Article
Language:English
Published: MDPI AG 2021-01-01
Series:Materials
Subjects:
Online Access:https://www.mdpi.com/1996-1944/14/3/516
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author Manuela Pacella
Sina Saremi-Yarahmadi
Luciano Lamberti
author_facet Manuela Pacella
Sina Saremi-Yarahmadi
Luciano Lamberti
author_sort Manuela Pacella
collection DOAJ
description Polycrystalline cubic boron nitride (PcBN) are super-hard materials with high hardness and excellent abrasive resistance, widely used in cutting tools for precision machining of automotive and aerospace parts; however, their brittle properties make them prone to premature failure. Coatings are often applied to PcBN to extend their range of applicability and durability. Conventional coating methods are limited to the thickness range of a few hundred nanometres, poor adhesion to the substrate, and limited stability under ambient conditions. To further the properties of PcBN composites, in this paper, we explore the use of ultrasonic bonding to apply thick coatings (30–80 μm) on PcBN cutting tools. For the first time, a multi-walled carbon nanotube (MWCNT) powder is preplaced on a PcBN substrate to allow an unconventional coating technique to take place. The effects of ultrasonic bonding parameters on the change of mechanical properties of the coated tools are investigated through scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), micro-hardness analyses, and white light interferometry. The structure of the carbon nanotubes is investigated through transmission electron microscopy (pre coating) and cross-section of the bonded MWCNTs is studied via focused ion beam milling and SEM to evaluate the bonding between the multi-walled nanotubes. Optimum processing windows (i.e., bonding speed, energy, and pressure) are discovered for coating MWCNTs on PcBN. Focus ion beam milling analyses revealed a relationship between consolidation parameters and porosity of MW(pCNT) bonds. The proposed method paves the way for the novel design of functional coatings with attunable properties (i.e., thickness and hardness) and therefore improved productivity in the machining of aerospace and automotive parts.
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spelling doaj.art-228fa90e9e254574a2c9554f97f4afef2023-12-03T14:12:00ZengMDPI AGMaterials1996-19442021-01-0114351610.3390/ma14030516Ultrasonic Deposition of Carbon Nanotubes on Polycrystalline Cubic Boron Nitride CompositesManuela Pacella0Sina Saremi-Yarahmadi1Luciano Lamberti2Wolfson School of Mechanical, Electrical and Manufacturing Engineering, Loughborough University, Loughborough, Leicestershire LE11 3TU, UKDepartment of Materials, Loughborough University, Loughborough, Leicestershire LE11 3TU, UKDipartimento di Meccanica, Matematica e Management, Politecnico di Bari, 70125 Bari, ItalyPolycrystalline cubic boron nitride (PcBN) are super-hard materials with high hardness and excellent abrasive resistance, widely used in cutting tools for precision machining of automotive and aerospace parts; however, their brittle properties make them prone to premature failure. Coatings are often applied to PcBN to extend their range of applicability and durability. Conventional coating methods are limited to the thickness range of a few hundred nanometres, poor adhesion to the substrate, and limited stability under ambient conditions. To further the properties of PcBN composites, in this paper, we explore the use of ultrasonic bonding to apply thick coatings (30–80 μm) on PcBN cutting tools. For the first time, a multi-walled carbon nanotube (MWCNT) powder is preplaced on a PcBN substrate to allow an unconventional coating technique to take place. The effects of ultrasonic bonding parameters on the change of mechanical properties of the coated tools are investigated through scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), micro-hardness analyses, and white light interferometry. The structure of the carbon nanotubes is investigated through transmission electron microscopy (pre coating) and cross-section of the bonded MWCNTs is studied via focused ion beam milling and SEM to evaluate the bonding between the multi-walled nanotubes. Optimum processing windows (i.e., bonding speed, energy, and pressure) are discovered for coating MWCNTs on PcBN. Focus ion beam milling analyses revealed a relationship between consolidation parameters and porosity of MW(pCNT) bonds. The proposed method paves the way for the novel design of functional coatings with attunable properties (i.e., thickness and hardness) and therefore improved productivity in the machining of aerospace and automotive parts.https://www.mdpi.com/1996-1944/14/3/516polycrystalline cubic boron nitrideultrasonic bondingcarbon nanotubesbonding of dissimilar materialssurface processingmicro-hardness
spellingShingle Manuela Pacella
Sina Saremi-Yarahmadi
Luciano Lamberti
Ultrasonic Deposition of Carbon Nanotubes on Polycrystalline Cubic Boron Nitride Composites
Materials
polycrystalline cubic boron nitride
ultrasonic bonding
carbon nanotubes
bonding of dissimilar materials
surface processing
micro-hardness
title Ultrasonic Deposition of Carbon Nanotubes on Polycrystalline Cubic Boron Nitride Composites
title_full Ultrasonic Deposition of Carbon Nanotubes on Polycrystalline Cubic Boron Nitride Composites
title_fullStr Ultrasonic Deposition of Carbon Nanotubes on Polycrystalline Cubic Boron Nitride Composites
title_full_unstemmed Ultrasonic Deposition of Carbon Nanotubes on Polycrystalline Cubic Boron Nitride Composites
title_short Ultrasonic Deposition of Carbon Nanotubes on Polycrystalline Cubic Boron Nitride Composites
title_sort ultrasonic deposition of carbon nanotubes on polycrystalline cubic boron nitride composites
topic polycrystalline cubic boron nitride
ultrasonic bonding
carbon nanotubes
bonding of dissimilar materials
surface processing
micro-hardness
url https://www.mdpi.com/1996-1944/14/3/516
work_keys_str_mv AT manuelapacella ultrasonicdepositionofcarbonnanotubesonpolycrystallinecubicboronnitridecomposites
AT sinasaremiyarahmadi ultrasonicdepositionofcarbonnanotubesonpolycrystallinecubicboronnitridecomposites
AT lucianolamberti ultrasonicdepositionofcarbonnanotubesonpolycrystallinecubicboronnitridecomposites