O presente trabalho teve como objetivo principal avaliar o efeito dos recobrimentos TiN e TiAlN depositados por PVD a plasma na liga Ti-6Al-4V sob condições de fluência a 600 °C e corrosão em meios contendo cloreto a 25, 60 e 80 °C. O trabalho foi complementado com análises microestruturais e dos revestimentos superficiais utilizando-se as técnicas de difração de raios X, microscopias óptica, eletrônica de varredura e de transmissão, medidas de microdureza e oxidação isotérmica. Os resultados permitiram concluir que a liga Ti-6Al-4V constituída pela configuração de Widmanstätten apresentou dureza média de 343 HV para a condição como recebida. Após os tratamentos por PVD a plasma observou-se um recobrimento à base de TiN de espessura de 2,2 ?m e composição igual a Ti0,7N. O recobrimento a base de TiAlN/TiAlCrN apresentou espessura em torno de 6 ?m e composição igual a (Ti0,38Al0,62)N/(Ti0,31Al0,50Cr0,19)N. As medidas do potencial em circuito aberto e polarização mostraram que a liga Ti-6Al-4V apresentou comportamento ativo com transição ativo-passiva em solução HCl e comportamento passivo em solução NaCl a 25, 60 e 80 °C. As amostras recobertas por TiN e TiAlN/TiAlCrN apresentaram comportamento passivo nas duas soluções corrosivas e em todas as temperaturas estudadas. A amostra revestida por TiN depositado por PVD apresentou os menores valores de taxa secundária em fluência para tensões maiores que 222 MPa, contudo a amostra nitretada a plasma apresentou maiores valores de vida útil e níveis de ductilidade. A análise conjunta dos expoentes de tensão, energia de ativação e estrutura de discordâncias indicaram que o principal mecanismo de deformação por fluência foi controlado por escalagem de discordâncias. O cálculo do parâmetro de tolerância ao dano (W) contribuiu para indicar que os revestimentos TiN e TiAlN/TiAlCrN, apesar de protegerem a superfície da oxidação, diminuíram a capacidade de deformação plástica ao longo do estágio terciário e vida útil da liga Ti-6Al-4V, reduzindo a ductilidade. Finalmente, os tratamentos superficiais utilizados neste trabalho foram eficientes por seu efeito de proteção através da deposição de um elemento cerâmico mais estável na superfície e não por transformações causadas na microestrutura. / This study aimed to evaluate the effect of the plasma-assisted PVD TiN and TiAlN/TiAlCrN coatings in the Ti-6Al-4V alloy under creep conditions at 600 °C and under corrosion conditions in environments containing chloride at 25, 60 and 80 °C. The study was complemented by microstructural and surface coatings analysis using XRD, optical, scanning and transmission electron microscopy, microhardness and isothermal oxidation. The results showed that the Ti-6Al- 4V alloy with Widmanstätten morphology presented an average hardness of 343 HV for as received condition. After treatment by plasma PVD, it was observed a TiN based coating, with 2,2 ?m and composition of Ti0,7N. The TiAlN/TiAlCrN based coating presented 6 ?m of thickness and composition of (Ti0,38Al0,62)N/(Ti0,31Al0,50Cr0,19)N. Anodic polarization and open circuit potential showed that Ti-6Al-4V alloy had active behavior with active - passive transition in HCl solution and passive behavior in NaCl solution at 25, 60 and 80 °C. The TiN and TiAlN/TiAlCrN coated samples showed passive behavior in both corrosive solutions and at all studied temperatures. The TiN coated sample showed the lowest values of secondary creep rate for stresses greater than 222 MPa, however, the plasma nitrided sample showed higher levels of service life and ductility. The analysis of stress exponents, activation energy and dislocations structures indicated that the main mechanism of creep was controlled by climbing dislocations. The damage tolerance parameter (W) calculation contributed to indicate that TiN and TiAlN/TiAlCrN coatings, although protect the surface from oxidation, decreased plastic deformation ability throughout tertiary stage and service life of the Ti-6Al-4V alloy, decreasing ductility. Finally, the surface treatments, used in this study, were efficient for their protective effect by depositing a more stable ceramic compound on surface and not by transformations caused on microstructure.

O presente trabalho teve como objetivo principal avaliar o efeito dos recobrimentos TiN e TiAlN depositados por PVD a plasma na liga Ti-6Al-4V sob condições de fluência a 600 °C e corrosão em meios contendo cloreto a 25, 60 e 80 °C. O trabalho foi complementado com análises microestruturais e dos revestimentos superficiais utilizando-se as técnicas de difração de raios X, microscopias óptica, eletrônica de varredura e de transmissão, medidas de microdureza e oxidação isotérmica. Os resultados permitiram concluir que a liga Ti-6Al-4V constituída pela configuração de Widmanstätten apresentou dureza média de 343 HV para a condição como recebida. Após os tratamentos por PVD a plasma observou-se um recobrimento à base de TiN de espessura de 2,2 ?m e composição igual a Ti0,7N. O recobrimento a base de TiAlN/TiAlCrN apresentou espessura em torno de 6 ?m e composição igual a (Ti0,38Al0,62)N/(Ti0,31Al0,50Cr0,19)N. As medidas do potencial em circuito aberto e polarização mostraram que a liga Ti-6Al-4V apresentou comportamento ativo com transição ativo-passiva em solução HCl e comportamento passivo em solução NaCl a 25, 60 e 80 °C. As amostras recobertas por TiN e TiAlN/TiAlCrN apresentaram comportamento passivo nas duas soluções corrosivas e em todas as temperaturas estudadas. A amostra revestida por TiN depositado por PVD apresentou os menores valores de taxa secundária em fluência para tensões maiores que 222 MPa, contudo a amostra nitretada a plasma apresentou maiores valores de vida útil e níveis de ductilidade. A análise conjunta dos expoentes de tensão, energia de ativação e estrutura de discordâncias indicaram que o principal mecanismo de deformação por fluência foi controlado por escalagem de discordâncias. O cálculo do parâmetro de tolerância ao dano (W) contribuiu para indicar que os revestimentos TiN e TiAlN/TiAlCrN, apesar de protegerem a superfície da oxidação, diminuíram a capacidade de deformação plástica ao longo do estágio terciário e vida útil da liga Ti-6Al-4V, reduzindo a ductilidade. Finalmente, os tratamentos superficiais utilizados neste trabalho foram eficientes por seu efeito de proteção através da deposição de um elemento cerâmico mais estável na superfície e não por transformações causadas na microestrutura. / This study aimed to evaluate the effect of the plasma-assisted PVD TiN and TiAlN/TiAlCrN coatings in the Ti-6Al-4V alloy under creep conditions at 600 °C and under corrosion conditions in environments containing chloride at 25, 60 and 80 °C. The study was complemented by microstructural and surface coatings analysis using XRD, optical, scanning and transmission electron microscopy, microhardness and isothermal oxidation. The results showed that the Ti-6Al- 4V alloy with Widmanstätten morphology presented an average hardness of 343 HV for as received condition. After treatment by plasma PVD, it was observed a TiN based coating, with 2,2 ?m and composition of Ti0,7N. The TiAlN/TiAlCrN based coating presented 6 ?m of thickness and composition of (Ti0,38Al0,62)N/(Ti0,31Al0,50Cr0,19)N. Anodic polarization and open circuit potential showed that Ti-6Al-4V alloy had active behavior with active - passive transition in HCl solution and passive behavior in NaCl solution at 25, 60 and 80 °C. The TiN and TiAlN/TiAlCrN coated samples showed passive behavior in both corrosive solutions and at all studied temperatures. The TiN coated sample showed the lowest values of secondary creep rate for stresses greater than 222 MPa, however, the plasma nitrided sample showed higher levels of service life and ductility. The analysis of stress exponents, activation energy and dislocations structures indicated that the main mechanism of creep was controlled by climbing dislocations. The damage tolerance parameter (W) calculation contributed to indicate that TiN and TiAlN/TiAlCrN coatings, although protect the surface from oxidation, decreased plastic deformation ability throughout tertiary stage and service life of the Ti-6Al-4V alloy, decreasing ductility. Finally, the surface treatments, used in this study, were efficient for their protective effect by depositing a more stable ceramic compound on surface and not by transformations caused on microstructure.

Stainless steel is a metal material widely used in many industries because of its high tensile strength, toughness, and corrosion resistance. Machining stainless steel is challenging due to its high work hardening tendency, low thermal conductivity, and ductility of the material resulting in built-up edge formation. Machining stainless steel at lower cutting speeds must be performed with coolant, which adds to the cost of the process and increases concerns for the environment and the operator's health and safety. Industries such as the aerospace and die-mold industries demand high-speed machining to realize productivity targets. Therefore, a cermet tool material was selected for the present study because of its high temperature resistance, high bending strength, and fracture toughness. The study focused on investigating wear mechanisms and developing a coating on a cermet tool for dry high-speed machining stainless steel to increase tool life. The wear mechanisms of tools were investigated at a fixed cutting interval in relation to the tool's composition and microstructure. Scanning Electron Microscope (SEM) was used to study the microstructure and identify elements on the tool. X-ray diffraction (XRD) was used to identify the phases and concentrations of key elements on the tool. The new advanced in-house coating was developed with Super Fine Cathode (SFC) technology on a Kobelco AIP-20 Physical Vapour Deposition (PVD) coater. The micromechanical properties of the commercial coating and in-house coatings were investigated with the help of nanoindentation and scratch tests. Atomic Force Microscopy (AFM) and SEM were used to investigate the coating microstructure and surface topography. An Alicona variable focus 3D microscope was used to investigate wear volume and wear behaviour. It was discovered that various secondary carbides used by manufacturers to manufacture cermet tools change the microstructure, which affects the machining performance of the cermet tool material. Microchipping at the depth of cut (DOC) causes catastrophic notch wear. It was found that the developed in-house coatings were able to delay the initial wear (microchipping), which improved the tool's life by 318%. This research contributes to meeting the manufacturing industry's challenging demand for dry-high speed machining with reduced manufacturing costs. / Thesis / Doctor of Philosophy (PhD) / Cutting is the process of removing unwanted material from the bulk material to obtain the desired shape. Each metal material has unique mechanical properties that lead to various machining challenges. The cutting process is done with the help of a cutting tool that wears out during the process, and a coating layer is often used to protect the tool. Stainless steel 304 is a widely used material that is difficult to machine. This study includes a systematic approach to understanding the wear mechanisms of tools and existing commercial coatings during the dry machining of stainless steel 304. An in-house coating was developed and deposited on the selected cutting tool to protect it, reduce tool wear and extend its working life. The research results will help reduce machining costs by reducing tool and coolant costs and meet the current industry demand for dry high-speed machining. It will also reduce environmental impact by reducing waste and hazardous chemicals and addressing occupational health and safety concerns.