International Journal of
Advanced Multidisciplinary Application

Volume 3, Issue 6

• Author(s)Rajesh Kumar , Sushil Chandra , Meenakshi Rathore
• AffiliationDepartment of Mechanical Engineering, Bundelkhand Institute of Engineering and Technology, Jhansi, Uttar Pradesh, India Department of Metallurgical and Materials Engineering, Government Engineering College, Bilaspur, Chhattisgarh, India
• Page No.135-142
• Volume, Issue & YearVolume 3, Issue 6, June 2026
• Published On2026/06/15
• JournalInternational Journal of Advanced Multidisciplinary Application (IJAMA)
• ISSN No.3048-9350

Abstract

The demand for high-performance cutting tool coatings in precision machining operations has intensified with the adoption of dry and near-dry cutting strategies aimed at minimising coolant costs and environmental contamination. Physical Vapour Deposition (PVD)-based hard coatings are the dominant surface engineering solution for extending the tool life of high-speed steel (HSS) and cemented carbide cutting tools, with titanium nitride (TiN) and titanium aluminium nitride (TiAlN) representing the commercially dominant systems. The incorporation of ceramic nano-particles, particularly aluminium oxide (Al₂O₃) in the 5-10% volume fraction range, into the TiAlN matrix has been proposed as a route to further enhance hardness, oxidation resistance, and tribological performance by exploiting nano-composite strengthening mechanisms including grain boundary pinning and impediment of dislocation motion. This study investigates the structural, mechanical, and tribological properties of magnetron-sputtered TiAlN/Al₂O₃ nano-composite coatings deposited on AISI M2 high-speed steel substrates at Al₂O₃ volume fractions ranging from 2% to 10%. Characterisation by X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), and nanoindentation quantifies crystal structure, surface morphology, elemental composition, and mechanical properties. Tribological performance under dry sliding conditions is evaluated by ball-on-disc testing against Al₂O₃ counter-bodies at 25°C to 500°C, with Rockwell C adhesion testing providing interfacial bond characterisation. The 6% Al₂O₃ nano-composite coating achieves a peak hardness of 34.8 GPa, friction coefficient of 0.31, and wear rate of 2.9 × 10⁻⁶ mm³/Nm — representing 84% reduction in wear rate relative to uncoated HSS substrate — with retained oxidation resistance to 500°C confirmed by post-thermal-anneal XRD. Tool life improvement factors of 3.4× in face milling of AISI 4340 steel confirm the industrial relevance of the nano-composite coating system.

Keywords: PVD coating, TiAlN, nano-composite coating, tribology, wear rate, hardness, magnetron sputtering, high-speed steel, cutting tool life, nanoindentation

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