International Journal of Refractory Metals and Hard Materials 107 (2022) 105880
Available online 5 May 2022
0263-4368/© 2022 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by- nc-nd/4.0/).
Texturing design of WC-Co through laser parameter selection to improve lubricant retention ability of cutting tools
J.M. V´azquez , J. Salguero , I. Del Sol
*Department of Mechanical Engineering and Industrial Design, Faculty of Engineering, University of Cadiz, Av. Universidad de Cadiz 10, Puerto Real (Cadiz) E11519, Spain
A R T I C L E I N F O Keywords:
Micro-texture Carbide tool WC-Co Cutting fluids Laser surface texturing Lubrication
A B S T R A C T
Laser Surface Texturing (LST) is widely used to modify hard material surfaces improving their physic-chemical and mechanical properties. This technology is particularly relevant for tungsten carbides, a material that requires high complexity methods when other micro-machining processes are used. LST allows innovative cutting tool designs that improve the machining behavior and enlarge the cutting tool lifetime.
This research analyses the influence of LST parameters on the track dimensions, roughness, microstructure, hardness, and lubricant retention ability of the modified surfaces. Twelve combinations of energy density of pulse and scanning speed created different geometrical patterns on WC-Co surfaces. LST parameters were related to specific shape and dimensions of the linear grooves. Energy density was proven as the most influential parameter for dimensional characteristics and roughness values. Specific channel morphologies increased the lubricant expansion area up to 50%, leading the lubricant to a linear track direction. Low scanning speed and high energy density also increased the surface hardness up to 20%. The surface composition was also modified.
The thermal effect of the laser treatments and the non-protective atmosphere increased the oxygen on the surface and modified the WC-Co microstructure. However, the thermal affected zone is considerably low compared to other texturing processes.
1. Introduction
High-performance metal applications usually select WC-Co tools and lubrication to increase tool life and achieve tight tolerances. Neverthe- less, cutting-tool design is basic to enhance the performance of cutting processes and increase their sustainability [1]. Particularly for light al- loys and hard-to-machine metals machining, tool texturing has been presented as a design characteristic to reduce tool wear and increase tool life by reducing tool-chip friction and cutting forces in machining ex- periments and simulation [2,3].
Several studies successfully improved the results regarding the forces involved in the process, the temperature achieved during the cutting operation, the surface quality of the part or the lubricant ability of the tool when textured tools were used [4,5]. However, apart from the differences presented by the material, the texture effect is determined by a wide range of parameters such as texture position, scale, shape, orientation, and dimension, and each of them has a different impact on the tool performance.
For instance, textures placed on the flank face reduce the
temperature involved in the process and the flank wear ratio, meanwhile the roughness of the machined part is usually slightly higher than the one obtained with non-textured tools [6,7]. Alternatively, textures placed on the rake face reduce chip-tool contact which leads to lower aluminum adhesion [8]. Additionally, rake face textures usually work as a storage for both, lubricant and debris. The fluid is stored into the texture which helps to keep it in contact with the chip on the edge of the tool for a longer period [9–12] reducing consequently the machining forces [13,14] while the debris storage reduces possible abrasion of the tool surface increasing its tool life [15]. Similarly, the use of specific combinations of laser processing parameters, mainly energy density (Ed) and scanning speed (Vs), allow the development of a wide range of textures on cutting tools, improving the characteristics of the tool for machining applications [16,17].
This effect on the lubricant ability only appears for microscale while nanoscale textures just affect the friction, being mainly used for multi- scale dimple patterns [18]. Besides, the selected shape is used to enhance some friction of wettability properties. Different patterns have been studied for machining tests, including zigzag patterns [19] and
* Corresponding author.
E-mail address: [email protected] (I. Del Sol).
Contents lists available at ScienceDirect
International Journal of Refractory Metals and Hard Materials
journal homepage: www.elsevier.com/locate/IJRMHM
https://doi.org/10.1016/j.ijrmhm.2022.105880
Received 2 February 2022; Received in revised form 29 April 2022; Accepted 30 April 2022
hybrid designs combining grooves and dimples [20,21], but the most extended design for these textures are dimple and groove patterns. Each design affects the tool behavior. Dimples modify friction and wear behavior generating micro-pool lubrication, improving the surface wettability, trapping abrasive particles, and reducing tool-chip contact [22]. Grooves present an anisotropic lubrication behavior [23] which
distributes the lubricant to the cutting area [24] but they may produce a derivative cutting of the chip depending on the pattern orientation.
Parallel grooves to the cutting edge may act as edges cutting the chip, increasing the forces and being fulfilled with chip debris instead of lubricant which removes its original purpose [25]. To inhibit the de- rivative cutting, Duan et al. [26] proposed a modified groove shape, which remarks the importance of the real manufactured texture shape and its possible effect on the cutting process.
Regarding the texture manufacturing process for tungsten carbides (WC-Co), laser is the most used technology. It enables to perform different texturing patterns with a reliable tolerance but the process parameters determine the texture geometry in terms of width, height, and homogeneity [27]. Hao et al. [28] studied the influence of the Ed on the height of the channel. Tong et al. [29] related the diameter of the grooves to the laser power and the laser speed to the homogeneity of the texture. Finally, Fang et al. [27] compared the dimensional deviation with the molten behavior of the material.
Table 1 Laser parameters.
Parameter Level
Ed (J/cm2) 5.89/11.79/17.68/35.37
Vs (mm/s) 50/100/150
Fig. 1. Indentation points for microhardness measurements.
Fig. 2. Laser track height of the samples.
Fig. 3. Vs effect in laser overlapping and microgrooves dimensions for Ed = 35.37 J/cm2.
Fig. 4. Track width of the samples.
Fig. 5. Aspect ratio of the tracks.
Additionally, the real manufactured texture will have an impact on the lubricant ability. Following the Cassie and Wenzel formula [23]
dimensional and geometrical characteristics can improve lubricant retention, which could lead to more effective MQL strategies. So far, few studies reveal the relation between the combined effect of the laser parameters and the lubricant retention ability of the carbide textures, and LST effect on the mechanical properties.
For this reason, this work presents an experimental study where micro-channels manufactured using LST are studied as a function of the processing parameters. Textures are characterized geometrically, analyzing width, height, and roughness; and morphologically. Addi- tionally, the lubricant retention ability of a commercial MQL lubricant was measured, also considering the anisotropy of the textures. Finally, the impact of the laser parameters on the hardness, microstructure, and composition is analyzed to verify no significant changes take place in the mechanical properties.
2. Experimental 2.1. Materials
Carbide WC-Co flat specimens with 2 mm thickness were extracted through wire electro-discharge machining (WEDM) from a carbide (10%
Co) cutting tool shank. All the specimens were polished up to a maximum roughness of Ra ≤ 0.1 μm and Rz ≤ 0.2 μm. Afterward, the specimens were textured using a nanosecond Ytterbium-fiber laser Rofin EasyMark F20 system with a pulse duration of 100 ns, and 60 μm spot diameter. According to Fang et al. [27], cemented carbide can have a complete ablation for ranges of Ed from 10 to 20 J/cm2. Based on this
premise, at least three different levels of Ed above 10 J/cm2 and three levels of Vs were used for the surface treatments of WC-Co, as shown in Table 1. The textured geometry for this study was a linear pattern with a 0.1 mm separation between lines and all the laser treatments were carried out under a non-protective atmosphere.
2.2. Micro-geometrical characterization of textured surfaces
Texture roughness was measured by a roughness measurement sta- tion (Mahr Perthometer Concept PGK 120). The measurements were taken following a perpendicular path to the texture pattern over three different areas of the sample. Roughness average (Ra), maximum height (Rz), and volume capacity (Vo) were analyzed. Additionally, the topo- graphical characteristics of the samples were also evaluated using a focus variable measurement machine Alicona IF-G5.
The irradiated morphology was evaluated on the cross-section of the textures where the height and width of the tracks were calculated using image processing analysis. From these measurements, the aspect ratio (AR) in percentage was calculated through Eq. (1).
AR (%) =(W − D)
W x100 (1)
Where W is the width of the track and D is the depth.
2.3. Lubricant retention characterization of textures
Contact angle measurements were performed with an MQL lubricant usually used for the machining of hard-to-machine materials (Acculube LB5000). A drop of 3 ml was placed on the top of the texture and the angle of the drop was measured through image processing using ImageJ software. This test was repeated 3 times.
Additionally, to evaluate the use of linear textures as micro-channels for the distribution of the liquid under specific directions, the surface area of the deposited droplets was measured by optical microscopy and image processing techniques.
2.4. Microstructure and mechanical properties of laser-treated surfaces Cross-section of the textures was obtained by WEDM and polished by mechanical techniques using diamond particles suspension as abrasive.
Vickers micro-hardness measurements were taken in five different depth values (y), separated 2, 4, 9,17, and 21 μm from the irradiated surface, using a Shimadzu HMV-2ADW micro-hardness tester (Fig. 1). Vickers micro-hardness measurements were performed at 0.49 N during 10 s.
Finally, optical and scanning electron microscopy (SEM) techniques were used to characterize the metallographic modification of the textured sections, evaluating the influence of the laser treatments on the microstructure of WC-Co. In addition, energy-dispersive X-ray spec- troscopy (EDX) was used to evaluate the oxidative phenomenon of the thermal surface treatment under an air atmosphere.
3. Results and discussion
3.1. Effect on the geometrical characteristics of the textures
The combination of laser processing parameters highly influences the morphological characteristics of the textures. Variations in Ed and Vs values define different topographies with specific laser track height and width.
On the one hand, Fig. 2 reveals a gradual increase in the height of the tracks with the Ed supplied. Low Ed values (5.89 J/cm2) do not ablate completely the surface of the carbide and created plane tracks where the laser irradiation modified the aspect without changing the geometry.
These results are consistent with the data obtained by Fang et al. [27], who did not find a complete ablation of the carbide at Ed lower than 10 J/cm2. On the contrary, deeper textures were obtained by more Fig. 6. Ra values of the textured surfaces.
Fig. 7. Rz values of the textured surfaces.
aggressive treatments. These modifications are related to the cooling process. It should be noticed that this increase is not linear due to the material characteristics, its volume, and the energy supplied. This fact may lead to slight stabilizations or even decreases of the texture ge- ometry for similar values of Ed.
However, it may be considered the opposite effect of Vs on height.
When high Ed is used, the influence of Vs becomes critical rising the depth of the track for low values. As is shown in Fig. 2, Ed height reaches a peak for the highest Ed (35.37 J/cm2) and the lowest Vs (50 mm/s).
This result may be explained by the fact that reduced Vs values keep the laser beam over the same area for a longer period, which is related to deeper tracks. This effect is produced by the overlapping of the laser Fig. 3.
On the other hand, width is mainly influenced by Ed. Fig. 4 shows an
increasing trend of width for Ed, slightly affected by Vs values. Vs in- creases the slope of the trend, enhancing it for higher values. This trend is consistent with Chu et al. [30] results, where it stands out that Vs does not follow a linear trend and differences between medium and high Vs values are not significant. This may be explained by the higher influence of the laser and deeper vaporization of the material, not affecting the surrounded areas. Similar to track depth, the overlapping rate is critical for width control. High rates were obtained for high Ed and low Vs, which correspond to 95% of overlapping. In this case, the material cannot cool as expected, increasing the laser effect in depth instead of width. This fact fixed the width values of Vs = 50 mm/s at a maximum of 50 μm. Comparing these results to those of Zhang et al. [31], it is confirmed that track depth and width depending on the Ed and Vs used during the process.
Fig. 5 shows the AR of the samples. This new parameter relates the width and depth obtained in each sample as a percentage, providing an idea of the shapes obtained with the beam incidence. Plain marks (100%) appear for insufficient Ed. No material was removed for Ed = 5,89 J/cm2, but the surface aspect was affected. AR values around 50%.
indicate a texture with the same dimension in the depth and width, usually developed as a semi-circular track. Most of the values are above 60%, which means tracks are wider than deeper, which may facilitate temporal lubricant retention.
3.2. Micro-geometrical characterization and visual aspects of the textures LST effect on WC-Co surfaces finishing was measured in terms of roughness. Fig. 6 shows Ra for the different sets of parameters and Fig. 7 reveals Rz values. These results are in agreement with those obtained by Xing et al. [32] and X. Jing [33]. Both parameters follow a similar trend to the height behavior previously described. Ra and Rz increase when Ed rises whereas Vs increase following different scales. As was expected, Fig. 8. Variation of track morphology with the scanning speed for fixed energy density (Ed = 11,79 J/cm2).
Fig. 9. Theoretical volume capacity (Vo) of the textures.
roughness parameters are highly influenced by the laser track shape, especially by its height and consequently by Ed.
However, other aspect features, mainly related to Vs, also impact roughness parameters. High Vs are related to a low overlapping of the laser beam which creates ununiformed laser tracks (Fig. 8). Despite the lack of uniformity on the surface of the microgroove may be reflected in the Ra, increasing its value just for some samples, the standard deviation of the results presented low variations (<0.17 μm), showing the stability of the process. Another aspect feature appreciated was the debris so- lidification on the external edges of the microgrooves (Fig. 8). The findings reflect those of Chu et al. [30] who found out that the solidi- fication is caused by the high thermal affected zone created by the nanosecond laser. This solidification appears for low values of Ed and high values of Vs, decreasing the real value of Ra. Nevertheless, the effect of debris solidification can be relatively reduced by using less aggressive irradiation conditions i.e. higher values of Vs and lower values of Ed. Additionally, Ra values are below 10 μm while Rz provides a similar range to the obtained for track height (0–35 μm). As a conse- quence, Ra could be discarded as a characterization parameter whereas Rz may be used as a measurement parameter to substitute channel height.
3.3. Effect on the fluid retention properties of the textured surfaces Fluid retention was evaluated through two different studies. The first one is based on the volume of the liquid that fits in the modified textures, while the second one analyzes the ability to expand lubricant droplets over the surface and through the laser tracks.
Fig. 9 shows the calculated Vo the texture can retain. This parameter is based on the roughness measurements. Vo results follow the same trend as the previously described in Fig. 2 and Fig. 4. Similar to height and width results, Vo has its maximum value for Ed = 35,37 J/cm2, which implies a high influence of Ed. Nevertheless, Vs does not have a clear influence on Vo. High Vs (Vs = 100 mm/s and Vs = 150 mm/s) do not have a gradual difference until Ed = 35,37 J/cm2, where Ra seems to have a considerable impact on the results. A singular point appears for Ed = 35,37 J/cm2 and Vs = 50 mm/s. At this point the impact of the AR is essential. Low AR values are related to knife shape grooves. These deeper and narrower tracks may have a poorer behavior than semi- circular ones. They are easier to fill with debris, losing their original purpose, lubricant retention [28].
Turning now to the lubricant retention, this parameter is tradition- ally measured using contact angle measurements. However, this value is Fig. 10. a) Lubricant retention areas b) non-textured lubricant contact angle, c) Expansion areas for non-textured samples and samples at different Ed and Vs = 150 mm/s.
Fig. 11. Material microstructure close to the laser track (Ed = 35.37 J/cm2; Vs = 100 mm/s).
not significant for angles lower than 10◦and due to the high fluidity of the selected commercial lubricant, most of the contact angle measure- ments presented values below 20◦. The non-textured value is 11.3◦, which enhanced the need to analyze the shape and the area of the drop expansion as an alternative measure.
The expansion area is highly influenced by the Ed (Fig. 10). It follows an increasing trend up to Ed = 17.68 J/cm2. This trend follows directly the roughness behavior, supporting the results of Edacherly et al. [34].
Since no microgrooves were created for Ed = 5.89 J/cm2, the values obtained are similar to the non-textured area, with an average area of 1.80 mm2. The linear patterns obtained in these cases are almost negligible in both width and height. This fact reduces its effect as micro- channels conduct fluids in specific areas and directions. At Ed = 11.79 J/
cm2 the linear patterns begin to behave as micro-channels (Fig. 10) but they have a double impact. The distance between the tracks does not act as a retention point of the drop, increasing its angle and allowing its fluidity in just one of the directions and acting as a retention element in the perpendicular direction of the textures. Then for Ed = 17.68 J/cm2 and Ed = 35.37 J/cm2, the distance and the height of the tracks increase enough to break the drop and expand it up to the limits of the texture.
Additionally, low Vs treatments (50 mm/s) produce channels with higher asperities height and depth, resulting in larger lubricated areas, as shown in Fig. 10. Therefore, it can be assumed that micro-textured
WC-Co surfaces improve the fluid-dynamic performance of cutting fluids conducting the fluid to specific directions following the texture patterns. This behavior is inversed to AR values, where low AR is related to the fluid-dynamic performance of the lubricant. Nevertheless, this behavior does not follow a linear trend and maximum values of lubricant expansion are achieved under 85% AR. It should be noticed that an AR value under 30% or knife grooves (Ed = 35.37 J/cm2 and Vs = 50 mm/s) may decrease the expansion area [28]. Therefore, the lubricant expan- sion may be optimized using a particular track geometry. This geometry may consider the correct AR and the uniformity of the track, including bulge size and distribution.
3.4. Effect on the microstructure of the textured surfaces
Fig. 11 shows the SEM analysis of one of the WC-Co textured sam- ples. This image was selected as an example but similar results were obtained for the different sets of parameters. According to SEM analysis, bulk material is a fine-grained WC-Co, within the submicron type [35].
Its grain size is between 0.5 μm to 0.9 μm and typical hexagonal sintered cemented carbides grains are observed. No significant changes in grain size are found between the texture area and the bulk material. No modifications on the η-phase or γ-phase were found either. EDX analysis shown in Fig. 12 confirms the stable composition of the carbide.
Fig. 12. Composition of the WC grain (blue) and the Co binder (red). (For interpretation of the references to colour in this figure legend, the reader is referred to the web version of this article.)
Fig. 13. Surface composition in areas close to the laser groove (Ed = 35.37 J/cm2; Vs = 100 mm/s).
Prismatic hexagonal grains have a (wt%) 77.10% W and 1.91%C composition and Co, V, and Na are found in the binder areas. These elements are common in WC-Co carbides. Co is the base binder, VC is usually added as a grain growth inhibitor, and Na as a process modifier to create platelet structures [36]. For this reason, it could be considered LST does not significantly modify the carbide microstructure.
However, the surface of the textured samples presented tone varia- tions. As it has been reported for other materials like steel or titanium alloys, surface tone modifications usually indicate oxidation [37–39].
This fact is particularly common for laser irradiation treatments under a non-protective atmosphere. Fig. 13 shows the EDX analysis carried out on a wide area close to the treated surface, which verifies this hypoth- esis. The total composition of the evaluated area is (wt%) of 79.28%W, 16.13%Co, 3.79%O, and 0.8%C. A modified oxygen-enriched layer is found on the bottom of the texture. Conglomerates of Co binder and oxygen are found in areas close to the edge of the laser track. Oxygen penetrated the surface using the gaps between WC grains produced during the laser treatment and it created the conglomerates between the WC grains.
3.5. Effect of laser texturing on the surface hardness of WC-Co
The average hardness value of the non-texture sample is 2332 HV.
This value is slightly higher than typical ultrafine tungsten carbide hardness, which value is within the range of 2000 to 2200 HV [36].
Nearly any sample reveal significant variations with the raw material, with an average hardness of 2142.12 HV. In contrast, small variations are observed at different distances from the texture (Fig. 14). Almost every sample is stable at 4 μm, with hardness values between the theoretical range. It should be noticed a slight drop (up to 10%) at 2 μm, followed by a slightly increasing trend as the measures go away from the surface at 3% on average. No significant changes were found for Ed from 5.89 J/cm2 to 17.68 J/cm2. At these Ed values, the impact of Vs is negligible with variations between the maximum (2367 HV) and mini- mum (1943 HV) hardness. However, Ed 5.89 J/cm2 and Vs = 50 mm/s sample shows a singular point up to 4 μm, reducing the hardness up to 27.46%. This low hardness could be due to the combination of low Ed and high overlapping conditions. These conditions may result in high cooling rates which produce micro-crack. These micro-cracks reduce surface hardness and become critical at the closest areas to the surface.
In contrast, Ed = 35.37 J/cm2 and V = 50 mm/s sample increase the
hardness by up to 36.43%. High Ed combined with high overlapping may produce larger thermal affected zones. This effect is also appreci- ated in Ed = 17.68 J/cm2 and V = 50 mm/s sample but on a lower scale.
These results may be explained by the thermal effects and oxidation induced by laser treatments. As it's been previously investigated, both effects may change mechanical properties such as the hardness of the material [1,40].
4. Conclusions
In this paper, LST was used to obtain different morphological laser tracks on WC-Co surfaces. Laser processing parameters (Ed and Vs) were modified to study their influence on the microgroove's shape and size and its effect on the functional behavior. The following conclusions were made:
• Ed is the most influential parameter increasing the height, width, and roughness (Ra and Rz) of the textures. In particular, Ed increases Ra and Rz up to 8 μm and 35 μm respectively.
• Vs also plays an important role in increasing the range obtained for width and roughness but it decreases the micro-channel height. Vs is also related to micro debris solidification on the channel borders.
• The cooling process of the textured zone may be the cause of varia- tions in the dimensions of the laser tracks. The volume of molten material, the nature of the material, and the energy supplied can cause slight increases or decreases in depth.
• Rz has been proved as an alternative parameter to evaluate the height of the channels, obtaining differences lower to 10% for high values.
• Microstructure was not affected by LST but the non-protective at- mosphere induced thermal oxidation in the closest areas to the textures.
• The hardness variation was detected in the thermal affected zone, increasing its value by up to 36% for the most aggressive parameters.
Similarly, micro-cracks on the surface may reduce sample hardness by up to 27%.
• Optimum geometry of the microgrooves improves the lubricant retention by increasing above 50% the liquid expansion area toward specific directions. This lubricant retention is highly influenced by the Rz and microgrooves uniformity.
Fig. 14. Micro-cracks detected for Ed 5.89 J/cm2 and Vs = 50 mm/s sample and Vickers hardness behavior and track development as a function of laser texturing parameters.
Fundings
This work was supported by the Spanish Government (MINECO/
AEI/FEDER, Grant Project DPI2017–84935-R).
CRediT authorship contribution statement
J.M. V´azquez: Conceptualization, Formal analysis, Visualization, Writing – original draft, Supervision. J. Salguero: Funding acquisition, Project administration, Resources. I. Del Sol: Conceptualization, Data curation, Methodology, Investigation, Writing – review & editing.
Declaration of Competing Interest
The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
Acknowledgments
The authors acknowledge the support from the research group TEP- 231 and cutting-tool manufacturer Kendu.
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