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Characterization and Wear Response of Magnetron Sputtered W–B and W–Ti–B Coatings on WC–Co Tools

In this work, α-WB2 and (W,Ti)B2 borides were applied as wear-resistant coatings to commercial WC–Co cutting inserts. Properties of coatings deposited by magnetron sputtering on WC–Co tools were studied. The crystal structure and chemical composition were analyzed. Vickers hardness and surface roughness were determined and wear test in semi-dry conditions was performed. The W–B and W–Ti–B coatings deposited on WC–Co substrate were smooth and very hard. However, titanium alloy W-B films with Vickers hardness of 3630 ± 260 HV0.02 were characterized by lower adhesion to the substrate, influencing the wear mechanism. Turning tests carried out on 304 stainless steel showed that the W–B film caused less wear compared to uncoated insert. Moreover, when W–B coating was applied, flank wear was reduced by 30% compared to uncoated WC–Co insert. Additionally, coating prevented chipping of the edge during cutting under test conditions. The research shows that W–B film deposited by magnetron sputtering has great potential as a coating for cutting tools for difficult-to-cut materials.