PVD Technology (Tools)


Ongoing projects


Portrait photo Kalscheuer © Copyright: Carl Brunn


Dr. Christian Kalscheuer

Chief Engineer and Team Leader PVD-W


+49 241 80 96512



Fundamental investigations for the simulative dimensioning and knowledge-based production of PVD-coated cutting tools for turning operations

Short description:

The project aim is the availability of fundamental knowledge about the correlation between coating properties, such as coating morphology, coating thickness, coating hardness and residual stresses, the cutting edge microgeometry and the resulting wear and failure phenomena during continuous and discontinuous turning processes. These findings are used to develop and validate a simulation-based design method for PVD-coated carbide tools with an adapted cutting edge microgeometry. In addition, knowledge about the influence of the coating parameters on the resulting coating, composite and system properties will be generated as part of the basic characterization of the tools. The TiAlSiN coatings are produced in direct current magnetron sputtering (dcMS) / high power pulse magnetron sputtering (HPPMS) coating processes using an industrial coating unit.

Funding: German Research Foundation (DFG)
Project number: BO 1979/82-1
Duration: December 1, 2021 to November 30, 2024

Influence of HPPMS pulse parameters on stoichiometry and the formation of reaction layers on nitridic hard coatings for metal cutting

Short description:

The overall aim of the research period now applied for is to gain knowledge about the influence of the chemical composition of TiAlCrSiON nanocomposites on the interaction with steel under tribological load and on the damage collective in machining. After coating deposition, an influence of the chemical composition on the coating properties is investigated. Moreover, the relationships between the coating properties, the frictional behavior and the formation of reaction layers are investigated in tribological system tests. It is also investigated whether wear can be reduced in the system tests by increasing the aluminium and oxygen content. Finally, it will be investigated whether the correlations found in the system tests can be transferred to field tests. Here, the extent of the fundamental damage mechanisms in the machining process is investigated as a function of the frictional behavior.

Funding: German Research Foundation (DFG)
Project number: BO 1979/57-2
Duration: October 1, 2021 to September 30, 2023

Investigations of temperature active, friction reducing coatings for turning titanium alloys

Short description:

Aim of the research project is to gain knowledge on the cause-effect relationships that can lead to a reduction of the tool load in the machining processes of the difficult to machine alloy TiAl6V4 by use of self-lubricating CrAlMoN coatings. The self-lubricating effect is based on temperature-induced formation of easily shearable molybdenum oxides on the coating surface during the cutting process. The deposition of the CrAlMoN coatings with varied element content are carried out in a hybrid direct current Magnetron Sputtering (dcMS) / High Power Pulse Magnetron Sputtering (HPPMS) coating process using an industrial coating unit. In subsequent analyses the influences of the temperature-active element molybdenum on coating and composite properties are determined. The oxidation and diffusion behavior as well as the friction behavior are investigated in model tests. Furthermore, the tools are used in machining tests and subsequently subjected to a detailed damage analysis. In addition, a novel temperature measurement setup is used to analyze the cutting temperature during the turning process. The machining tests are planned on the one hand with CrAlMoN-coated tools. On the other hand, reference tests with uncoated and CrAlVN-coated tools are planned in order to clarify open questions regarding the present cutting temperature.

Funding: German Research Foundation (DFG)
Project number: BO 1979/69-2
Duration: March 1, 2022 to February 28, 2023