ナノレベルのコーティング技術
2020年5月27日切削工具材料に求められる特性とは、１硬いこと、２強靱であること、３高温で科学的に安定であることとの３つである。具体的には１では被削材の３倍以上の硬さや、２では２万気圧の応力に耐えられる。３では700～1100℃で被削材と反応しないことが求められている。
超硬合金、コーティング技術、ダイヤ、CBN工具、ナノ多結晶イヤモンドの中でも特に興味を持ったのが、コーティング技術だ。超硬合金をセラミックスなどでコーティングする。主にCVD化学的蒸着とPVD物理的蒸着の２つある。これら２つは原理から残留応力まで特徴がある。個人的にはアーク放電が見ることができるPVD法が好みだ。この物理的に表面にコーティング膜を形成する技術はコーティング温度400℃から600℃にもなる。アーク放電により蒸発・イオン化させた金属とガスが反応し、工具表面に蒸着するのである。驚くのは次である。PVDコーティング材種の進化だ。切削効率の増大から耐酸化性と切削速度がともに大きく増大しているのである。これにより高精度加工の増加が期待できる。今注目の第五世代と言われている「潤滑膜、酸化膜」の耐擬着性AIN膜とAI合金加工法DLC膜の新コーティングプロセスが採用されている（住友電工）。結果、コーティング技術の進化で加工速度が６倍以上になった。AC602Mなどが工具の例として挙げられるが、連続加工の実験は興奮した。今回は動画で残念だが、その精密な技術は日本が誇れる術である。住友電工によるとコーティング膜を薄くすることで耐摩耗性が上がった例がある。ACZ150だ。従来の材種では膜の損傷から溶着が発生し、膜の異常損傷からチッピングが発生するなど問題だったが、ACZ150は溶着が少なくエッジが立っている。ナノレベルで美しく正常摩耗できるのはコーティングお安堵や密着強度、母材など調整するのが困難だが「ACZ150」は可能にした。これからの住友電工の挑戦が楽しみだ。
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