Effect of Pulsed Substrate Bias on the Micromechanical Properties, Edge Integrity, and Machining Performance of Cathodic Arc AlTiN Coatings

Controlling deposition parameters is fundamental to obtaining the desired properties of cathodic arc physical vapor deposition (PVD) coatings. Achieving uniform coatings on tools with complex, sharp geometries remains a significant challenge due to localized ion flux concentration. Pulsing the substrate bias is an effective way of controlling deposition energy. However, while widely used in cathodic arc PVD, the relationship between the actual bias waveform, coating integrity on sharp tool geometries, and resulting machining performance has not been systematically established. This study investigates the effect of pulsed bias duty cycle (20% to 90%) and frequency (1 to 20 kHz) on the microstructural evolution, residual stress state, and machining performance of AlTiN coated tools. Real-time oscilloscope measurements demonstrated that system inductance and capacitance significantly distort the ideal bias waveform. Microstructural analysis via Focused Ion Beam/Scanning Electron Microscopy (FIB/SEM) cross-sectioning confirmed that all bias parameters generated a dense microstructure. While pulse frequency had no significant influence on micromechanical properties or residual stress states, the duty cycle was the dominant variable. High-energy deposition (90% duty cycle) increased hardness to 33.9 GPa but generated severe compressive residual stresses (−5.2 GPa). This extreme compressive stress led to catastrophic edge delamination on sharp solid carbide endmills. Conversely, a low-energy 20% duty cycle generated a coating with lower hardness (29.4 GPa) and a near-neutral stress state (0.5 GPa), effectively preserving the edge integrity. Unlike the endmills, the turning inserts maintained their edge integrity across all deposition conditions. During the high-speed (350 m/min) dry turning of AISI 304 stainless steel, all evaluated coatings exhibited comparable tool life and cutting forces. Wear progression was characterized by rake cratering, combined with abrasion and adhesion-induced attrition on the flank. The results indicate that tool life in this extreme environment is governed primarily by high-temperature thermo-chemical stability rather than initial room-temperature hardness. Lower-energy pulsed bias deposition therefore represents a robust strategy for coating a wide range of tool geometries, delivering equivalent high-speed machining performance while preventing stress-induced delamination on sharp features.