Abstract The limited lifetime of hot forging tools, caused by severe wear mechanisms such as abrasion, adhesion, thermal fatigue, and plastic deformation, remains a major challenge in forging operations. The study encompasses the entire process, from concept to industrial implementation. It begins with basic laboratory tests of the innovative material, followed by the application of protective coatings on an industrial scale to forging dies, which were then successfully used in production. The research presents the development and evaluation of novel hybrid surface treatments combining plasma nitriding with nanocomposite coatings based on tungsten boride alloyed with either tantalum (W-Ta-B) or titanium (W-Ti-B). The coatings were deposited using High Power Impulse Magnetron Sputtering (HiPIMS) from SPS-fabricated ternary targets. Laboratory characterization included structural, mechanical, tribological, and oxidation resistance analyses. The W-Ti-B films exhibited superhardness above 40 GPa and superior wear resistance, while the W-Ta-B coatings demonstrated enhanced oxidation resistance and adhesion. Both coatings revealed fine columnar microstructures and favorable H/E* and H³/E² ratios, indicating high resistance to plastic deformation and cracking. Industrial trials under hot forging conditions confirmed their effectiveness, with tool life extended by up to 80% compared with conventional nitrided tools. These findings demonstrate the strong potential of HiPIMS-deposited W-based boride coatings to significantly improve tool performance in demanding thermal and mechanical environments.
Mościck et al. (Mon,) studied this question.
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