Simulating erosion tests with statistically distributed micro-scale impact: a study on PVD TiAlN and AlCrN coatings

Beake, BD ORCID: https://orcid.org/0000-0001-6645-5057, Roberts, J, Zhu, Y ORCID: https://orcid.org/0000-0002-0591-3808 and Liskiewicz, TW ORCID: https://orcid.org/0000-0002-0866-814X (2025) Simulating erosion tests with statistically distributed micro-scale impact: a study on PVD TiAlN and AlCrN coatings. Wear. 205911. ISSN 0043-1648

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Abstract

A novel test method for more closely replicating the statistical, and apparently stochastic, distribution of multiple impacts that occur in solid particle erosion is to perform multiple impacts with controlled energy at different locations on the sample surface using a nanomechanical test instrument where sample stage movement between impacts enables each impact to be at a new position. In this work we have applied the new method to investigate the behaviour of hard, wear resistant PVD TiAlN and AlCrN coatings on cemented carbide, comparing their behaviour to that in cyclic micro-impact tests where the multiple impacts occur at the same position. Both coatings showed a strongly load-dependent behaviour in the statistically distributed impact test. A transition to lateral cracking with continued impact occurred more readily on AlCrN, with more extensive lateral cracking at higher load than on TiAlN. In contrast, in cyclic impact tests the TiAlN performed poorly at lower load whilst the AlCrN was resistant to lateral cracking. At high load AlCrN was more variable, with dramatic failure in some tests and no failure in others. Reasons for these differences are discussed.