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The forging of lead-free brass alloys is characterized by low tool durability, presenting a significant challenge in industrial applications. To address this issue, unique magnetron-sputtered coatings based on WB and with the addition of Tantalum, were employed to increase tool life. These coatings were produced from proprietary sintered targets using the SPS-HiPIMS technology. Initially, the coatings underwent laboratory testing, where their microstructure, adhesion to the substrate, and mechanical properties were tested and evaluated. The next phase involved testing these coatings on tools used in hot flashless forging processes. The experiments were conducted on dies that were preliminarily gas-nitrided to provide a suitable substrate for the coating application. The results were compared with those of only nitrided dies.
The study involved the use of nitrided dies, dies with WB2.5 and with W0.76Ta0.24B2.5 coatings. After forging, the tools were observed to assess the wear mechanisms. Surface scans were performed to measure material loss by comparing the surface profiles before and after forging. Scanning Electron Microscopy (SEM) was used to analyze the contribution of various wear mechanisms, such as abrasive wear, thermo-mechanical fatigue, and plastic deformation, to the overall tool wear.
The results confirmed the beneficial impact of these coatings on enhancing tool durability. In certain cases, the service life of the tools was extended by up to 50 %. This study demonstrates that the application of newly developed W0.76Ta0.24B2.5 coating which can significantly improve the durability of tools used in the flashless forging of lead-free brass alloys, offering a promising solution for industrial manufacturing challenges.