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In this work, AlZrCrN composite dual-gradient coating was deposited on cemented carbide substrate using physical vapor deposition. Using the composite dual-gradient structure design, the thermal residual stress between layers was decreased and the bonding strength between coating and substrate was increased. Finite element simulation indicates that thermal residual stress in composite dual-gradient coatings is significantly smaller than that in CrN and ZrN single coatings. The bonding strength between composite double-gradient coating and substrate is found to be greater than that of the single-layer coating. The factors and conditions influencing the performance of composite dual-gradient coating can be obtained through numerical calculation. Based on the simulation, coating structure that has a gradual transition from the internal high-plastic long-comb Cr/CrN layer to the outer AlZrCrN wear-resistant layer with stubby morphology was prepared.

3D FEM modelling for stress simulation and experimental investigation of dual-gradient coating using PVD