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Ceramic cutting inserts coated with ten-fold alternating micro- and nanocrystalline diamond (MCD/NCD) layers grown by hot filament chemical vapor deposition (CVD) were tested in the machining of an Al based metallic matrix composite (MMC) containing 15 vol % Al2O3 particles. Inserts with total coating thicknesses of approximately 12 µm and 24 µm were produced and used in turning: cutting speed (v) of 250 to 1000 m·min−1; depth of cut (DOC) from 0.5 to 3 mm and feed (f) between 0.1 and 0.4 mm·rev−1. The main cutting force increases linearly with DOC (ca. 294 N per mm) and with feed (ca. 640 N per mm·rev−1). The thicker coatings work within the following limits: DOC up to 1.5 mm and maximum speeds of 750 m·min−1 for feeds up to 0.4 mm·rev−1. Flank wear is predominant but crater wear is also observed due to the negative tool normal rake. Layer-by-layer wear of the tool rake, and not total delamination from the substrate, evidenced one of the advantages of using a multilayer design. The MCD/NCD multilayer diamond coated indexable inserts have longer tool life than most CVD diamond systems and behave as well as most polycrystalline diamond (PCD) tools

Multilayer CVD Diamond Coatings in the Machining of an Al6061-15 Vol % Al2O3 Composite