A Severity Threshold for Frictional Stability in ZrB2SiC/ZrO2 Coatings: Implications for Tool Life in Titanium Machining

Ultra-high-temperature ceramic (UHTC) coatings offer a promising route to extending cutting tool service life under severe conditions. This work evaluates the tribological behaviour and wear regime transitions of ZrB2–SiC/ZrO2 coatings, deposited by physical vapour deposition (PVD) onto ASSAB-17 high-speed steel tool bits, during dry turning of Ti-6Al-4V. Structural, microstructural, mechanical, and tribological characterisation was performed by X-ray diffraction (XRD), scanning electron microscopy (SEM), nanoindentation, and pin-on-disc testing under three pressure–velocity (PV) severity levels, with worn surfaces analysed by SEM and profilometry. The coating exhibited a nanostructured ZrB2/β-SiC/t-ZrO2 architecture with a hardness (H) of 24 ± 3 GPa, a hardness-to-reduced-elastic-modulus ratio (H/Er) of 0.100, and an elastic resistance to plastic deformation (H3/Er2) of 0.240 GPa. Three tribological regimes were identified: running-in, steady-state sliding, and progressive degradation, with the highest severity (PV = 6.0 N·m/s) triggering degradation beyond approximately 620 m, a more than one-order-of-magnitude rise in wear rate, and the only case exceeding the tool-life criterion of maximum flank wear (VBmax = 0.30 mm) according to ISO 3685. The main advantage of the proposed approach is that it condenses tool-life-relevant behaviour into a single, easily measurable severity parameter, the PV product, directly applicable to coating design and the selection of safe machining-condition windows. The overall behaviour is consistent with a mechanism governed by the stability and regeneration capacity of a protective tribofilm. As the composition of this layer was not directly characterised, this mechanism is proposed as a phenomenological interpretation, from which a PV threshold is derived as a design criterion for UHTC coatings.