A new titanium aluminium nitride (TiAlN) PVD coating has been developed for the machining of titanium, cobalt-chrome and stainless steel alloys used in medical devices. Both laboratory and production tests were conducted to evaluate the performance of the TiAlN coating. The ductility of the TiAlN coating was determined with a 4 point bend test connected to an acoustical emission detector. End mill cutting performance was determined by measuring flank wear for machining at two cutting speeds. Results indicate that the ductility of TiAlN is higher than TiN, TiC and TiCN coatings. The TiAlN coating also exhibits good hot hardness and oxidation stability up to 800°C. Cutting tests indicate that TiAlN outperforms TiN coatings. The TiAlN coating improved tool life 30 to 40% over un coated and TiN coated M-35 end mills. Field tests corroborate the results of lab tests. TiAlN coated end mills lasted twice as long as un-coated M35 tool steel when machining Ti-6Al-4V and 15-5-PH alloys. Overall productivity was increased 36% through increased speed and feed of cutting.
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