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Investigation of Wear Behaviour and Surface Analysis of a Coated H13 Material for
Friction Drilling Application
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Manuscript Number: PONE-D-25-17191

Article Type: Research Article

Full Title: Investigation of Wear Behaviour and Surface Analysis of a Coated H13 Material for
Friction Drilling Application

Short Title: Investigation of Wear Behaviour and Surface Analysis of a Coated H13

Corresponding Author: Sachin Salunkhe

Gazi Üniversitesi: Gazi Universitesi
Ankara, TÜRKIYE

Keywords: Coating; AlCrN coating; TiAlN coating; Wear; Surface roughness; Co-efficient of
friction; Surface Morphology; Scanning Electron Microscope; Oxditation wear;
Adhesive wear; Friction Drilling

Abstract: In recent years, industries have seen many advancements in finding proper tools for
machining to enhance productivity. It is essential to choose a proper friction drilling tool
that minimizes surface damage and improves tool life and productivity. In this study,
the wear characteristics of H13 steel were investigated through a pin-on-disc machine.
The wear mechanisms are focused on analyzing the surface morphology and wear
behavior. This investigation analyzes the wear characteristics of AlCrN and TiAlN
coating to improve tool life. The tempering process where carried out to improve the
hardness of the H13 steel tool from 37 HRC to 57 HRC. During the wear test process,
the temperature is maintained at 250 °C. Using an Atomic Force Microscope (AFM),
the worn surface of the samples was analyzed. Among the four samples (untreated,
heated, TiAlN, and AlCrN), the untreated samples were affected by adhesive wear and
oxidation. It is observed that the tempering helps the coated H13 samples to appear
wear-resistant; the material loss obtained for the coated samples is much less
compared to the uncoated samples. The abrasive wear is observed in the samples,
leading to an extensive friction coefficient. The untreated and heated sample CoF
values observed are 0.417 and 0.49; for TiAlN and AlCrN, the CoF values observed
are 0.014 and 0.047. This study reveals that TiAlNand AlCrN Coated H13 steel
exhibited the best wear response. Hence, it is suitable for Friction drilling applications.

Order of Authors: B Saravanan

S Selvakumar

Mathew Alphonse

Robert Čep

Sachin Salunkhe

Emad Abouel Nasr

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Cover Letter

To,
Editor,
PLOS ONE

Subject: Regarding manuscript submission

Dear Editor,

We would like to submit the enclosed manuscript entitled “Investigation of Wear

Behaviour and Surface Analysis of a Coated H13 Material for Friction Drilling
Application”, which we wish to be considered for publication in “PLOS ONE”.

No conflict of interest exits in the submission of this manuscript, and manuscript

is approved by all authors for publication. I would like to declare on behalf of me
co-authors that the work described was original research that has not been
published previously, and not under consideration for publication elsewhere, in
whole or in part. All the authors listed have approved the manuscript that is
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Thank you and best regards.

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Prof. Dr. Sachin Salunkhe (Corresponding author)
 Click here to access/download;Manuscript;Article- Wear &
FD_Revised.doc

Investigation of Wear Behaviour and Surface Analysis of a Coated H13

Material for Friction Drilling Application
1B Saravanan, 2#S. Selvakumar, 3Mathew Alphonse, Robert Čep4 Sachin Salunkhe5
Emad Abouel Nasr6
1
Department of Mechanical Engineering, Sri Ramakrishna College of Engineering,
Perambalur, Tamil Nadu, India
2
Department of Mechanical Engineering, Roever Engineering College, Elambalur (P.O),
Perambalur, Tamil Nadu, India
3
Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute
of Science and Technology, Tamil Nadu, India
4
Department of Machining, Assembly and Engineering Metrology, Faculty of Mechanical
Engineering, VSB-Technical University of Ostrava, 17. Listopadu 2172/15, 708 00 Ostrava,
Czech Republic;
5a
Department of Biosciences, Saveetha School of Engineering, Saveetha Institute of Medical
and Technical Sciences, Chennai, India
5b
Department of Mechanical Engineering, Gazi University Faculty of Engineering, Maltepe,
Ankara, Turkey
6
Department of Industrial Engineering, College of Engineering, King Saud University, P.O.
Box 800, Riyadh 11421, Saudi Arabia
Corresponding Author#: [email protected]
Abstract

In recent years, industries have seen many advancements in finding proper tools for
machining to enhance productivity. It is essential to choose a proper friction drilling tool that
minimizes surface damage and improves tool life and productivity. In this study, the wear
characteristics of H13 steel were investigated through a pin-on-disc machine. The wear
mechanisms are focused on analyzing the surface morphology and wear behavior. This
investigation analyzes the wear characteristics of AlCrN and TiAlN coating to improve tool
life. The tempering process where carried out to improve the hardness of the H13 steel tool
from 37 HRC to 57 HRC. During the wear test process, the temperature is maintained at 250
°C. Using an Atomic Force Microscope (AFM), the worn surface of the samples was
analyzed. Among the four samples (untreated, heated, TiAlN, and AlCrN), the untreated
samples were affected by adhesive wear and oxidation. It is observed that the tempering helps
the coated H13 samples to appear wear-resistant; the material loss obtained for the coated
samples is much less compared to the uncoated samples. The abrasive wear is observed in the
samples, leading to an extensive friction coefficient. The untreated and heated sample CoF
values observed are 0.417 and 0.49; for TiAlN and AlCrN, the CoF values observed are
0.014 and 0.047. This study reveals that TiAlNand AlCrN Coated H13 steel exhibited the
best wear response. Hence, it is suitable for Friction drilling applications.
Keywords: Coating, AlCrN coating, TiAlN coating, Wear, Surface roughness, Co-efficient
of friction, Surface Morphology, Scanning Electron Microscope, Oxditation wear, Adhesive
wear, Friction Drilling

1. Introduction

The usage of coating on materials plays a crucial role in improving performance and
durability [1]. Industries are finding a suitable abrasive, oxidation, and adhesion wear
solution. In the case of adhesion wear, the defect occurs due to the surface bonding, due to
this large amount of material transfers and delamination happens [2-3]. Because of more rigid
material and softer material mating the surface quality might go high in abrasive wear [4]. In
oxidation, the brittle oxides are formed based on oxygen reaction. Given finding a better
solution, an effective strategy like selectingthe appropriate material and surface treatment is
essential to reduce these types of wear [5]. It is observed that recent trends in nanotechnology
support in ensuring against corrosion and wear. Moreover, the coating industries look
forward to promoting sustainability by depositing eco-friendly coating [6]. The coating helps
extend material life, preventing thermal damage, and is heat resistance. Few coatings like
titanium nitride have confirmed that they can reduce friction, resulting be better surface finish
material [7-8]. Another advantage of coating is the reduction in the usage of coolants, this
helps in promoting an environmental practice [9]. Telasang et al. studied the magnetron
sputtering method; they reported that coatings like AlCrand AlCrFe are intricately structured,
offering various advantages like corrosion resistance and wear [10]. Chayeuski et al. reported
that coatings like titanium nitride (TiN) and diamond-like carbon coating can improve the
wear resistance and hardness of the material. In this investigation, the bonding between the
coating and subtract was analyzed, and the strong bonding between the surfaces improved the
tools' life [11-12]. Mishra et al. have examined WC/Co material usage on surfaces. The
samples were coated using AlCrN and AlTiN, respectively. The findings were compared with
untreated steel, indicating a 30% improvement in wear behavior [13]. In another study,
Arrabal et al. found that the alloys could be better protected using Plasma electrolytic
oxidation (PEO) coating; the wear rate was lower, up to 30%. The coating results have
proved an increase in hardness and porosity reduction. Further, the friction coefficient has
improved concerning the rise in load [14]. In another study, the content of TaCand TiC was
increased and added to substrates, which led to an improvement in the wear behavior of a
TiAlN-coated tool. Moreover, the results showed a 20% reduction in wear rate and a 15%
increase in tool hardness [15]. Due to the deposition of TiAlN in the subtract, it is observed
that the adhesion strength and hardness improved, rising from 16.7 N and 24.6 GPA to 17.3
N and 30.1 GPA, respectively [16-17]. It is also essential to study parent materials, especially
the research and the usage of H13 steelies characteristics of H13 steel and toughness and
wear resistance, making the H1 useful in the industry and extending the tool's life.
Furthermore, H13 steel has unique properties like toughness and wear resistance, and the
lower hardness of materials has led many industries to use it effectively. Adopting coating
will help reduce the risk of surface damage and withstand higher temperatures [18-20]. In
addition, the coating helps to serve as a barrier against abrasion, thermal fatigue, and friction
[21 -23]. Friction drilling is an innovative method in the hole-making process; the production
industry faces many challenges in saving the tool life, particularly in the heat-generated
process. To reduce heat generation, coating plays a significant role; it helps in migrating heat
and friction. Also, coating enhances the tool's hardness, which could help improve the tool's
wear resistance. The process parameters like spindle speed and load play a crucial role in
machining, directly affecting the coefficient of friction (CoF). In this study, two different
coating methods, TiAlN and AlCrN, have been compared for tribological investigation, and
the impact on the friction drilling tool was also investigated.

2. Experimental Procedure

The steel tool's chemical composition is stated in Table 1. Initially, the hardness is about 28
HRC; after the quenching and hardening of H13 steel improves the material hardness [24-25].
In the hardening process, the H13 samples were preheated at 950°C to 1050°C, followed by
the tempering process between 500-600°C for toughness. This helps refine the steel structure;
the hardness has been elevated up to 55 HRC and increased the wear and toughness. The
surface heat treatment process typically supports and improves the steel's hardness [26-27].
After the hardening, the samples were cleaned and kept in the vacuum chamber for
depositing coating. In the vacuum chamber, the Titanium Aluminum Nitride (TiAlN) is
vaporized by evaporation or sputtering. TiAlN atoms are deposited into the sample during
sputtering. The TiAlN turns into vapor while heating and then condenses on the substrate
during evaporation. This process is repeated until sufficient coating is deposited into the
sample. This process continues for the AlCrN process also.
 Table 1: Chemical Composition of H13 Steel

C Si Mn Cr Mo V Fe
0.39 1.14 0.41 5.0 1.4 1.1 Balance

The H13 steel tool is prepared as a pin (12 mm), and EN31(30 mm) is prepared as disc
material. Initially, the disk is mounted on a platform, where the platform rotates at a higher
rpm, and the pin is loaded against the disc. The rated parameters for the process are sliding
distance, diameter, and velocity are 1000 m, 30 mm, and 1.5 m/s respectively. Based on the
above parameters, the pin is loaded up to 20 N. Speed and time for wear study are calculated
as 955 rpm and 10 minutes, respectively. The wear rate and frictional forces were
continuously monitored and recorded during the Pin-on-Disc test. This research has focused
on adhesive wear and abrasive wear mechanisms.

Figure 1 Pin on Disk Setup (H13 sample mounted)

After the wear study Scanning Electron Microscopy (SEM) begins with testing the samples
[28-29]. SEM and EDS analysis interprets the samples to evaluate the surface morphology,
identify defects like cracks, and determine material composition. This study uses energy-
dispersive X-ray Spectroscopy (EDS) to analyze the crucial elemental composition with high
accuracy of materials [30]. EDS enables quantitative and qualitative identification of
elements present in coated samples. Finally, the powerful tool Atomic Force Microscope
(AFM) is used to find the surface wear characteristics on the nanoscale. A sharp probe on a
flexible cantilever scans all samples separately. AFM captures surface material properties and
topography with sub-nanometer resolution, providing deep insights into surface roughness
[31]. Friction drilling is a five-step process; in the initial step, the rotating conical tool
approaches the work material, as shown in Figure 2. In the next stage, due to the high rotation
of the tool, friction is generated between the tool and the workpiece. This helps the workpiece
to soften and allows the tool to penetrate the workpiece without removing the excess
material. As a result, excess material forms at the top and bottom of the workpiece, known as
bosh and bush, which supports holding and acts as a washer. In the final stage tool retracted,
which helps in improving the surface finish. The whole process helps minimize the waste,
and no chips are formed.

Figure 2 Vertical Machining Centre

3. Results and Analysis

Using the Rockwell hardness measuring instrument, the hardness of H13 steel was evaluated.
This investigation shows the H13 steel tool hardness as 53-55 HRC. The hardness is achieved
based on tempering; the values are displayed in Fig. 2. The hardness has been observed based
on the distance from the surface; while the tempering temperature is less, the hardness values
are more. The hardness is achieved based on the carbides that have started to grow, similar to
the loss of the alpha phase, while the tempered martensite maintains higher hardness.
 Figure 2 Wear Loss vs. Hardness of sample
Fig. 3 shows the wear performance of H13 steel at varied times. The untreated steel has
presented the most wear. The wear rates have shown deviations with respect to the elapsed
time taken for the run. As the temperature has maintained up to 150 °C, the wear rate has also
maintained. However, the coated samples have shown a lower wear rate when compared with
uncoated and heated samples.

Figure 2 Wear Loss on H13 Steel Tool

Figure 3 shows the frictional co-efficient results obtained from the samples after 10 seconds.
The CoF plays a vital role in reducing wear rate; lower CoF values have achieved better
performance in wear and sliding. The frictional coefficient is observed to be low in coated
and increases in uncoated samples. Because of the sample's lubricating effect, a low CoF
value is found in coated samples. All samples initially had the same friction coefficient, but
the untreated sample's friction coefficient rose due to significant wear. The abrasive wear is
observed in the samples, leading to extensive friction coefficient; the untreated and heated
sample CoF values observed are 0.416 and 0.591, and for TiAlN and AlCrN, the CoF values
observed are 0.013 and 0.046.

untreated Heated

AlCrN TiAlN
Figure 3 CoF Images of All Samples

4.1 Surface Morphology of Wear Sample

Scanning electron microscopy images of the wear quality of coated samples and heat-treated
samples are expressed in Fig. 4. Micro cracks are visible in all the samples; microgrooves are
also visible in a few samples. The depth of the wear is not the same in all samples. However,
from Figure 4 d, it is seen uniform wear and a few scratches are visible in Figure 4 c. The
occurrence of plastic deformation and scratches is evident in the samples. Abrasive wear
resulted from higher hardness, as seen in Figure 4b. The plastic deformation, oxidation, and
material removal resulted from the surface mating at the point of contact; here, due to the
coating, the layers are sheltered even when there is a rise in temperature up to 250 °C. Due to
the plastic deformation, the oxide layers are formed at different places. Traces of adhesive
wear were found on the exterior of the uncoated sample and heated sample; these damages
are based on the shear and the contact pressure between the metal surfaces. In addition to the
findings, a minimal amount of oxide patches can be observed in Figs 4 a and 4b, while the
hardness difference cannot find any patches in the coated samples. The coated samples
covered the oxide layers based on the surface coating and its hardness, even though the
temperature was maintained up to 250 ℃. The surfaces 4c and 4d were smooth, a glaze-worn
surface was observed on the coated sample. The oxide layer during sliding may lead to crack
and spall off due to the brittle nature, further sliding may lead to delamination.

a) b)

Oxide Scale

Oxide Zone
Pits

c) d)
Wear debris
Scratches

Figure 4 Surface Morphology of all Samples a) untreated b) Heated c) AlCrN d) TiAlN

4.2 Energy Dispersive X-Ray (EDS)
Energy Dispersive Spectroscopy (EDS) is used in this work to observe the elemental
composition of the samples following the wear study and provide thorough quantitative data.
Figure 5 compares the composition of the wear surface and the coated region. As shown in
the figure, few surface micro-cracks were observed at the initial stages of the test. Moreover,
the spallation of the coating was also visible on the edges of the workplace. Compared with
untreated samples, the coated samples have better adhesion properties and wear resistance.
The untreated H13 sample's surface exhibits the noticeable adhesive wear depicted in Figure
5a. This results from the untreated steel's decreased hardness compared with the other
samples. The EDS inspections have confirmed the presence of iron nitrides based on the
existence of nitrogen and iron on the surface. As seen in Figs. 5a and 5b, the untreated and
hardened samples were discovered to have a high ferrous content; however, the samples'
resistance was aided by chromium and molybdenum. The EDS analysis confirmed the nitride
layer's existence in sample 5 c- f. This helps in improving the hardness in the sub-surface of
the coated H13 steel tool. In the coated samples also after the run, it is observed that the
existence of coating. However, when comparing the wear and un-wear places for TiAlN and
AlCrN coatings, the TiAlN coating demonstrated superior wear resistance, as seen by the
absence of H13 components in the worn areas.

a) b)

c) d)
 e) f)

Figure 5 Composition and Morphology of the wear surface of H13 samples 5 a)

untreated, 5 b) Hardened, 5 c) AlCrN non wear, 5 d) AlCrN wear, 5 e) TiAlN non wear
5 f) TiAlN Wear
4.3 Surface Topography
Figure 6 displays the 3D pictures obtained from the Atomic Force Microscope (AFM). After
the wear process, the images are captured to study the roughness of the worn surface. The
roughness of the surface was captured over the entire work area. The height values along the
z-axis were presented statistically. The parameters are primarily defined as Sv (maximum
height of Valleys), Sp (maximum height of peaks), Sz (surface height in max.), Sa (Surface
arithmetical mean height), and Sq (root mean square of surface). Atomic Force Microscopy
(AFM) is used to observe the sample's surface roughness; Figures 6 (a) and 6 (b) illustrate the
roughness values. It is understood that the coatings exhibited roughness compared to the face
of the samples. The roughness is high in the first two samples, mainly on the untreated
sample; better wear resistance was observed because of improving hardness. The surface
values are shown in Table 2. The AlCrN and TiAlN coating has exhibited less exterior
roughness than untreated and heated steel, as shown in Figures 6 (c) and 6 (d). Both the
coating surfaces contain higher levels of deposition TiAlN and AlCrN using the PVD
technique, resulting in elevated roughness. During cathodic deposition, the material
evaporates at a lower melting point, which leads to more particles with larger size and
volume. The untreated sample presented significantly less hardness but was relatively brittle.
For the entry of oxygen, cracks were found near the damaged surface, which may guide the
development of oxides finally into delamination. The plastic behavior leads to less surface
deformation; the heated sample has high hardness, which is less brittle. When compared to
the untreated sample, there are fewer wear cracks. The coated sample has strength, toughness,
and very fracture resistance, which will lead to improvement.
Table 2 Surface values using Atomic Force Microscopy (AFM)
Parameters Untreated Heated AlCrN TiAlN
Sa (nm) 72.631 169.26 164.869 148.75
Sq (nm) 87.404 211.25 199.03 193.13
Sy (nm) 532.48 1687.8 1053.8 1184.2
Sp (nm) 262.43 792.19 479.26 574.2
 Figure 6 The 3D Profile Optical profilometer

4.4 Surface Morphology of Friction Drilling Tool

The friction drilling process was carried out at a spindle speed of 3000 rpm and a feed rate of
0.1 mm/rev. The TiAlN-coated tool has a better surface finish compared to the AlCrN-coated
tool. Even after continuous running, the nanocrystalline layer is visible on the surface of both
tools. The bonding between the tool and the surface is deviated in a few places. Figure 7
shows the SEM morphologies of the Coated H13 steel tool. The worn surface of the TiAlN-
coated H13 steel tool is visible in Figure 7 (a). The image represents the typical oxidation
wear characteristics and delamination in the center areas where the temperature was higher in
that region. The oxidation wear can be visible only on the side walls in grey. In the TiAl-
coated tool material, peeling is visible in the central region. However, the material peeling is
very low, as shown in Figure 7 (b). the bonding between the tool and the coating is evident in
the TiAlN-coated friction drilling tool.

a) b)

Figure 7 Friction Drilling Tool a) AlCrN Coated Tool b) TiAlN Coated Tool
4.5 Surface Morphology of AZ31B

a) b)

Figure 8 Surface Morphology of AZ31B Material a) AlCrN Coated Tool b) TiAlN Coated
Tool
The surface morphology of Friction drilling AZ31B material of AlCrN and TiAlN coated tool
is shown in Figure 8 (a & b). The chips melt, and the additionals help to form a bushing in the
surface. In the image, there is no evidence of edge serrations, and also, the help of a
cylindrical portion of the tool helps to finish the surface with very little roughness. Because
of the heat generation and high friction, a strong adhesion is observed on the AZ31B
magnesium alloy in the deformation zone. The crack growth is prevented because of the
ductile nature of the AZ31B. The plastic deformation is observed due to the material's heat
behavior, which also helps promote early yielding.
4.6 Friction Drilling Analysis

a) b)

c) d)

Figure 9 a) Friction Drilling tool, b) Bushing Formation, c) Cylindricity

The friction drilled tool and bushing formed, and the conical shape is shown in Figure 9 (a, b,
c). The formation of the bushing and the surface roughness became evident in the above
figure. The surface roughness exhibited a smoother surface finish at 3000 rpm and 0.1
mm/rev. The bushing height is also well formed during the process because of the heat
generated and material flow. This process involves significant thermal and mechanical
interactions based on the selection of a lower feed rate selection. The high spindle speed and
the lower feed rate help form the material's bushing quality.
Conclusion
The results of the experimental study were used to make the findings. The wear resistance
and friction between the samples are analyzed under a variety of settings. Wear resistance
strongly depends on features such as adhesive wear and oxidation wear. The steel's hardness
influences the choice to offer a surface treatment. The coating aids in lowering delamination
and fracture resistance.

 Adhesive wear and oxidation wear were noted for the heated and untreated samples.
  TiAlN and AlCrN coatings show lower wear rates when compared to other samples.
The sample coated with TiAlN showed less wear than the one covered with AlCrN.
 For TiAlN and AlCr-coated H13, the material loss has been reported up to 0.00013
and 0.00079grams, respectively.
 The coefficient of friction for untreated steel was 0.147; for heated samples, it was
0.49; for AlCrN-coated samples, it was 0.047; and for TiAlN-coated samples, it was
0.014.
 The bushing height was also well formed at 3000 rpm and 0.1 mm/rev.
 Due to the ductile nature of the material, very minimal cracks were observed on the
surface of AZ31B.

Acknowledgments: The authors also extend their appreciation to King Saud University for
funding the publication of this work through Researchers Supporting Project number
(RSP2025R164), King Saud University, Riyadh, Saudi Arabia. This article was co-funded by
the European Union under the REFRESH – Research Excellence For Region Sustainability
and High-tech Industries project number CZ.10.03.01/00/22_003/0000048 via the
Operational Programme Just Transition and has been done in connection with project
Students Grant Competition SP2024/087 “Specific Research of Sustainable Manufacturing
Technologies” financed by the Ministry of Education, Youth and Sports and Faculty of
Mechanical Engineering VŠB-TUO. Article has been done in connection with project
Students Grant Competition SP2024/087 “Specific Research of Sustainable Manufacturing
Technologies” financed by the Ministry of Education, Youth and Sports and Faculty of
Mechanical Engineering VŠB-TUO.

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