Coating Boehlerit Takes Tool Performance to a New Level

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With state-of-the-art HiPIMS coating technology, Boehlerit enhances the performance of its tools for titanium and stainless steels. Customized coatings ensure maximum tool life, optimal chip formation, and utmost precision for demanding machining tasks.

Boehlerit's carbide and precision tools solve demanding machining tasks worldwide and set standards in the processing of metal, wood, plastic, and composite materials. The Austrian experts' recipe for success undoubtedly includes high manufacturing depth with the latest technologies and extensive expertise in all aspects of tool manufacturing—from design to coating technology. With the CC800-HiPIMS coating system as one of the key components, Boehlerit is setting new standards in the machining of high-performance materials.

HiPIMS Technology Provides Competitive Advantages

The HiPIMS technology significantly enhances the quality and performance of the coatings: HiPIMS coatings are very smooth, yet hard and tough. They offer excellent adhesion and, thanks to the uniform coating thickness distribution, provide optimal wear protection for the tool.

Boehlerit benefits from both the exceptional performance of HiPIMS coatings and the flexibility of the coating systems. The ability to tailor coatings to the specific requirements of particular applications makes all the difference—especially for demanding applications. The technology, for example, enables the production of coatings with customized residual stresses—a crucial advantage in machining difficult materials.

Titanium Machining At the Highest Level

To machine unalloyed titanium grades such as Ti (ASTM1-11), α alloys, or α+β alloys (e.g., Ti-6Al-4V) with high reliability, Boehlerit has developed new indexable inserts. These achieve up to 40 percent longer tool life in practice compared to conventional solutions.

We owe these impressive results to the well-matched combination of selected carbide, special chipbreaker geometry, and high-performance HiPIMS coating.

André Feiel, Segment manager for machining at Boehlerit

"The carbide base is a K10 fine-grain substrate. It is particularly temperature-stable and shows low susceptibility to plastic deformation. The specially developed MT (Medium Titanium) chip breaker ensures secure chip breaking with sharp edges during medium and light roughing operations. And the icing on the cake is the 3-micrometer-thick (0.00012 inches) HiPIMS coating based on AluCon (TiB2)," says André Feiel, Segment Manager for Machining at Boehlerit.

The low affinity for non-ferrous metals and the high hardness make the TiB2 coating so successful in machining titanium with sharp edges. The HiPIMS coating material optimally protects against built-up edge formation. The extremely smooth coating surface ensures efficient chip evacuation. Thanks to reduced friction, the temperature in the machining process is lowered. The result: significantly longer tool life. The excellent adhesion, combined with the high hardness of up to 5,000 HV 0.05, enables peak performance in both wet and dry machining—often with increased cutting parameters.

Unmatched for Stainless Steels

High abrasive wear, poor chip breaking, built-up edges—milling stainless steels is among the most demanding tasks in machining technology. "Such high demands require a perfectly refined tool concept. Our newly developed grades BCM35M and BCM40M for milling stainless steels provide users with the perfect solution for these challenges," says André Feiel.

Proprietary HiPIMS Coating for Maximum Performance

Both milling grades are made from fine-grain carbides with an optimized hardness-to-toughness ratio—combining abrasion resistance with fracture toughness. Boehlerit determined the chipbreaker geometry and edge preparation after extensive simulations and application tests. The result: excellent cutting efficiency and perfect chip flow.

With the coating, we are breaking new ground and have developed a multilayer HiPIMS coating: it consists of alternating AlTiN and AlCrN single layers. The multilayer structure results in excellent abrasion resistance, even at higher temperatures, combined with good fracture toughness. Additionally, it delays crack formation. Extremely smooth coating surfaces minimize built-up edges and ensure outstanding machining results when milling stainless steels.

André Feiel, Segment manager for machining at Boehlerit

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