About BOR4MACH
The BOR4MACH project aims to develop and validate advanced boride-based coatings — TiB₂, TaB₂, and their mixtures (TixTa(1-x)B₂) — for cutting tools used in the machining of high-strength nickel-based superalloys.
Nickel-based superalloys, widely used in the aerospace and energy sectors, pose major challenges during machining due to their high strength, poor thermal conductivity, and strong chemical reactivity at elevated temperatures. These factors lead to intense heat concentration at the cutting edge, rapid tool wear, material adhesion (built-up edge formation), and frequent tool chipping or failure. As a result, machining operations are less efficient and require frequent tool replacement. The development of coatings that simultaneously offer high hardness, thermal stability, oxidation resistance, and low friction is therefore essential for improving performance and extending tool life in demanding Ni-alloy cutting environments.
This international collaboration brings together four partners: Rzeszow University of Technology (RUT), Ultratech Sp. z o.o., Empa — Swiss Federal Laboratories for Materials Science and Technology, and Platit AG.
The project focuses on improving tool life and machining performance through a comprehensive workflow that integrates carbide substrate preparation, coating deposition, high-throughput combinatorial synthesis, advanced material characterization, and real-world industrial validation. Initial benchmarking is conducted using existing commercial coatings (e.g. AlTiN, TiN, TiCN), followed by the development and validation of novel TixTa(1-x)B₂ coatings. The project combines academic and industrial expertise to generate a large dataset that can guide the future design of oxidation-resistant, hard coatings optimized for cutting nickel-based superalloys.
The project runs for 24 months, from June 2026 to May 2028, and is funded under the Swiss-Polish Cooperation Programme, Research and Innovation Programme — Applied Research.
Project objectives
The overall objective of BOR4MACH is to develop, validate, and industrially benchmark a new class of boride-based coatings (TiB₂, TaB₂, and their mixtures) for cutting tools dedicated to machining nickel-based superalloys. The project aims to overcome current limitations of commercially available coatings in high-temperature machining by improving wear resistance, thermal stability, and oxidation resistance.
The specific objectives include:
- Synthesis and screening of TixTa(1-x)B₂ thin-film libraries using combinatorial HiPIMS techniques to identify compositions with maximized hardness and structural integrity.
- Advanced characterization of coatings’ mechanical, thermal, and oxidation properties using high-throughput methods and state-of-the-art techniques (nanoindentation, LFA, DSC/TGA, SEM, TEM, APT, FIB-TOF-SIMS, ERDA/RBS).
- Industrial deposition of the three most promising TixTa(1-x)B₂ coatings, selected from laboratory tests, onto real cutting tools using Platit’s commercial PVD systems.
- Tool performance validation in machining IN738 turbine blades at Ultratech under industrial conditions, followed by detailed wear and degradation analysis at RUT.
- Comparison with state-of-the-art commercial coatings to define performance benchmarks.
The project aims to deliver a validated coating solution with measurable benefits: +30% tool lifetime, reduced replacement frequency, and improved machining efficiency.
Consortium
Rzeszow University of Technology
Rzeszów, Poland — Consortium leader
Broad expertise in machining difficult-to-cut materials, including nickel superalloys, titanium alloys, and stainless steels. As project coordinator, RUT prepares substrates and tools, performs laboratory testing of coatings, and coordinates data integration across the consortium.
Visit website
Ultratech
Sędziszów Małopolski, Poland
Industrial machining company with real-world experience cutting nickel superalloys. As the project's industrial end-user, Ultratech validates coating performance under real production conditions, providing critical feedback based on rapid tool wear challenges in its own operations.
Visit website
Empa
Thun, Switzerland
Swiss Federal Laboratories for Materials Science and Technology. A pioneer in high-throughput material development, Empa uses advanced combinatorial deposition and characterization platforms to rapidly identify high-performance TixTa(1-x)B₂ coatings.
Visit website
Platit AG
Selzach, Switzerland
Global leader in developing and producing industrial PVD systems for hard coatings. Platit contributes benchmark coatings from its commercial portfolio and scales up the most promising lab-developed boride coatings for industrial validation.
Visit websiteImpact and Sustainable Development Goals
The BOR4MACH project supports multiple United Nations Sustainable Development Goals through concrete, verifiable contributions:
Quality education
Structured doctoral and postdoctoral training in materials science, equipping early-career researchers with expertise in thin-film coatings and industrial validation.
Gender equality
Gender balance in recruitment and decision-making roles across partner institutions.
Decent work and economic growth
Durable boride-based coatings that extend tool life and reduce production waste, fostering sustainable growth in advanced manufacturing.
Industry, innovation and infrastructure
Advancing PVD coating technologies and strengthening collaboration between academia and industry, enhancing European industrial innovation.
Reduced inequalities
Promoting access to advanced material technologies and engaging partners from different regions, fostering innovation capacity across borders.
Responsible consumption and production
Minimizing material waste and reducing the need for frequent tool replacement in energy-intensive sectors such as aerospace.
Climate action
Reducing energy use and indirect emissions related to machining through improved tool efficiency and lifetime.
Partnerships for the goals
Facilitating international cooperation, knowledge exchange, and long-term R&D partnerships across Poland, Switzerland, and the broader EU.
BOR4MACH is funded under the Swiss-Polish Cooperation Programme, Research and Innovation Programme — Applied Research, through the Support Measure "Research and Innovation in the field of Applied Research," implemented via the National Centre for Research and Development (NCBR) in Poland and Innosuisse — Swiss Innovation Agency in Switzerland.
Project number SPPW/BOR4MACH/0003/2025