Influence from surface roughness on steel transfer to PVD tool coatings in continuous and intermittent sliding contacts

► Continuous and intermittent sliding tests of PVD TiN and AlCrN against 20NiCrMo2. ► Two types of oxidised tribofilms form irrespective of sliding mode. ► The tribofilm formed in high pressure areas grew thicker in continuous sliding. ► Besides tribofilm formation, rougher surfaces result in steel transfer. ► Increased sliding length leads to cracking of the TiN but not of the AlCrN coating.