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Forming the structure and properties of hybrid coatings on reversible rotating extrusion dies

Lukaszkowicz K.

Journal of Achievements in Materials and Manufacturing Engineering

2012

Vol. 55, nr 2

159--224

Purpose: The purpose of this monograph was to develop the methodology of formation, classification of properties and analysis of the structure of the surface layers, particularly the zone connecting the core and the coating and between the single layers created on the working surfaces of dies for the plastic formation on non-ferrous metals, with particular consideration to the specific nature of the extrusion process with reversibly rotating die (the KOBO method). Design/methodology/approach: Nanocrystalline structure layers production technology was developed, which included nanocomposite and low-friction layers with desired usable properties ensuring increased durability, abrasive and adhesion wear strength. The production process of dual-layer coatings, such as hard nitride layer - low friction DLC layer, was carried out in the continuous mode, on a device furnished with technologies of lateral, rotating cathodes and central rotating cathode, within one technological process. The developed coatings were tested under the working conditions for the elements coated with them (tools - dies), in order to establish the anticipated responses and properties during their use. Findings: The numerous interdisciplinary tests and analyses carried out in the scope of material science, production technology and computer techniques as well as the results obtained provided foundation for the formation of structure and tribological properties of the dies by controlled process conditions. The required final quality and durability of the tools for plastic metal formation in the extrusion process was obtained, which has been proven under operating conditions. Practical implications: Economically efficient process improvement, increased production efficiency and quality and products reliability through increased durability and unfailing operation time of tools for plastic formation of non-ferrous metals and improved usable properties shall guarantee measurable economic effects to the manufacturers and users of the products. Moreover, it will enhance their competitiveness both on the domestic and overseas markets. Originality/value: The Author’s original approach was the development of a dual-layer coating within one process. Such coatings consists of the internal hard PVD layer providing the appropriate hardness, strength, low thermal conductivity and restricting the impact of external factors on the wear process of the dies used for non-ferrous metals extrusion and the external low-friction layer providing good tribological properties, which, in combination with the appropriate formation of the transition zone between the base material and coating, and between the single layers in the coating, providing adhesion sufficiently high, enabled increased operating durability of the dies, and this has been proved in this paper.