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Investigations of the structure and properties of PVD coatings deposited onto sintered tool materials

Pakuła D., Staszuk M., Dobrzański L. A.

Archives of Materials Science and Engineering

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2012

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Vol. 58, nr 2

219--226

EN

Purpose: The paper presents investigation results of the structure and properties of the coatings deposited by cathodic arc evaporation - physical vapour deposition (CAE-PVD) techniques on the sialon tool ceramics. The Ti(B,N), Ti(C,N), (Ti,Zr)N, (Ti,Al)N and multilayer (Al,Cr)N+(Ti,Al)N, (Ti,Al)N+(Al,Cr)N coatings were investigated. Design/methodology/approach: The structural investigation includes the metallographic analysis on the scanning electron microscope. Examinations of the chemical compositions of the deposited coatings were carried out using the X-ray energy dispersive spectrograph EDS. The investigation includes also analysis of the mechanical and functional properties of the material: microhardness tests of the deposited coatings, surface roughness tests, evaluation of the adhesion of the deposited coatings and tribological test made with the „pin-on-disk”. Findings: Deposition of the multicomponent coatings with the PVD method, on tools made from sialon’s ceramics, results in the increase of mechanical properties in comparison with uncoated tool materials, deciding thus the improvement of their working properties. Practical implications: The multicomponent coating carried out on multi point inserts (made on sintered sialon’s ceramics) can be used in the pro-ecological dry cutting processes without using cutting fluids. However, application of this coating to cover sialon ceramics demands still both elaborating and improvement adhesion to substrates in order to introduce these to industrial applications. Originality/value: The paper presents some researches of multicomponent coatings deposited by PVD method on sialon tool ceramics

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Application of artificial intelligence methods in PVD and CVD coatings properties modelling

Dobrzański L.A., Staszuk M., Honysz R.

Archives of Materials Science and Engineering

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2012

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Vol. 58, nr 2

152--157

EN

Purpose: The aim of this paper is the presentation of developed computational model build with use of artificial neural networks. This model describes the influence of PVD and CVD coatings properties on the cutting edge durability from sialon tool ceramics covered with these layers. Design/methodology/approach: Obtained model has the ability to compute the durability of the PVD and CVD coatings coated on sialon tool ceramics blades determined in technological cutting trials of grey cast iron, basing on PVD and CVD coatings microhardness, thickness, grain size and their adhesion to the substrate. Findings: Results of researches, performed with use of computational model, revealed, that the greatest influence on the durability of coated sialon tool ceramics blades have the adhesion to the substrate. Smaller influence on blades durability has the size of grains. Minor influence on the cutting tool from other properties was obtained. Practical implications: Achieved results indicates, that the best coating’s adhesion to the substrate for coating material selection and design of PVD and VD coatings deposition process should have priority in implementation. Originality/value: Obtainment and utilisation of computational model builded with use of artificial intelligence methods

3

Low friction and wear resistant coating systems on Ti6Al4V alloy

Wendler B. G., Pawlak W.

Journal of Achievements in Materials and Manufacturing Engineering

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2008

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Vol. 26, nr 2

207-210

EN

Purpose: Development of an original multiplex hybrid treatment of Ti6Al4V alloy: diffusion hardening+intermediate hard gradient TiCxNy layer with use of continuous CAE+top low friction and wear resistant hard amorphous a-C layer with use of pulsed CAE method. Design/methodology/approach: Ti6Al4V substrates were diffusion hardened with interstitial O or N atoms with use of glow discharge plasma in the atmosphere Ar+O2 or Ar+N2. Next they were deposited with a hard gradient TiCxNy layer and with a hard amorphous a-C coating as the top one. The morphology, microstructure, chemical and phase composition, chemical bonds, microhardness and tribological properties during dry friction of the alloy after multiplex treatment have been investigated with use of SEM, EDS, XRD, XPS, Vickers diamond indenter and ball-on-plate test. Findings: An important increase of hardness of the near surface zone of the Ti6Al4V alloy has been achieved (from ∼ 350VHN to ∼ 1000 VHN), good adhesion between the gradient TiCxNy coating and the Ti6Al4V substrate as well as an important decrease of dry friction coefficient (down to ∼ 0.15) and a substantial increase of the resistance to wear (up to two orders of magnitude in comparison with non treated Ti alloy). Research limitations/implications: The research will be continued on greater number of specimens and against other counterbodies. Practical implications: It looks like that the Ti alloys can be used as mobile parts of machines due to high resistance to wear and low friction. Originality/value: A novel original multiplex hybrid treatment of Ti alloys has been developed at the Lodz University of Technology.

4

Selected manufacturing techniques of nanomaterials

Baron A., Szewieczek D., Nowosielski R.

Journal of Achievements in Materials and Manufacturing Engineering

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2007

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Vol. 20, nr 1-2

83-86

EN

Purpose: Enabling nanofabrication techniques as tools for experiments to understand the underlying science and engineering in the nanometer scale are required. This paper is a resume a range of technology and characterization tools relevant for nanoelectronics devices. Design/methodology/approach: An overview on bottom - up and bottom - down fabrication techniques are presented in this paper. As an alternative to the continually increasing cost of nanotechnology for manufacturing electronic devices, new strategies are examined in research, which are based on basic principles of physics and chemistry. For example, molecular self-organization mechanisms are developed in order to manufacture well-defined nanostructures with desired properties. Findings: This paper includes description of three methods of production nanolayers and monolayers molecular self-organization, Langmuir-Blodget films and Nanoimprint Litography. Research limitations/implications: The most extreme approach is to build nanostructures atom by atom with the help of scanning tunneling microscope at low temperatures. This is very slow method to build nanostructures, usually a couple of hours. An alternative approach for the formation of nanostructures is self-organization of atoms. Practical implications: The greatest advantage of litographic patterning is very large variety of different structures which can be defined by lithographic methods, Langmuir - Blodget (LB) films is another unpopular method to produce nanomaterials. Originality/value: Materials engineering technology stands today at the edge of a huge challenge: produce cheap nanomaterials for nanoelectronics. Building materials from the bottom up requires a multidisciplinary approach. This arena is unquestionably in the nano-dimension, where all fields of science and engineering meet.

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Mechanical properties of monolayer coatings deposited by PVD techniques

Dobrzański L. A., Lukaszkowicz K., Zarychta A.

Journal of Achievements in Materials and Manufacturing Engineering

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2007

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Vol. 20, nr 1-2

423-426

EN

Purpose: This research was done to investigate the mechanical properties of monolayer coatings (Ti/CrN, Ti/TiAlN, Ti/ZrN, CrN, TiAl/TiAlN, Zr/ZrN, TiN) deposited by PVD technique (reactive magnetron sputtering method) onto the substrate from the CuZn-40Pb2 brass. A thin metallic layer was deposited prior to deposition of ceramic monolithic coatings to improve adhesion. Design/methodology/approach: The microstructure of the coatings was cross section examined using scanning electron microscope. The residual stress was obtained from the parabolic deflection of the samples, after the coating deposition applying Stoney's equation. The microhardness and Young's modulus tests were made on the dynamic ultra-microhardness tester. Tests of the coatings' adhesion to the substrate material were using the scratch test. Findings: Obtained results show that all the coatings are in a state of compressive residual stress. The stiffness of the examined coatings is between 224 - 330 mN/micrometres, while Young's modulus is between 258 - 348 GPa. Concerning the adhesion of the coatings measured by scratch test, it has been stated that the critical load LC2 for coatings, deposited onto the brass ranges from 41 to 57 N. Research limitations/implications: In order to evaluate with more detail the possibility of applying these coatings in products used in the building and power industries, further investigations should be concentrated on the determination of the tribological properties of the coatings. Originality/value: The paper contributes to better understanding and recognition the structure of thin coatings deposited by PVD techniques. It should be stressed that the mechanical properties of the PVD coatings obtained in this work are very encouraging and therefore their application for products manufactured at mass scale is possible in all cases where reliable, very hard and abrasion resistant coatings, deposited onto brass substrate are needed.

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Improving adhesion and wear resistance of carbon coatings using Ti:C gradient layers

Cłapa M., Batory D.

Journal of Achievements in Materials and Manufacturing Engineering

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2007

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Vol. 20, nr 1-2

415-418

EN

Purpose: Very interesting combination of mechanical, physical and chemical properties of carbon films results in may possibilities of their industrial applications. Unfortunately the area of their usability is restricted due to poor adhesion caused by high internal stress. This problems are being solved using many different techniques including the deposition of Me:C (metal containing) gradient layers. A new deposition system allowing for simultaneous radio frequency plasma activated chemical vapour depostion (RF PACVD) and DC magnetron sputtering is presented in this paper. Design/methodology/approach: Ti:C gradient carbon layers were deposited on steel in a hybrid deposition chamber, employing radio frequency (13.56 MHz) plasma and DC magnetron sputtering. Layers with different thicknesses obtained by varied deposition parameters were examined. Friction coefficients and wear resistances were measured using the ball-on-disc method. Findings: Presented hybrid deposition system makes it possible to obtain thicker and still well adherent layers. Wear resistance was also improved noticeably and became several times better then for carbon layers with the same friction parameters. Research limitation/implications: Owed to the plasma based deposition method is the difficulty in covering complicated shapes. Use of materials other than titanium as a magnetron target, although certainly possible, is not covered in this paper. Practical implications: Ti:C gradient layers offer better wear resistance and allow for obtaining thicker carbon layers important in many tribological applications. They can be used where low friction coefficients are required. Originality/value: The combination of plasma deposition and magnetron sputtering in one process. This allows us to obtain varied gradients of chemical and phase composition in the deposited layers.