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1

Structure and properties of CrN/DLC coating deposited by PVD ARC-cathodes and PACVD technology

Lukaszkowicz K., Paradecka A., Wiśniewska J.

Archives of Materials Science and Engineering

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2013

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Vol. 64, nr 1

40--44

EN

Purpose: The main aim of the this research was the investigation of the microstructure and the mechanical properties of the CrN/DLC coating deposited by hybrid PVD/PACVD process onto the X40CrMoV5-1 hot work tool steel substrate. Design/methodology/approach: The microstructure of the investigated coating was observed on the scanning electron microscopy and transmission electron microscopy. Tests of the coatings’ adhesion to the substrate material were made using the scratch test. A friction coefficient and the wear of coatings were determined in a test according to the ball-on-disk method. Findings: It was found that the microstructure of the CrN layer consisted of fine crystallites, while their average size fitted about 10 nm. The low-friction DLC show an amorphous character. The coating demonstrated a satisfactory adhesion to the substrate. The values of the critical load LC1 and LC2 of investigation coating account for, respectively, 9 and 39 N. In sliding dry friction conditions, after the break-in time, the friction coefficient for the investigated elements is set in the range between 0.03-0.06. The investigated coatings reveals high wear resistance. 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 double-layer coating within one process. Such coating 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 and the external low-friction layer providing good tribological properties.

2

Thermal stability of protective coatings produced on nickel based superalloy

Pytel M., Góral M., Motyka M., Miziniak T

Journal of Achievements in Materials and Manufacturing Engineering

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2012

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Vol. 51, nr 2

67--77

EN

Purpose: In this paper the results of high temperature cyclic oxidation tests of the protective diffusion coatings were presented. One of the main purposes of this work was to produce three different types of protective coatings by three different methods, i.e. slurry method, vapour phase aluminizing (VPA) and chemical vapour deposition (CVD), applied on nickel based Rene 80 superalloy substrate. Design/methodology/approach: The high temperature cyclic oxidation tests were carried out in 23h cycles at constant temperature 1100°C using Carbolite CWF 1300 chamber furnace. The samples were removed outside and were weighted after each cycle. The microstructure investigations of all kinds of the coatings were conducted by the use of light microscope (Nikon Epiphot 300) and a scanning electron microscope (Hitachi S-3400N). In the analysis influence of each method have been taken into consideration, i.e. especially influence of the kind of process on microstructure, coating thickness, chemical composition, first of all aluminium content (in outer β-NiAl layer so-called additive layer, diffusion layer and substrate). For the chemical composition examination x-ray energy dispersive (EDS) method was applied using Thermo equipment. Findings: It was found that the best high cyclic oxidation resistance of coating was obtained using CVD method (the maximal increase of samples weight after 28th cycle was observed, whereas in case of the slurry sample after 3rd and VPA after 5th). Research limitations/implications: The research results will be used in the future in order to increase coating thickness, aluminium content and to produce Pt, Pd, Zr, Hf and Si modified aluminide coatings. Practical implications: The CVD method will be used to coat internal passages of turbine blades, for example to produce modified aluminide bond coats on single crystal nickel based superalloys. Originality/value: Chemical vapour deposition is an unique method which is a “pure method” and allows to coat hardly accessible locations/areas.

3

Modification of the structure of the layers of superficial soda - calcium - silicon glasses nano molecules inorganic compounds

Drajewicz M., Sieniawski J.

Journal of Achievements in Materials and Manufacturing Engineering

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2012

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Vol. 53, nr 2

76--80

EN

Purpose: Finding a new surface treatment of glass. Design/methodology/approach: Testing results of the glass operational properties, such as bending strength, scratching resistance, micro-hardness, chemical resistance and optical properties have been presented. Nano-molecules were spread onto the heated glass surface, or onto cold glass surface and then heated up to temperatures close to the glass transformation, when nano-molecules penetrate into the glass surface. Findings: Refining method of soda - calcium - silicon glassy surfaces with inorganic compounds nanomolecules assures profitable operational properties of the glass, such as increased bending strength, scratching resistance, micro-hardness and chemical resistance without deterioration of the optical properties. Research limitations/implications: Structural definition of inorganic compounds nano-powders exposed to thermal processing, including grain-size analysis has been discussed. Practical implications: Optimal technical and technological parameters of the refining process have been selected. Originality/value: The presented method undoubtedly develops new possibilities not only in case of container glass, float glass and glass fibres but also in the field of glass processing.

4

Microstructure of thermal barrier coatings deposited by APS method with application of new type ceramic powders

Góral M., Sosnowy P.

Journal of Achievements in Materials and Manufacturing Engineering

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2012

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Vol. 55, nr 2

912--917

EN

Purpose: The paper presents results of structural research into thermal barrier coatings obtained by the APS. For the base the Rene 80 alloy was used, whereas a MeCrAlY-type multicomponent alloy was used for an interlayer. Design/methodology/approach: Throughout the research an optic microscope as well as a scanning electron microscope were employed. Measurements of the formed structure’s porosity were taken. Findings: It has been observed that application of novelty ceramic powders allows for a possibility of forming thermal barrier coatings, which can be used for protecting of the combustion chamber’s surface as well as turbine’s blades in an aircraft engine. Research limitations/implications: Further research into resistance to oxidation of these coatings seems necessary for experimental determination of their actual work temperature. Practical implications: They can be successfully applied in automotive industry for coating of petrol or diesel engine’s components. Originality/value: Investigation into possible applications of two-layer and composite coatings, which may improve the work temperature of thermal barrier coatings, is feasible.

5

Investigations of nanocrystalline and gradient coatings produced by cathodic arc evaporation technology

Lukaszkowicz K.

Journal of Achievements in Materials and Manufacturing Engineering

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2012

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Vol. 52, nr 2

75--82

EN

Purpose: The main aim of the this research was the investigation of the microstructure, corrosion resistance and the mechanical properties of the nanocrystalline TiAlSiN, CrAlSiN, AlTiCrN and the gradient TiAlN, TiCN, AlSiCrN coatings deposited by cathodic arc evaporation technology onto the X40CrMoV5-1 hot work tool steel substrate. Design/methodology/approach: The surfaces’ topography and the microstructure of the investigated coatings were observed on the scanning electron microscopy. Diffraction and thin film structure were tested with the use of the transmission electron microscopy. The microhardness tests were made on the dynamic ultra-microhardness tester. Tests of the coatings’ adhesion to the substrate material were made using the scratch test. Findings: It was found that the microstructure of the nanocrystalline coatings consisted of fine crystallites, while their average size fitted within the range of 11-25 nm, depending on the coating type. The critical load LC2 lies within the range of 46-54 N. In case of the gradient coatings it was found that the microstructure consisted of crystallites while their average size fitted within the range of 25-50 nm, depending on the coating type. The coatings demonstrated columnar structure as well as good adhesion to the substrate. The critical load LC2 lies within the range 46-59 N. The coatings demonstrate a high hardness (40 GPa) and corrosion resistance. Practical implications: In order to evaluate with more detail the possibility of applying these surface layers in tools, further investigations should be concentrated on the determination of the thermal fatigue resistance of the coatings. The very good mechanical properties of the nanocrystalline and gradient coatings make them suitable in industrial applications. Originality/value: The investigation results will provide useful information to applying the nanocrystalline and gradient coatings for the improvement of mechanical properties of the hot work tool steels.

6

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

7

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

8

Surface modification of sialon ceramics and cemented carbides by PVD coating deposition

Dobrzański L. A., Staszuk M.

Journal of Achievements in Materials and Manufacturing Engineering

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2011

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Vol. 49, nr 2

158--165

EN

Purpose: The paper includes investigation results of structures and mechanical properties of coatings deposited by the physical vapor deposition (PVD) techniques onto both sialon tool ceramics and sintered carbides. The paper includes two kinds of coating materials, isomorphic containg phases with TiN and AlN. Design/methodology/approach: In the paper were presented some observations of coating structures, before carried out in the scanning electron microscope. Phases composition analysis was carried out with using a XRD and GIXRD method. The roughness of surface measurements, microhardness tests and adhesion coatings to substrates tests were carried out It was found that some coatings showed a fine-grained structure. Cutting ability were defined on basis of technological cutting trials. Findings: Coatings, which had contained a AlN phase about hexagonal lattice showed a considerably higher adhesion to substrate from sialon ceramics rather than a coating contained a TiN phase about cubic lattice. As a result of setting coatings onto substrates, it was found a significant increase of both coatings hardness and surface roughness. The coatings contains a TiN phase shows a low adherence to substrate ceramic, what is the consequence of low cutting ability. Whereas, a coatings contains a AlN phase about hexagonal lattice show very good adherence to ceramic substrate as well as very good cutting ability. Research limitations/implications: The good adhesion (Al,Ti)N coating to sialon substrate is connecting with the same type of bonding in coat and sialon substrate. Originality/value: The good properties of the PVD gradient coatings make them suitable for various engineering and industrial applications.

9

Structure and adhesion of thin coatings deposited by PVD technology on the X6CrNiMoTi17-12-2 and X40CrMoV5-1 steel substrates

Lukaszkowicz K., Kriz A., Sondor J.

Archives of Materials Science and Engineering

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2011

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Vol. 51, nr 1

40-47

EN

Purpose: The main aim of the research was the investigation of the structure and adhesion of AlTiCrN, CrAlSiN and TiAlSiN coatings deposited by physical vapour deposition technology on the X40CrMoV5-1 hot work tool steel and the X6CrNiMoTi17-12-2 austenitic stainless steel substrate. Design/methodology/approach: Observations of surface and microstructure of the deposited coatings were carried out on cross sections in the SUPRA 35 scanning electron microscope. The microhardness tests of coatings were made with the SHIMADZU DUH 202 ultra-microhardness tester. The cohesion and adhesion properties of the coatings were made using the scratch test on the CSEM REVETEST device. Findings: It was found that the coatings present a compact structure, without any visible delaminations or defects. The morphology of the fracture of coatings is characterized by a dense structure, in some cases there is a columnar structure. The coatings demonstrated good adhesion to the substrate. The critical load LC2 lies within the range of 39-47 N, depending on the coating and substrate type. The coatings demonstrate a high hardness (~40 GPa). Practical implications: The process of covering steels with the thin PVD coatings is currently the most commonly method used to extend their life. Investigations of those coatings determining their scratchresistant properties and structure enable to pick out the optimum coatings for given industrial applications. Originality/value: The results of the investigation provide useful information on microstructure and scratch-resistant properties of the quaternary coatings deposited on the hot work tool steels and austenitic stainless steels.

10

Corrosion study of Ti6Al7Nb alloy after thermal, anodic and alkali surface treatments

Chrzanowski W.

Journal of Achievements in Materials and Manufacturing Engineering

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2008

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Vol. 31, nr 2

203-211

EN

Purpose: The aim of the work was to work out methods to improve biocompatibility of the Ti6Al7Nb alloy by creating thick, porous layer which ensure corrosion resistance and which could be a base for biological reactions leading to improvements in the tissue bond with the implant. Design/methodology/approach: Surface were prepared using electropolishing, thermal oxidation, thermal oxidation in TiO2 powder, anodic oxidation in NaH2PO4, in NaOH and spark oxidation in H2SO4+H3PO4. The roughness was examined using MSP and LPM. Corrosion resistance tests were carried out in SBF with pH values characterized for neutral, inflammatory and stagnation state. Topographical features were determined using confocal microscope. Findings: The surface treatments guarantee a smooth surface (low value of Ra and RZDIN) or porous surface structure and high corrosion resistance. Topographical parameters of the layer can be altered according to the duration of that process. The corrosion resistance of the specimens anodically oxidized in NaOH and spark oxidized possessed high corrosion resistance in SBF also in SBF with low and high pH value. Research limitations/implications: For the layers, further mechanical, chemical, biological and composition examinations are planed. Practical implications: The paper presents different surface treatments and their influence on corrosion and topographical properties and it could be useful for implant producers to take into consideration one of these methods. Anodic oxidation is a very simple method to ensure high corrosion resistance of implants. Originality/value: The paper presented new approaches to the surface preparation by spark oxidation in the acids and anodic oxidation in NaH2PO4 and NaOH at different parameters which haven't previously been used. There were proposed thermal oxidation in TiO2 powder that was not presented before. The paper compares corrosion resistance and topographical features of the Ti6Al7Nb modified by the new proposed and commonly used techniques.

11

Characteristics of Ti(C,N) and (Ti,Zr)N gradient PVD coatings deposited onto sintered tool materials

Dobrzański L. A., Staszuk M., Pawlyta M., Kwaśny W., Pancielejko M.

Journal of Achievements in Materials and Manufacturing Engineering

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2008

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Vol. 31, nr 2

629-634

EN

Purpose: The purpose of this paper is the characterisation of Ti(C,N) and (Ti,Zr)N thin films produced by cathode arc evaporation physical vapour deposition (CAE-PVD) method onto sintered carbides and sialon tool ceramics. Design/methodology/approach: The GDOS spectrometer was used to indicated chemical concentration changes of the coating components. The phase composition of the investigated coatings was determined by means of the X-ray diffractometer: standard and grazing incidence X-ray diffraction methods. Observations of surface topography and fractures of the deposited coatings were carried out in the scanning electron microscope. Tests of the coatings adhesion to the substrate material were made by use of the scratch test. The microhardness of substrates and coatings were measured by Vickers method. Cutting ability was determined by technological cutting trials. Findings: The studied PVD gradient coatings deposited by cathodic arc evaporation method are demonstrated high hardness, adhesion and wear resistance. The critical load LC2, which is in the range 21-53 N, depends on both the coating type and material substrate. Coatings deposited on sintered carbides are extending tools life. Practical implications: Ti(C,N) and (Ti,Zr)N gradient coatings can be applied for cutting tools. Originality/value: It should be emphasized, that the mechanical properties of the PVD coatings described in this work are very encouraging and therefore their application for products manufacturing at mass scale is possible in all cases where reliable, very hard and abrasion resistant coatings, deposited onto sintered tools substrate are required.

12

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.

13

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.

14

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.