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1

The development perspectives of Physical Vapour Deposition technologies

Dobrzańska-Danikiewicz A. D.

Journal of Achievements in Materials and Manufacturing Engineering

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2012

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Vol. 54, nr 1

103--109

EN

Purpose: The goal of this paper is presentation of comparative analysis results concerning the most perspective technology groups included in common called Physical Vapour Deposition (PVD) during the next 20 years. Design/methodology/approach: In the framework of carried out research the value of the given technologies against the environment background has been determined and the development strategies for them has been defined. Moreover, for each from 10 analysed technology groups the technology roadmaps has been created. In carried out research source data collected during the three iterations of wide e-foresight expert research concerning the priority technologies in surface materials engineering area having the best development perspectives or key importance in industry has been used. Findings: The carried out research pointed out the industrial importance of PVD technologies and good perspectives for these technology groups. Especially, the research results shows the best long-term development perspectives for CAD and RMS, however the strategic positions of PLD, ED-PVD, BARE, PPM, and IBAD are also promising. Research limitations/implications: Research concerning PVD technologies constitute a part of a larger research project aimed at identifying, researching, and characterising the priority innovative technologies in the field of materials surface engineering. Practical implications: The practical implementation possibilities of the given technology groups taking into account market products and industry branches in the last part of the paper are presented. Originality/value: The novelty of this paper is to evaluate the value of PVD technologies in the background environment with their future development perspectives determination using custom computer integrated development prediction methodology.

2

Synergy effect of heat and surface treatment on properties of the Mg-Al-Zn cast alloys

Tański T.

Journal of Achievements in Materials and Manufacturing Engineering

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2012

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Vol. 54, nr 2

260--274

EN

Purpose: The aim of this paper is to present the results of the author’s own investigations concerning heat and surface treatment of Mg-Al-Zn magnesium alloys. Design/methodology/approach: The test results presented concern the characteristics of synergic heat and surface treatment impact on the structure and properties of Mg-Al-Zn cast magnesium alloys. The surface treatment of the magnesium alloys was carried out with the use of chemical and physical deposition methods from PA CVD and CAE PVD gas phase and laser surface treatment, including in particular laser feeding of hard ceramic particles into the surface of materials produced, enabling the production of a quasi-composite MMCs (Metal Matrix Composites) structure. The tests of the surface and internal structure of materials with the use of macro- and microscopic methods were made with the use of light, transmission and scanning electron microscopy as well Raman spectrometry and X-ray phase analysis. The physical and mechanical properties of magnesium alloys after the standard heat and surface treatment operations were tested by methods appropriate for the properties. Findings: The results of mechanical and functional properties measurements of heat treated samples confirms, that the performed heat treatment, consisting of solution heat treatment with cooling in water, as well aging with cooling in air, causes strengthening of the MCMgAl12Zn1, MCMgAl9Zn1 and MCMgAl6Zn1 cast magnesium alloys according to the precipitation strengthening mechanism, induced by inhibition of dislocation movement due to the influence of strain fields of the homogeny distributed y-phase Mg17Al12 precipitates. The combination of properly chosen heat treatment with the possibilities of structure- and phase composition modeling of the magnesium alloys matrix using laser feeding provides an additive increase of mechanical and functional properties by significant grain refinement and production of micro-composite layers with homogeny distributed dispersion phases particle and characteristic zone structure. Increase of mechanical and functional properties of the investigated alloys is also possible by creating coatings on the surface from the gas phase. Practical implication Achieving of new operational and functional characteristics and properties of commonly used materials, including the Mg-Al-Zn alloys is often obtained by heat treatment, ie, precipitation hardening and/or surface treatment due to application or manufacturing of machined surface layer coatings of materials in a given group of materials used for different surface engineering processes. Originality/value: The originality of this paper consists in the presentation of a very extensive knowledge related to the methods of structure and properties forming of the surface of Mg-Al-Zn alloys, supported by the results of wide author’s research.

3

Surface layers on the Mg-Al-Zn alloys coated using the CVD and PVD methods

Tański T.

Journal of Achievements in Materials and Manufacturing Engineering

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2012

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Vol. 53, nr 2

89--96

EN

Purpose: The aim of this paper was investigated structure and properties of gradient coatings produced in PVD and CVD processes on MCMgAl9Zn1 magnesium alloys. Design/methodology/approach: The following results concern the structures of the substrates and coatings with the application of electron scanning microscopy ZEISS SUPRA 35; phase composition of the coatings using X-ray diffraction and grazing incident X-ray diffraction technique (GIXRD); microhardness and wear resistance. Findings: The deposited coatings are characterized by a single, double, or multi-layer structure according to the applied layers system, and the individual layers are coated even and tightly adhere to the substrate as well to each other. The analysis of coatings obtained on the surface of cast magnesium alloys by the PVD and CVD processes show a clear - over 100% - increase of the microhardness, compared to the base material microhardness. The best results of the sliding distance were obtained for the DLC coatings. Practical implications: Achieving of new operational and functional characteristics and properties of commonly used materials, including the Mg-Al-Zn alloys is often obtained by heat treatment, ie, precipitation hardening and / or surface treatment due to application or manufacturing of machined surface layer coatings of materials in a given group of materials used for different surface engineering processes. Originality/value: The paper presents the research involving the PVD and CVD coatings obtained on an unconventional substrate such as magnesium alloys. Contemporary materials should possess high mechanical properties, physical and chemical, as well as technological ones, to ensure long and reliable use. The above mentioned requirements and expectations regarding the contemporary materials are met by the non-ferrous metals alloys used nowadays, including the magnesium alloys.

4

Disadvantages of applied lacquer coatings on polymer substrate

Wierzbicki Ł., Kulesza J.

Journal of Achievements in Materials and Manufacturing Engineering

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2012

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Vol. 55, nr 2

291--298

EN

Purpose: The use of polymer parts in automotive industry gives economic and practical savings. This is evoked by weight reduction of the used construction elements. However, polymer parts usually require application of coatings to ensure high quality surface. The painting of polymer materials is one of the most popular and well known methods. Assumptions of the study presented in this article were an attempt to create an atlas of lacquer coating disadvantages. Design/methodology/approach: Assumptions of this study were an attempt to identify lacquer coating disadvantages. Samples of the parts with disadvantages were prepared with the use of microtome and then viewed on an optical microscope. The defects have been described and the causes of their formation have been identified. Findings: The paper shows the examples of common disadvantages of polymer coatings’ application in automotive industry. Research limitations/implications: In automotive industry, they are often used as a substrate - metals or other materials. The description and identification of disadvantages of coatings on these substrates requires further study. Practical implications: The identification of disadvantages of the applied lacquer coatings on polymer substrate allows to eliminate them. Through the improvement and generation of new technologies of coating industry as a major supplier to the very large automotive industry, the industry will continue to thrive, grow and maintain its economical competitiveness in the global marketplace. Originality/value: Applications of multilayer polymer coatings in automotive industry are rarely described in literature - especially the application on polymers substrate. The description and identification for the emergence of the most frequent reasons of lacquer disadvantage is a novelty in this article.

5

Microstructure and corrosion resistance of CrAlSiN, CrAlSiN+DLC, and CrN coatings

Lukaszkowicz K., Kwaśny W., Szewczenko J

Journal of Achievements in Materials and Manufacturing Engineering

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2011

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Vol. 45, nr 1

23--29

EN

Purpose: The main aim of the research was the investigation of microstructure and corrosion resistance of the nanostructured CrAlSiN, CrAlSiN+DLC, CrN coatings deposited by cathodic arc evaporation method onto hot work tool 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. Diffraction and thin film microstructure were tested with the use of the JEOL JEM 3010UHR transmission electron microscope. X-ray study for the analyzed coatings was carried out using X'Pert PRO system. A phase identification of the investigated coatings was carried out in Bragg-Brentano geometry (XRD), and in grazing incidence geometry (GIXRD). Investigation of the electrochemical corrosion behaviour of the samples done in a PGP 201 Potentiostat/Galvanostat, using a conventional three-electrode cell. To simulate the aggressive media, 1-M HCl solution was used under aerated conditions and room temperature. Findings: It was found that the microstructure of the PVD coatings consisted of fine nanocrystallites, of an average size of 8 nm -13 nm, depending on the coating type. The morphology of the coatings fracture is characteristic of a dense microstructure. Basing on the GIXRD pattern of the investigated coatings, only fcc phases was encountered. The tests carried out with the use of a GDOS technique indicate the occurrence of a transition zone between the substrate material and the coating. Deposition of the PVD coatings increases the hardness of the tool steel surface up to 22-40 GPa. The CrN coated sample showed the best corrosion resistance. Practical implications: In order to evaluate with more detail the possibility of applying these nanocomposite coatings for protection of tool steels, further investigations should be undertaken in order to determine the thermal fatigue resistance of the coatings. The very good mechanical properties of the nanocomposite coatings make them potentially suitable for industrial applications. Originality/value: The results of the investigation provide useful information on microstructure and protective properties of the nanocomposite coatings on hot work tool steels.

6

Characterization of powders used for LPPS Thin Film plasma spraying of thermal barrier coatings

Góral M., Drajewicz M., Pytel M., Kotowski S.

Journal of Achievements in Materials and Manufacturing Engineering

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2011

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Vol. 47, nr 2

157--165

EN

Purpose: The authors described in this article the basic properties of materials used for spray process of thermal barrier coatings under low pressure The characteristic of selected powders applied for bond-coats and outer ceramic layer was introduced. The authors presented the analysis of powders based on zirconium oxide stabilized by yttrium oxide, magnesium and calcium. Design/methodology/approach: The described powders was analyzed by scanning electron microscopy and particle distribution by IPS U analyzer. Findings: The ceramic powders were characterized by irregular particle shape caused by grinding process. The only exception was Metco 204 powder, with spheroid-shaped particles. Research limitations/implications: The ceramic powders were made of zirconium oxide, which was stabilized by different types of oxides: yttrium (Metco 204), calcium (Metco 201) and magnesium (Metco 210). It is necessary to assess influence of the oxide, stabilizing the yttrium oxide, on stability of obtained ceramic layer of TBC coating. Practical implications: Powders analysed in the article will be submitted to plasma spraying process with different methods. Originality/value: The ceramic powder used for LPPS-Thin Film process were first time described.

7

Structure of TiBN coatings deposited onto cemented carbides and sialon tool ceramics

Dobrzański L., Staszuk M., Konieczny J., Kwaśny W., Pawlyta M.

Archives of Materials Science and Engineering

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2009

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Vol. 38, nr 1

48-54

EN

Purpose: The aim of this paper was investigated structure of sintered carbides WC-Co type and sialon tool ceramics with wear resistance ternary coatings TiBN type deposited by cathodes arc evaporation process (CAE-PVD). Design/methodology/approach: Observation of fracture and topography studied coatings were done by scanning electron microscope. Chemical composition was determine by energy dispersive spectrometry (EDS) method. Thin foils of substrates and coatings by transmission electron microscopy (TEM) was done. Phases composition analysis carried out by XRD and GIXRD method. Findings: The investigated PVD gradient coatings deposited by CAE-PVD method are demonstrating fine-grained structure. The TiN, TiB and TiB2 phases were found in coatings and Β-Si3N4 phase was found in sialon tool ceramics. Coating onto sialon tool ceramics reveal shallow pinhole while coating onto cemented carbide is without discontinuity. Research limitations/implications: In the future investigations will progress for mechanical properties, e.g. roughness, microhardness, adhesion strength and operating properties. Originality/value: In this work the influence of parameters deposited coatings by CAE-PVD technique on structure and phases composition the ternary TiBN gradient coatings were investigated.

8

Criteria of microstructural assessment of the conventional and new TBC layers

Moskal G.

Archives of Materials Science and Engineering

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2009

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Vol. 38, nr 1

19-25

EN

Purpose: The purpose of this paper is to present principles and criteria of microstructural assessment of thermal barrier coatings (TBCs). The conventional layers are described in expert papers, whereas there is no literature on new type of thermal barrier coatings on the basis of RE2Zr2O7 compounds Design/methodology/approach: The study was carried out on the TBC layers, sprayed by using the conventional powders on the basis of yttria stabilized zirconium (YSZ) oxides and by using the powders of pyrochlore structure. Industrial powder type Gd2Zr2O7 was sprayed as a representative of a new group of materials to be sprayed with the APS method. Findings: The carried out analysis allowed to compare guidelines and criteria, which were used to assess the conventional TBC layer and their reference to barrier layers of a new type. The carried out study proved that heretofore used criteria of assessment for the TBC layers by using the conventional powders are sufficient to assess layers of a new type. Research limitations/implications: The carried out study suggests necessity to verify the received results in the case of the TBC layers, sprayed by using the powders of pyrochlore structures of other types. Practical implications: The received results show the possibility of using the heretofore criteria of microstructural assessment of the TBC layers as sufficient to get information on quality of the TBC layers of a new type. Originality/value: The information concerning basic principles in assessment of microstructural layers of a new type, which are sprayed with the APS method on high temperature creep resisting alloys, is an original value presented in this paper.

9

Comparison of the PVD coatings

Polok-Rubiniec M., Dobrzański L., Adamiak M.

Archives of Materials Science and Engineering

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2009

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Vol. 38, nr 2

118-125

EN

Purpose: of the paper was comparison of the structure, adhesion and wear resistance of the monolayers CrN and TiN PVD coatings deposited onto plasma nitrited X37CrMoV5-1 type hot work tool steel. Design/methodology/approach: Diffraction and thin film structue were tested with the use of the transmision electron microscopy. The surfaces’ thopography and the structure of the PVD coatings were observed on the scanning electron microscopy.The evaluation of the adhesion of coatings to the substrate was made using the scratch test. The wear and friction tests were performed on a pin-on-disc device at the room temperature and at the temperature of 500°C. Findings: The best wear resistance in both conditions (20°C, 500°C temperature) demonstrate the TiN coating. These test results correspond with the very good adhesion of the coating to the substrate material and its high hardness. The critical load Lc5 (coating total delamination) lies within the range 86-92 N, depending on the coating type. It was revealed that the coating damage mechanism in the scrtch test commences in all cases with the widespread coating at the edge of the scratch being made and next develops depending on the coating type and location of the originated defects. Practical implications: The good properties of the plasma nitriding and the PVD coatings make them suitable in various engineering and industrial applications. Originality/value: The duplex surfaces treatment of the hot work tool steel for tools made for work at the elevated temperature improves their abrasion wear resistance significantly, compared to coatings developed with the PVD process.

10

Comparison of the structure, properties and wear resistance of the TiN PVD coatings

Polok-Rubiniec M., Dobrzański L. A., Lukaszkowicz K., Adamiak M.

Journal of Achievements in Materials and Manufacturing Engineering

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2008

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Vol. 27, nr 1

87-90

EN

Purpose: The aim of the paper was to compare the structure, mechanical propeties, adhesion and wear resistance of the monolayer TiN PVD coatings deposited onto heat treated and plasma nitrided hot work tool steel X37CrMoV5-1. Design/methodology/approach: The microhardness tests of the PVD coatings were made with use of a dynamic ultra-microhardness tester. The topography of the surface and the structure of the PVD coatings was observed with use of scanning electron microscopy. The evaluation of the adhesion of coatings to the substrate was made with use of the scratch test. The wear and friction tests were performed with use of a pin-on-disc device at the room temperature and at the temperature of 500*C. Findings: IIn case of the TiN coating deposited onto the nitrided hot work steel X37CrMoV5-1 a very good adhesion to the substrate has been revealed in comparison with the TiN coating deposited onto the heat treated hot work steel. Taking into account the results of measurements, one can state that the lowest wear at certain conditions at both room and elevated temperatures is characteristic for the TiN coating deposited onto plasma nitrided hot work steel type X37CrMoV5-1. Practical implications: The results of the investigations provide useful information for applying the plasma nitriding and the TiN PVD coating for the improvement of the mechanical properties and wear resistance of tools made from hot work steels. Originality/value: The paper contributes to better understanding of the adhesion and wear resistance at the elevated temperature up to 500*C of the monolayer TiN PVD coating deposited onto the heat treated and plasma nitrided hot work tool steel.

11

Comparison of the PVD gradient coatings deposited onto X40CrMoV5-1 and HS6-5-2 tool steel substrate

Lukaszkowicz K., Dobrzański L. A., Staszuk M., Pancielejko M.

Journal of Achievements in Materials and Manufacturing Engineering

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2008

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Vol. 27, nr 1

79-82

EN

Purpose: The main aim of this research was investigation and comparison of selected properties of gradient coatings TiCN and AlSiCrN. In this paper both coatings were deposited by cathode arc evaporation physical vapour deposition (CAE-PVD) method onto high speed steel HS6-5-2 and hot work tool steel X40CrMoV5-1. Design/methodology/approach: Observations of surface and structures of the deposited coatings were carried out on cross sections in the scanning electron microscope. The phase composition of the investigated coatings was determined by means of the X-ray diffractometer. Tests of the coatings' adhesion to the substrate material were made using the scratch test. The microhardness tests of coatings were made with the ultra microhardness tester. Findings: The hard PVD gradient coatings deposited by cathodic arc evaporation method demonstrate the high hardness, adhesion and wear resistance. The critical load LC2, which is in the range 35-67 N, depends on the coating type and material substrate. The values of friction coefficient for the investigated coatings are changing within the range of 0.08-0.25. Research limitations/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. Originality/value: It should be emphasized 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 tools steel substrate are needed.

12

Mechanical properties of monolayer coatings deposited by PVD techniques

Dobrzański L. A., Lukaszkowicz K.

Archives of Materials Science and Engineering

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2007

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Vol. 28, nr 9

549-556

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 CuZn40Pb2 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 made 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/µm, 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 tools, 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.

13

Characterisation of APS TBC system during isothermal oxidation at 1100oC

Swadźba L., Moskal G., Mendala B., Gancarczyk T.

Archives of Materials Science and Engineering

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2007

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Vol. 28, nr 12

757-764

EN

Purpose: The purpose of presented investigations was metallographical characterization of failure modes of air plasma sprayed thermal barrier coatings system in isothermal oxidation test conditions at 1100C. Design/methodology/approach: The research allowed the characterization of microstructural changes during oxidation test of zirconia coating in area of ceramic top-layer, bond coat and superalloy substrate. The examinations were conducted on TBC's specimens after 50, 120, 500, 1000, 1500 and 2000h of exposition and encompassed a microstructural analysis with the use of macro and micro investigation-LM, SEM microscopy. Findings: It was found that the durability of commercially quality TBC system is related to progress of degradation modes of bond coat and top layer. During isothermal oxidation test, the bond coat was oxidized to form of a dens alumina and a porous mixed oxide layer between the top coat of YSZ and bond coat of NiCoCrAlY alloy. At the moment of oxidation acceleration, the process of cracks initiation and propagation was observed mainly in the mixed oxide layer near the YSZ. The observed crack propagation inducted the delamination and spallation of top coat after 1000h oxidation. Research limitations/implications: The discussed research showed that main reason of degradation in TBC system is related to development of cracks at the interface between thermally grown oxide and bond coat, within the top coat or at its interface with TGO. Practical implications: The results allow the determination of the degree of durability lost of the thermal brier coating system and specification of the time of safety operation. Originality/value: The obtained results are valuable contribution to characterization of TBC systems. They enable the identification of the degradation mechanisms, which enhances the durability and safety of high temperature operation.