Study on tribological behavior and cutting performance of CVD diamond and DLC films on Co-cemented tungsten carbide substrates

The tribological behaviors of diamond and diamond-like carbon (DLC) films play a major role on their machining and mechanical applications. In this study, diamond and diamond-like carbon (DLC) films are deposited on the cobalt cemented tungsten carbide (WC-Co) substrate respectively adopting the hot filament chemical vapor deposition (HFCVD) technique and the vacuum arc discharge with a graphite cathode, and their friction properties are evaluated on a reciprocating ball-on-plate tribometer with counterfaces of silicon nitride (Si₃N₄) ceramic, cemented tungsten carbide (WC) and ball-bearing steel materials, under the ambient air without lubricating condition. Moreover, to evaluate their cutting performance, comparative turning tests are conducted using the uncoated WC-Co and as-fabricated CVD diamond and DLC coated inserts, with glass fiber reinforced plastics (GFRP) composite materials as the workpiece. The as-deposited HFCVD diamond and DLC films are characterized with energy-dispersive X-ray spectroscopy (EDX), scanning electron microscope (SEM), X-ray diffraction spectroscopy (XRD), Raman spectroscopy and 3D surface topography based on white-light interferometry. Furthermore, Rocwell C indentation tests are conducted to evaluate the adhesion of HFCVD diamond and DLC films grown onto WC-Co substrates. SEM and 3D surface topography based on white-light interferometry are also used to investigate the worn region on the surfaces of diamond and DLC films. The friction tests suggest that the obtained friction coefficient curves that of various contacts exhibit similar evolution tendency. For a given counterface, DLC films present lower stable friction coefficients than HFCVD diamond films under the same sliding conditions. The cutting tests results indicate that flank wear of the HFCVD diamond coated insert is lower than that of DLC coated insert before diamond films peeling off.     

Deposition of TiSiN coatings by arc ion plating process

Titanium silicon nitride (TiSiN) thin films were deposited on tungsten cemented carbide tools by cathode arc ion plating (AIP) process using alloy TiSi targets. The effects of silicon addition and negative substrate bias on the development of the textures of films were studied systematically by varying the bias voltage from −20 to −200 V. The structural features of the films were investigated in detail using X-ray diffraction. The effect of the texture on such mechanical properties as hardness and adhesion of the films was also studied. A maximum hardness of 42 GPa was obtained at a DC substrate bias of −150 V. The characteristics of TiSiN thin films exhibited excellent adhesion of over 150 N. The cutting performance of end-mills and drillers was evaluated by milling and drilling of highly hardened material under high-speed cutting conditions. The results reveal that cutting tools with TiSiN coatings markedly outperformed those with TiN coatings, and the uncoated cutting tools. TiSiN coating increased the cutting lifetime to seven times that of the uncoated one.     

Chemical reactivity of PVD-coated WC-Co tools with steel

The chemical reactivity of CrN, ZrN, TiC_xN_1−x and naCo^® PVD coatings on a WC-Co cemented carbide substrate with steel has been evaluated by means of the static interaction couples technique. Diffusion experiments with coated and uncoated tools were carried out at 900, 1100 and 1300 °C in order to establish the maximum temperature at which the substrate-coating-workpiece combinations are chemically stable. Computational equilibrium thermodynamics was used to identify the interaction products formed at elevated temperature and the chemical solubility of the different coating materials into iron. A metallic (Fe, Co) fcc solid solution was identified at the steel side of the interface from 1100 °C on for all the coated tools and from 900 °C for the uncoated carbide. In addition to this interaction product, the ?-carbide was identified at 1300 °C on the WC-Co side of the interface. Both of the experimental findings and thermodynamic equilibrium solubility calculations demonstrated that the PVD-coated WC-Co tools exhibit a lower chemical reactivity with respect to the uncoated tools.     

The improvement of moisture resistance and thermal stability of Ca3SiO4Cl2:Eu phosphor coated with SiO2

Green-emitting phosphors Ca₃SiO₄Cl₂:Eu²⁺ were prepared by the high temperature solid-state method. Sol-gel process was adopted to encapsulate the as-prepared phosphors with tetraethylorthosilicate (TEOS) as silicon coating reagent. Fluorescence spectrometer, scanning electron microscopy (SEM) and powder X-ray diffraction (XRD) patterns were employed to characterize the emission spectra, the surface morphologies and the phase structures, respectively. The chemical stability testing was operated by the method of soaking the phosphors in deionized water and roasting them at different temperatures. The results indicated that the surfaces of the green phosphors were evenly coated by SiO₂ and the phase structure of the coated phosphors remained the same as the uncoated samples. The luminance centre of Eu²⁺ did not shift after surface treatment and the luminance intensity of coated phosphors was lower than that of the uncoated samples. The results demonstrated that the water-resistance stability of the coated phosphor was improved to some degree because the pH value and the luminance intensity variation were both smaller than the uncoated phosphor after steeping within the same time. Moreover, the thermal stability of coated phosphors was enhanced obviously compared to the original samples based on the temperature dependent emission spectra measurement.     

Formation of Al2O3 coatings on NiTi alloy by micro-arc oxidation method

Rough and porous Al₂O₃ coatings containing Ca and P were prepared on Ti–50.8 at.% Ni alloy by micro-arc oxidation (MAO) technique. The microstructure, elemental and phase composition of the coatings were investigated by scanning electron microscopy (SEM), energy dispersive X-ray spectrometer (EDS) and thin-film X-ray diffraction (TF-XRD). The thickness of the coatings was measured by eddy current coating thickness gauge. The corrosion resistance and the nickel release of the coated and uncoated samples were examined by potentiodynamic polarization tests and immersion tests in Hank’s solution, respectively. The results show that the coatings are mainly composed of γ-Al₂O₃ crystal phase. The Ni content of the coatings is about 3.5 at.%, which is greatly lower than that of NiTi substrate. With increasing treatment time, both thickness and roughness of the coatings increase. The corrosion resistance of the coated samples is about two orders of magnitude higher than that of the uncoated NiTi alloy. The concentration of Ni released from coated NiTi samples is much lower than that of uncoated NiTi sample. It can be reduced in the factor of one-seventh compared with the uncoated NiTi sample after 3 weeks immersion in Hank’s solution.     

The evaluation of the performance of two pyroelectric detectors with vertically aligned multi-walled carbon nanotube coatings

Two LiTaO₃ pyroelectric detectors coated with vertically aligned multi walled carbon nanotube (MWCNT) black coatings were assembled and evaluated using NPL’s detector characterisation facilities. The vertically-aligned nanotube array (VANTA) black coatings were grown on a silicon substrate and subsequently lifted off the silicon and bonded on the pyroelectric crystal substrates. Despite some drawbacks, this method was shown to provide a reliable way of coating delicate substrates such as pyroelectric crystals with VANTA coatings. The performance of the coated and uncoated detectors was evaluated and compared by coating only half of the active area of the test detectors, leaving the other half uncoated. The relative spectral responsivity of the VANTA-coated pyroelectric detectors was shown to be spectrally flat in the 0.8–14 μm wavelength range within the uncertainty of the measurements. The spatial uniformity of response of both detectors exhibited fine structure which was assigned either to the thickness of the VANTA coatings or to their bonding to the pyroelectric crystal. Both coated and uncoated detectors exhibited a super-linear response. This observation was expected in the case of the uncoated detectors, but was surprising in the case of the coated detectors and indicates that the thermal conductivity of vertically aligned multi-walled carbon nanotubes is high along their long axis. The spatial variations of the phase delay experienced by the signal propagating through the VANTA coatings indicate that the thermal diffusivity of the coatings is not spatially uniform.     

High-temperature oxidation studies of cold-sprayed Ni-20Cr and Ni-50Cr coatings on SAE 213-T22 boiler steel

The high-temperature oxidation behavior of cold-sprayed Ni-20Cr and Ni-50Cr coatings on SAE 213-T22 boiler steel has been investigated at 900 °C in air under cyclic heating and cooling conditions for 50 cycles. The kinetics of oxidation of coated and bare boiler steel has been established with the help of weight change measurements. It was observed that all the coated and bare steels obeyed parabolic rate law of oxidation. X-ray diffraction, FE-SEM/EDAX and X-ray mapping techniques were used to analyse the oxidation products of the coated and uncoated boiler steel. The uncoated steel suffered corrosion in the form of intense spalling and peeling of its oxide scale, which was perhaps due to the formation of unprotective Fe₂O₃ oxide scale. Both the coatings showed better resistance to the air oxidation as compared to the uncoated steel. The Ni-50Cr coating was found to be more protective than the Ni-20Cr-coated steel. The formation of oxides and spinels of nickel and chromium may be contributing to the development of air oxidation resistance in the coatings.     

Deposition and characterization of TiAlSiN nanocomposite coatings prepared by reactive pulsed direct current unbalanced magnetron sputtering

This work reports the performance of high speed steel drill bits coated with TiAlSiN nanocomposite coating at different Si contents (5.5-8.1 at.%) prepared using a four-cathode reactive pulsed direct current unbalanced magnetron sputtering system. The surface morphology of the as-deposited coatings was characterized using field emission scanning electron microscopy. The crystallographic structure, chemical composition and bonding structure were evaluated using X-ray diffraction, energy-dispersive X-ray analysis, X-ray photoelectron spectroscopy, respectively. The corrosion behavior, mechanical properties and thermal stability of TiAlSiN nanocomposite coatings were also studied using potentiodynamic polarization, nanoindentation and Raman spectroscopy, respectively. The TiAlSiN coating thickness was approximately 2.5-2.9 μm. These coatings exhibited a maximum hardness of 38 GPa at a silicon content of approximately 6.9 at.% and were stable in air up to 850 °C. For the performance evaluation, the TiAlSiN coated drills were tested under accelerated machining conditions by drilling a 12 mm thick 304 stainless steel plate. Under dry conditions the uncoated drill bits failed after drilling 50 holes, whereas, TiAlSiN coated drill bits (Si = 5.5 at.%) drilled 714 holes before failure. Results indicated that for TiAlSiN coated drill bits the tool life increased by a factor of more than 14.     

In vitro degradation of biodegradable polymer-coated magnesium under cell culture condition

Magnesium (Mg) coated with four kinds of polymers, poly (l-lactic acid) (PLLA)-high molecular weight (HMW), PLLA-low molecular weight (LMW), poly (?-caprolactone) (PCL)-HMW and PCL-LMW, and uncoated Mg were immersed under cell culture condition to study the degradation/corrosion behavior of the polymer-coated Mg. The releases of Mg²⁺ are measured during the immersion. Surface morphology and chemical composition are observed and identified by SEM and EDX. The tomography is obtained by X-ray CT observation and degradation rate is calculated by image analysis after 10-day immersion. All kinds of polymer-coated Mg showed significantly low release of Mg²⁺ (p < 0.05) in the whole immersion process comparing to that of uncoated Mg. In SEM and EDX results show, a corrosion layer can be observed on both polymer-coated and uncoated Mg after immersion. There is no obvious difference on the morphology and chemical composition of the corrosion layer between polymer-coated and uncoated Mg, indicating the corrosion/degradation process and corrosion product of Mg substrate are not changed by the polymer films under the present condition compared with uncoated Mg. Concerning the tomography and degradation rate of 10-day immersion, it can be found that the polymer-coated Mg shows a significantly low corrosion rate (p < 0.05) compared with that of uncoated Mg. PLLA coated Mg shows relatively uniform corrosion than PCL coated Mg and uncoated Mg. The largest pitting corrosion depth of PCL-LMW is about 3 times as large as the PLLA-LMW, which might be attributed to the difference of polymer microstructure. It is suggested that PLLA coating might be a suitable option for retarding the loss of mechanical properties of Mg substrate.     

Highly water resistant surface coating by fluoride on long persistent Sr4Al14O25:Eu/Dy phosphor

A novel and efficient method of providing moisture resistance of inorganic particles such as divalent europium activated strontium aluminate phosphors (Sr₄Al₁₄O₂₅:Eu²⁺/Dy³⁺) was developed by firing the phosphor in the presence of appropriate amount of ammonium fluoride at a temperature of 600-700 °C. Scanning electron microscopy, X-ray diffraction, FT-IR, EDAX and Photoluminescence measurements were carried out to characterize the uncoated and coated samples. The pH measurements were carried out for the water resistivity measurements. The phosphor particles became coated with a moisture-impervious thin coating that did not suppress the luminescence of the phosphor and can withstand complete immersion in water for long periods of time, showing very high water resistivity.     

Preparation and properties of ceramic coating on Q235 carbon steel by plasma electrolytic oxidation

Ceramic coating was achieved on Q235 carbon steel by PEO (plasma electrolytic oxidation, PEO) without any pretreatment in sodium aluminate system. The discharge process as well as the accompanied surface morphology evolution was analyzed. The phase and elemental composition of the coatings were also investigated. The corrosion, mechanical and tribological properties of the ceramic coating were primarily studied. It is found that the coating surface was porous and the thickness of the coating was about 120 μm. The coating mainly consisted of FeAl₂O₄, Fe₃O₄ and a little γ-A1₂O₃. The corrosion current of the coated sample was 3.082 × 10⁻⁷ A/cm², which was decreased by two orders of magnitude compared with the uncoated one. The micro hardness of the ceramic coating was 1210 Hv, which was about three times as that of the uncoated sample. The friction coefficient of coated sample was also well improved. Investigations revealed that PEO provided a promising technique for preparation of protective ceramic coatings on steels.     

Microstructure development and properties of the AlCuFe quasicrystalline coating on near-α titanium alloy

A protective quasicrystalline AlFeCu coating was deposited on TIMETAL 834 substrate by nonreactive magnetron sputtering in order to improve resistance of the alloy to oxidation. Microstructure characterisation of the substrate and the coating was performed by analytical scanning- and transmission electron microscopy as well as X-ray diffractometry. Depending on annealing temperature and time, the deposited coating (2.7 μm thick) has a different microstructure. The coating in Specimen 1 (annealed 600 °C/4 h in vacuum) consisted of two zones: outer, composed of Al₅Fe₂ and Al₂Cu₃ phases and inner, in which only quasicrystalline ψ phase was present. The coating in Specimen 2 (annealed 600 °C/4 h + 700 °C/2 h in vacuum) was fully quasicrystalline and consisted of icosahedral ψ phase.Both coatings exhibit higher microhardness than the substrate material. It was established that the applied surface treatment essentially improves oxidation resistance of the alloy tested at 750 °C during 250 h in static air. Sample weight gain was 60% lower than in the case of uncoated sample. Oxide scale spallation occurred for uncoated alloy while the coated one did not show any spallation. It was found that the very brittle scale formed during oxidation on the uncoated alloy was consisting of TiO₂, while that on the coated one consisted mainly of α-Al₂O₃.     

Improved moisture resistance of SrS:Eu phosphors with nanoscale SiO2 coating

Orange-emitting SrS:Eu²⁺ phosphors were coated with nanoscale SiO₂ and their photoluminescence (PL) degradation behavior in moist air was investigated. The SiO₂ coating was obtained by sol-gel process using diethoxydimethylsilane (DEDMS) and the coating content was varied from 0.5 to 2 wt%. The coatings were composed of a uniform, continuous, and amorphous SiO₂ layer of 30-50 nm thickness and the coating thickness was not varied significantly with the coating content. No peak shift and no decrease of PL intensity were observed after coating. The PL intensity of the coated phosphors decreased to ∼75% of the original value after 10 h exposure to moist air, while the uncoated phosphor decreased to ∼33%, which indicates the improved moisture resistance of the nanoscale SiO₂ coated SrS:Eu²⁺ phosphors.     

The Tensile Properties of Uncoated and TiO2 Coated Bombyx Mori Silk Yarns Exposed to Thermal Treatment

Bombyx mori silk yarns were coated with a TiO₂ network by sol-gel processing. The tensile properties of TiO₂ coated silk yarns heated at various temperatures were examined and compared with those of uncoated silk yarns. The thermal properties of uncoated silk yarns and TiO₂ coated silk yarns were also discussed. Prominent changes were seen in the rigidity and Young's modulus. The Young's modulus of TiO₂ coated silk yarn increased by 13% at room condition and remained higher than that of uncoated silk yarns with increasing temperature. The shape of the stress–strain curve of TiO₂ coated silk yarns became the same as uncoated silk yarns and showed a similar tendency of change to uncoated silk yarns with increasing temperature. The rupture values of uncoated silk yarns and TiO₂ coated silk yarns decreased significantly, e.g., the breaking extension decreased from 17.28 to 2.44% and from 15.25 to 1.96% for uncoated silk yarns and TiO₂ coated silk yarns, respectively, when the temperature was increased from 25 to 225°C. Structural changes and degradation processes due to thermal effects for both uncoated and TiO₂ coated silk yarns are discussed.     

Enhancement of the thermal properties of silver-diamond composites with chromium carbide coating

The present work reports the enhancement of the thermal properties in Ag/diamond matrix composites reinforced with chromium carbide coated diamond particles. The coated diamond particles were characterized by x-ray diffraction, x-ray photoelectron spectroscopy and Raman spectra. The composites were synthesized by spark plasma sintering. The chromium carbide coating on the diamond particles resulted in composites exhibiting improved wettability and strong interfacial bonding between the diamond particles and Ag matrix. The composites with coated diamonds showed a low coefficient of thermal expansion of 8.24 × 10^?6/K and a high thermal conductivity of 695 W/mK at 60 % particle volume fraction, which greatly outperformed the composites with uncoated diamonds at the same particle volume fraction. The obtained results are useful for synthesizing Ag/diamond composites with greatly improved thermal performance.     

Composite SiO2/TiO2 and amine polymer/TiO2 nanoparticles produced using plasma-enhanced chemical vapor deposition

Plasma-enhanced chemical vapor deposition was used to conformally coat commercial TiO₂ nanoparticles to create nanocomposite materials. Hexamethyldisiloxane (HMDSO)/O₂ plasmas were used to deposit SiO₂ or SiO_xC_yH_z films, depending on the oxidant concentration; and hexylamine (HexAm) plasmas were used to deposit amorphous amine-containing polymeric films on the TiO₂ nanoparticles. The composite materials were analyzed using Fourier-transform infrared spectroscopy (FTIR), X-ray photoelectron spectroscopy (XPS) and scanning electron microscopy (SEM). These analyses reveal film composition on the nanoparticles was virtually identical to that deposited on flat substrates and that the films deposit a conformal coating on the nanoparticles. The performance of the nanocomposite materials was evaluated using UV-vis spectroscopy to determine the dispersion characteristics of both SiO_x and HexAm coated TiO₂ materials. Notably, the coated materials stay suspended longer in distilled water than the uncoated materials for all deposited films.     

Microstructure and infrared emissivity property of coating containing TiO2 formed on titanium alloy by microarc oxidation

Ceramic coatings containing TiO₂ were formed on Ti6Al2Zr1Mo1V alloy surface by microarc oxidation (MAO) method. The microstructure, phase and chemical composition of the coatings were analyzed by SEM, XRD and EDS techniques. The coating mainly consists of rutile TiO₂ and a small amount of anatase TiO₂. The infrared emissivity values of coated and uncoated titanium samples when exposed to 700 °C were tested. It was found that the coating exhibits a higher infrared emissivity value (about 0.9) in the wavelength range of 8–14 μm than that of the uncoated titanium alloy, although which shows a slight increase from 0.1 to 0.3 with increasing exposure time at 700 °C. The relatively high infrared emissivity value of the MAO coating is possibly attributed to the photon emission from the as formed TiO₂ phase.     

The microstructure, mechanical and friction properties of protective diamond like carbon films on magnesium alloy

Protective hard coatings deposited on magnesium alloys are believed to be effective for overcoming their poor wear properties. In this work, diamond-like carbon (DLC) films as hard protective films were deposited on AZ91 magnesium alloy by arc ion plating under negative pulse bias voltages ranging from 0 to −200 V. The microstructure, composition and mechanical properties of the DLC films were analyzed by scanning electron microscopy, Raman spectroscopy, X-ray photoelectron spectroscopy and nanoindentation. The tribological behavior of uncoated and coated AZ91 magnesium alloy was investigated using a ball-on-disk tribotester. The results show that the negative pulse bias voltage used for film deposition has a significant effect on the sp³ carbon content and mechanical properties of the deposited DLC films. A maximum sp³ content of 33.3% was obtained at −100 V, resulting in a high hardness of 28.6 GPa and elastic modulus of 300.0 GPa. The DLC films showed very good adhesion to the AZ91 magnesium alloy with no observable cracks and delamination even during friction testing. Compared with the uncoated AZ91 magnesium alloy, the magnesium alloy coated with DLC films exhibits a low friction coefficient and a narrow, shallow wear track. The wear resistance and surface hardness of AZ91 magnesium alloy can be significantly improved by coating a layer of DLC protective film due to its high hardness and low friction coefficient.     

Excimer laser decoating of chromium titanium aluminium nitride to facilitate re-use of cutting tools

This work reports on the technical feasibility and establishment of a process window for removing chromium titanium aluminium nitride (CrTiAlN) coating from steel substrates by laser irradiation. CrTiAlN coating has high hardness and oxidation resistance, with applications for use with cutting tools. The motivation for removing such coatings is to facilitate re-use of tooling by enabling regrinding or reshaping of a worn tool and hence promote sustainable material usage. In this work, laser decoating was performed using an excimer laser. The effect of laser fluence, number of pulses, frequency, scanning speed and laser beam overlap on the decoating performance was investigated in detail. The minimum threshold laser fluence for removing the CrTiAlN coating was lower than that of the steel substrate and this factor is beneficial in controlling the decoating process. Successful laser removal of CrTiAlN coating without noticeable damage to the steel substrate was demonstrated.     

Preparation and properties of composite ceramic coating containing Al2O3–ZrO2–Y2O3 on AZ91D magnesium alloy by plasma electrolytic oxidation

A composite ceramic coating containing Al₂O₃–ZrO₂–Y₂O₃ was successfully prepared on AZ91D magnesium alloy by plasma electrolytic oxidation (PEO) technique in an alkaline aluminate electrolyte. The morphology, elemental and phase composition, corrosion behavior and thermal stability of the uncoated and coated samples were studied by environmental scanning electron microscopy (ESEM), energy dispersive X-ray spectrometer (EDS), X-ray diffractometer (XRD), electrochemical corrosion test, high temperature oxidation test and thermal shock test. The results showed that the composite ceramic coating was composed of Al₂O₃, c-ZrO₂, t-ZrO₂, Y₂O₃ and some magnesium compounds, such as MgO, MgF₂ and MgAl₂O₄. After PEO treatment, the corrosion potential of AZ91D alloy was increased and the corrosion current density was significantly reduced. Besides, the coated magnesium alloys also showed excellent high temperature oxidation resistance and thermal shock resistance at 500 °C environment.