Synthesis and evaluation of TiN–WC/TiN nanocomposite by the hybrid technique with arc ion plating and magnetron sputtering

By adjusting the power of WC target, novel TiN–WC films with different proportions of WC phase were prepared on TiN interlayer using the hybrid technique of arc ion plating (AIP) and magnetron sputtering (MS). The TiN–WC films were characterized by XRD, XPS, AFM, FESEM, Nano-indenter, and UMT-2MT tribometer. The TiN–WC film that is composed with TiN and WC phases was grown by 15–25 nm nanodotes along the primarily growth direction TiN (1 1 1) in AIP interlayer. Among the three TiN–WC films deposited at various powers of WC target, the TiN–WC2 (500 W) has the highest deposition rate of 1.4 nm/min. The content of WC phase increases as WC target power increases in the TiN–WC films. However, the deposition rate of TiN–WC film gains at first and then declines when WC target power exceeds 500 W because of the addictive poisoning of Ti target. In the present case, the incorporation of WC into TiN is found to result in a slight decrease in friction coefficient. Furthermore, the wear mechanism of multilayer AIP TiN films and MS TiN–WC/AIP TiN films was transformed from “severe wear” to “mild wear”. As a result, the 48TiN52WC film of 35 GPa hardness exhibits better tribological performance.     

Comparative study of titanium carbide and nitride coatings grown by cathodic vacuum arc technique

Titanium nitride (TiN), titanium carbide (TiC) thin films and TiC/TiN bilayers have been deposited on AISI 304 stainless steel substrates by plasma assisted physical vapor deposition technique—reactive pulsed vacuum arc method. The coatings were characterized in terms of crystalline structure, microstructure and chemical nature by X-ray diffraction and X-ray photoelectron spectroscopy, respectively. Tribological behavior was investigated using ball on disc technique. The average coefficient of friction was measured, showing lower values for the TiN/TiC bilayer. Dynamic wear curves were performed for each coating, observing a better wear resistance for TiN/TiC bilayers, compared to TiN and TiC monolayers. On the other hand, the TiCN formation in the TiN/TiC bilayer was observed, being attributed to the interdiffusion between TiN and TiC at the interface. Moreover, the substrate temperature influence was analysing observing a good behavior at T_S = 115 °C.     

Reduction of core loss in non-oriented (NO) electrical steel by electroless-plated magnetic coating

An important issue in development of electrical steels for core-laminated products is to reduce core loss to improve energy conversion efficiency. This is usually obtained by tailoring the composition, microstructure, and texture of electrical steels themselves. A new technique to reduce core loss in electrical steel has been investigated. This technique involves electroless plating of magnetic thin coating onto the surface of electrical steel. The material system was electroless Ni–Co–P coatings with different thicknesses (1, 5, and 10 μm) deposited onto the surface of commercially available Fe–3% Si electrical steel. Characterization of deposited Ni–Co–P coating was carried out using X-ray diffraction (XRD), scanning electron microscope (SEM), and energy dispersive X-ray (EDX) spectrometer. The deposited Ni–Co–P coatings were amorphous and composed of 56–59% Ni, 32–35% Co, and 8–10% P by mass. The effect of coatings on core loss of the electrical steel was determined using single sheet test. A core loss reduction of 4% maximum was achieved with the Ni–Co–P coating of 1 μm thickness at 400 Hz and 0.3 T.     

Direct-soldering 6061 aluminum alloys with ultrasonic coating

In this study, the authors applied furnace soldering with ultrasonic coating method to solder 6061 aluminum alloy and investigated the effects of both coating time and soldering temperature on its properties. The following results were obtained: firstly, the solder region mainly composed of four kinds of microstructure zones: rich Sn zone, rich-Pb zone, Sn–Pb eutectic phase and rich Al zone. Meanwhile, the microanalysis identified a continuous reaction product at the alumina–solder interface as a rich-Pb zone. Therefore, the joint strength changed with soldering time and soldering temperature. Secondly, the tensile data had significantly greater variability, with values ranging from 13.99 MPa to 24.74 MPa. The highest value was obtained for the samples coated with Sn–Pb–Zn alloy for 45 s. Fractures occurred along the solder–alumina interface for the 6061 aluminum alloy with its surface including hybrid tough fracture of dimple and tear ridge. The interface could initially strip at the rich Bi zone with the effect of shear stress.     

Microstructure and wear resistance of Fe-based WC coating by multi-track overlapping laser induction hybrid rapid cladding

The carck-free Fe-based +20 wt% WC coating with large area was produced by mutli-track overlapping laser induction hybrid rapid cladding. The results showed that the maximum laser scanning speed and the maximum feeding rate of powder can be increased to 3500 mm/min and 120 g/min, respectively. The cast WC particles were dissolved almost completely and had a worse wettability with Fe-based metal matrix. The precipitated carbides such as M₁₂C and M₂₃C₆ (M=Fe, W, Cr) formed an intergranular network around the primary Fe-based phase enriched with tungsten. The microhardness of coating decreased first, and then increased slightly with an increase in the track. The first track had the highest microhardness (i.e. 870HV_0.2). Moreover, the wear weight of coating approximately had a linear relationship with the sliding distance, and increased with an increase in the sliding speed. The wear rate approximately remained constant with an increase in the sliding distance and was two times lower than that of the hardened steel AISI 1045 with a hardness of 60HRC. The wear mechanism during the dry sliding wear was a combination of oxidation wear and abrasion wear.     

Design and fabrication of multi-layers infrared antireflection coating consisting of ZnS and Ge on ZnS substrate

We have designed, fabricated and characterized a multi-layers antireflection coating on multispectral ZnS substrate, suitable for the infrared range of 8–12 μm. The 4-layers coating (Ge/ZnS/Ge/ZnS) with optimized thicknesses was fabricated by PVD technique and studied by FTIR, nanoindentation and AFM. From FTIR spectroscopy it was found that, in the wavelength range of 8–12 μm, the average transmittance of the double-side coated sample increases by about 26% and its maximum reaches about 98%. To improve the mechanical hardness, a bilayer of Y₂O₃/carbon was deposited on the coating. Nanoindentation test shows that the coating enhances the mechanical properties. The final coating have successfully passed durability and environmental tests.     

EIS diagnosis on the corrosion behavior of TiN coated NiTi surgical alloy

In this work titanium nitride (TiN) coatings were deposited on NiTi surgical alloy by arc ion plating (AIP). The open circuit testing and electrochemical impedance spectroscopy (EIS) have been employed to study the corrosion performance of the TiN coated samples in Troyde’s simulated body fluid. It was found that the TiN coating showed a good corrosion resistance at the beginning of long-term immersion; with the increase of immersion time, however, the corrosion resistance of the coating deteriorated after nearly 24 h of immersion; moreover, the large areas of the coating had fallen off the substrate after 30 days of immersion.     

Development and characterization of laser surface cladding (Ti,W)C reinforced Ni–30Cu alloy composite coating on copper

To improve the wear resistance of copper components, laser surface cladding (LSC) was applied to deposit (Ti,W)C reinforced Ni–30Cu alloy composite coating on copper using a cladding interlayer of Ni–30Cu alloy by Nd:YAG laser. The microstructure and phases of the composite coating were investigated by scanning electron microscopy (SEM), X-ray diffraction (XRD) and X-ray energy dispersive microanalysis (EDX). Microhardness tester and pin-on-disc wear tester were employed to evaluate the hardness and dry-sliding wear resistance. The results show that crack-free composite coating with metallurgical bonding to the copper substrate is obtained. Phases identified in the (Ti,W)C-reinforced Ni–30Cu alloy composite layer are composed of TiWC₂ reinforcements and (Ni,Cu) solid solution. TiWC₂ reinforcements are distributed uniformly in the (Ni,Cu) solid solution matrix with dendritic morphology in the upper region and with particles in the mid-lower region. The microhardness and wear properties of the composite coating are improved significantly in comparison to the as-received copper substrate due to the addition of 50 wt% (Ti,W)C multicarbides.     

Nanocomposite Ni–TiN coatings prepared by ultrasonic electrodeposition

Nanocomposite Ni–TiN coatings were prepared by ultrasonic electrodeposition and the effects of ultrasonication on the coatings were studied. X-ray diffraction analysis was utilized to detect the crystalline and amorphous characteristics of the composite coatings. The surface morphology and metallurgical structure were observed by scanning electron microscopy, high-resolution transmission electron microscopy and scanning probe microscopy. The results showed that ultrasonication had great effects on TiN nanoparticles in composite coatings. The moderate ultrasonication conduced to homogeneous dispersion of TiN particles in the coatings. Moreover, the TiN nanoparticles that entered and homogeneously dispersed in the composite coating led to an increase in the number of nuclei for nucleation of nickel grains and inhibition of grain growth. Therefore, the introduction of ultrasonication and TiN nanoparticles resulted in the formation of smaller nickel grains. The average grain diameter of TiN particles was ∼33 nm, while Ni grains measured approximately 53 nm.     

Tribological behaviors of self-assembled 3-aminopropyltriethoxysilane films on silicon

3-Aminopropyltriethoxysilane (APTES) thin films were prepared on the hydroxylated silicon substrate by a self-assembling process from formulated solution. Chemical compositions of the films were detected by X-ray photoelectron spectrometry (XPS). The thickness of the films was determined with an ellipsometer, while the morphologies of the original and worn surfaces of the samples were analyzed by means of atomic force microscopy (AFM) and scanning electron microscopy (SEM), respectively. The tribological properties of APTES thin films sliding against GCr15 steel ball were evaluated on a UMT-2MT reciprocating friction and wear tester. It was found that the macroscopic friction coefficients for coating times more than 1 h ranged from 0.177 to 0.3 whereas the value for short coating time was as high as 0.8. It was also found that the tribological behaviors of APTES films were sensitive to normal load and sliding velocity. SEM observation of the morphologies of worn surfaces indicates that the wear of silicon is characteristic of brittle fracture and severe abrasion. Differently, abrasion and micro-crack dominate the wear of APTES–SAM. The superior friction reduction and wear resistance of APTES films compared to the silicon substrate are attributed to good adhesion of the films to the substrate.     

Studies of Li intercalation of hydrogenated graphene on SiC(0001)

The effects of Li deposition on hydrogenated bilayer graphene on SiC(0001) samples, i.e. on quasi-freestanding bilayer graphene samples, are studied using low energy electron microscopy, micro-low-energy electron diffraction and photoelectron spectroscopy. After deposition, some Li atoms form islands on the surface creating defects that are observed to disappear after annealing. Some other Li atoms are found to penetrate through the bilayer graphene sample and into the interface where H already resides. This is revealed by the existence of shifted components, related to H–SiC and Li–SiC bonding, in recorded core level spectra. The Dirac point is found to exhibit a rigid shift to about 1.25 eV below the Fermi level, indicating strong electron doping of the graphene by the deposited Li. After annealing the sample at 300–400 °C formation of LiH at the interface is suggested from the observed change of the dipole layer at the interface. Annealing at 600 °C or higher removes both Li and H from the sample and a monolayer graphene sample is re-established. The Li thus promotes the removal of H from the interface at a considerably lower temperature than after pure H intercalation.     

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.     

Application of indium tin oxide (ITO) thin film as a low emissivity film on Ni-based alloy at high temperature

Indium tin oxide (ITO) films as the low emissivity coatings of Ni-based alloy at high temperature were studies. ITO films were deposited on the polished surface of alloy K424 by direct current magnetron sputtering. These ITO-coated samples were heat-treated in air at 600–900 °C for 150 h to explore the effect of high temperature environment on the emissivity. The samples were analyzed by X-ray diffraction (XRD), SEM and EDS. The results show that the surface of sample is integrity after heat processing at 700 °C and below it. A small amount of fine crack is observed on the surface of sample heated at 800 °C and Ti oxide appears. There are lots of fine cracks on the sample annealed at 900 °C and a large number of various oxides are detected. The average infrared emissivities at 3–5 μm and 8–14 μm wavebands were tested by an infrared emissivity measurement instrument. The results show the emissivity of the sample after annealed at 600 and 700 °C is still kept at a low value as the sample before annealed. The ITO film can be used as a low emissivity coating of super alloy K424 up to 700 °C.     

Electrochemical synthesis of polythiophene on nickel coated mild steel and corrosion performance

Electrochemical polymerization of polythiophene (PTh) was investigated on nickel coated mild steel (MS) electrode, in LiClO₄ containing acetonitrile medium (ACN-LiClO₄). Nickel layer (1 μm thick) was deposited galvanostatically, from a proper bath solution. Then, the synthesis of PTh film was achieved in 0.1 M thiophene containing ACN-LiClO₄, by using cyclic voltammetry technique. The corrosion performances of nickel coated samples with and without polymer top coats were investigated in 3.5% NaCl solution, by using electrochemical impedance spectroscopy (EIS) and anodic polarization curves. The nickel coating behaved like a physical barrier and provided some protection to MS against corrosion. But its barrier property diminished significantly with time and failed to protect MS. It was shown that PTh top coat improved the barrier efficiency remarkably, and excellent protection efficiency was obtained against MS corrosion, for considerable exposure time in such aggressive environment.     

Chemically sprayed ZnO:(F,Zr) thin films: Effect of starting solution ageing time and substrate temperature on the physical properties

Conductive and transparent fluorine and zirconium co-doped zinc oxide [ZnO:(F, Zr)] thin films have been deposited onto sodocalcic glass substrates by the chemical spray technique. The effects of starting solution ageing time and the substrate temperature on the transport, structural, and morphological properties of as-deposited ZnO:(F, Zr) thin films are presented in this paper. A decrease in the electrical resistivity values is observed as the starting solution used is more aged, reaching a minimum resistivity of the order of 1.3×10^?2 Ω cm in samples deposited from a 17-day-aged solution, then increasing in samples deposited from solutions aged beyond this ageing time. According to the characterization results, the surface morphology is dependent on the solution ageing time. The X-ray diffraction patterns reveal that the ZnO:(F, Zr) thin films are polycrystalline in nature, fitting well with a hexagonal wurtzite structure, and showing the (0 0 2) planes as preferential growth in all the deposited films. The average optical transmittance, measured in the near UV–visible region, was of the order of 75% in all the cases.     

Optical and morphological properties of N-doped TiO2 thin films

Nitrogen doped titanium dioxide (TiO₂) thin films were deposited by RF magnetron sputtering onto various substrates. The films were prepared in plasma of argon, oxygen, and nitrogen, with varying the nitrogen content, from 0% up to 70%. The resulting TiOx–Ny films were found to consist of cubic TiN osbornite and tetragonal TiO₂ rutile phases. Using optical spectroscopy with large spectral range from 350 to 1000 nm, the band gap width was determined and a narrowing of the optical gap from 2.76 to 2.32 eV was observed as a function of the N-content. It was found that the optical properties of the TiOx–Ny layers are influenced by the surface morphology, roughness, surface energy and phase content. The chemical composition, the crystalline structure, the surface morphology and the surface energy were thoroughly studied by the Rutherford backscattering spectrometry (RBS), grazing-angle XRD, atomic force microscopy (AFM) and contact angle measurements (wettability), respectively.     

Irradiation induced modifications in morphology and magnetic property of Mn/Si structure

Mn films of ∼50 nm has been deposited by electron beam evaporation technique on cleaned and etched Si [(1 0 0), 8–10 Ω cm] substrates to realize a Mn/Si interfacial structures. The structures have been irradiated from energetic (∼100 MeV) ion beam from Mn side. The irradiated and unirradiated structures have been characterized from atomic force microscopy, X-ray diffractometry, magnetic force microscopy, and vibrating sample magnetometer facilities. It has been found that surface/interfacial granular silicide phases (of Mn_xSi_y) are formed before and after the irradiation with a irradiation induced modifications of surface morphology and magnetic property. The surface/interface roughness has been found to increase on the irradiation from the atomic force microscopy data. The magnetic property on the irradiation shows an interesting and significant feature of an increased coercivity and a ferromagnetic like behavior in the Mn–Si structure. The observed increased coercivity has been related to the increased roughness on the irradiation. The ferromagnetism after the irradiation is a curious phenomenon which seems due to the formation of Mn–C–Si compound from the carbon dissolved in silicon.     

Ultrasonic cavitation erosion of high-velocity oxygen-fuel (HVOF) sprayed near-nanostructured WC–10Co–4Cr coating in NaCl solution

The high-velocity oxygen-fuel (HVOF) spraying process was used to prepare near-nanostructured WC–10Co–4Cr coating. The cavitation erosion behavior and mechanism of the coating in 3.5 wt.% NaCl solution were analyzed in detail. The results showed that the amorphous phase and WC grain were present in the coating. The cavitation erosion resistance of the coating was about 1.27 times that of the stainless steel 1Cr18Ni9Ti under the same testing conditions. The effects of erosion time on the microstructural evolution were discussed. It was revealed that cracks initiated at the edge of pre-existing pores and propagated along the carbide–binder interface, leading to the pull-out of carbide particle and the formation of pits and craters on the surface. The main failure mechanism of the coating was erosion of the binder phases, brittle detachment of hard phases and formation of pitting corrosion products.     

Application of laser in seam welding of dissimilar steel to aluminium joints for thick structural components

Laser welding-brazing technique, using a continuous wave (CW) fibre laser with 8000 W of maximum power, was applied in conduction mode to join 2 mm thick steel (XF350) to 6 mm thick aluminium (AA5083-H22), in a lap joint configuration with steel on the top. The steel surface was irradiated by the laser and the heat was conducted through the steel plate to the steel-aluminium interface, where the aluminium melts and wets the steel surface. The welded samples were defect free and the weld micrographs revealed presence of a brittle intermetallic compounds (IMC) layer resulting from reaction of Fe and Al atoms. Energy Dispersive Spectroscopy (EDS) analysis indicated the stoichiometry of the IMC as Fe₂Al₅ and FeAl₃, the former with maximum microhardness measured of 1145 HV 0.025/10. The IMC layer thickness varied between 4 to 21 μm depending upon the laser processing parameters. The IMC layer showed an exponential growth pattern with the applied specific point energy (E_sp) at a constant power density (PD). Higher PD values accelerate the IMC layer growth. The mechanical shear strength showed a narrow band of variation in all the samples (with the maximum value registered at 31.3 kN), with a marginal increase in the applied E_sp. This could be explained by the fact that increasing the E_sp results into an increase in the wetting and thereby the bonded area in the steel-aluminium interface.     

Marine environment compatible antireflection coating with nanotop layer on silicon optics

Antireflection coating on silicon optics have crucial importance in thermal device working in 3.6–4.9 μm wavelength region. When the thermal device is used in marine environment, the optics face harsh saline weather condition compared to normal field environment. This deteriorates coated optics and to improve mechanical strength of the coating, a nanotop layer on the antireflection coating has been developed. In this paper a study has been carried out to improve marine environment compatibility by employing a nanolayer on the top of antireflection coating on silicon optics. Optimac synthesis method was used to design the multilayer stack on the substrate with germanium and IR-F625 as high/low refractive index respectively and the layer number was restricted to four layers. The top nanolayer was 60 ± 2 nm thick hafnium dioxide layer developed with ion assisted deposition (End–Hall) on the optics during coating process. The deposition of multilayer coating was carried out inside the coating plant fitted with cryo pump and residual gas analyzer. The evaporation was carried out at high vacuum (2–6 × 10⁻⁶ mbar) using electron beam gun and layer thicknesses were measured with crystal monitor. The average transmission achieved was 97% in the spectral band of 3.6–4.9 μm with a hardness of 9.7 GPa on the coated optics.