Review of recent progress in nanoscratch testing

Nanoscratch testing, as an important technique for the assessment of the mechanical failure behaviour and adhesion strength of ceramic coatings and a simulation tool of single asperity contact in tribological experiments, is increasingly becoming an established nanomechanical characterisation method. This paper reviews recent work in nanoscratch testing in different engineering applications including thin ceramic films, automotive organic coatings, chemical- mechanical polishing and biomaterials. In the main part of the paper, nanoscratch results from experiments performed using NanoTest systems fitted with tangential force sensors and spherical indenters as scratch probes are presented and discussed. The types of nanoscratch tests described include constant load nanoscratches, ramped load nanoscratch tests and multipass repetitive unidirectional constant load nanoscratch tests (nanowear). The results are discussed in terms of critical load sensitivity to intrinsic and extrinsic factors, impact of scan speed and loading rate, influence of probe radius and geometry, estimation of tip contact pressure, influence of surface roughness and film stress and thickness, and finally role of ploughing on friction evolution

Probing polymer chain constraint and synergistic effects in nylon 6-clay nanocomposites and nylon 6-silica flake sub-micro composites with nanomechanics

In this study, we report that a synergistic effect exists in the surface mechanical properties of nylon 6–clay nanocomposites (NC) that can be shown by nanomechanical testing. The hardness, elastic modulus, and nanoindentation creep behavior of nylon 6 and its nanocomposites with different filler loading produced by melt compounding were contrasted to those of model nylon 6 sub-microcomposites (SMC) reinforced by sub-micro-thick silica flakes in which constraint cannot occur due to the difference in filler geometry. Polymer chain constraint was assessed by the analysis of nanoindentation creep data. Time-dependent creep decreased with increasing the filler loading in the NC consistent with the clay platelets exerting a constraint effect on the polymer chains which increases with filler loading. In contrast, there was no evidence of any reduced time-dependent creep for the SMC samples, consistent with a lack of constraint expected due to much lower aspect ratio of the silica flake

Failure mechanism and protective role of ultrathin ta-C films on Si (100) during cyclic nano-impact

Complex mechanical behavior with phase transformation and high brittleness limits the reliability of silicon-based microelectromechanical systems. Although very hard ultra-thin films are being considered as protective overcoats to improve the service life of substrate materials, their resistance to fatigue can be at least as important as hardness when exposed to cyclic loading. In this study repetitive nano-impact tests with a spherical diamond probe have been used to investigate the fatigue behavior and protective role of 5 and 80 nm tetrahedral amorphous carbon (ta-C) films on silicon. At the lowest load there was delamination of the 80 nm film but not for the 5 nm film. At higher loads failure involved lateral cracking of the silicon substrate. Single impact tests showed that this was preceded by ring and radial cracking. Changing contact pressure during the test provided further support for the degradation mechanism and the influence of phase transformation in the Silicon substrate. Under repetitive contact the thin film systems showed lower impact depth and greater impact cycles before substrate fracture than the uncoated Silicon. This is related to their enhanced load support which affects phase transformation in the substrate, with potentially delamination providing an additional impact energy dissipation mechanism

Tribological performance of graphite-like carbon films with varied thickness

Graphite-like carbon (GLC) films with different thickness were deposited on 316 L stainless steel using closed field unbalanced magnetron sputtering system to investigate the influence of film thickness on the microstructure, mechanical and tribological properties. The results showed that the surface of the deposited films exhibited granular-like morphology, and the sp2 content, surface roughness increase with the increase of film thickness, leading to the lower of hardness and higher of the internal stress. Both of the friction curves obtained by nano-tribological tests and fretting wear experiments revealed a three-stage evolution tendency with the same wear mechanism for the first two stages. The intermediate thick GLC film had the lowest specific wear rate, whilst the fretting fatigue life increased with film thickness

Dynamic changes of mechanical properties induced by friction in the Archard wear model

© 2019 Elsevier B.V. Fretting is small-amplitude, oscillatory motion between two bodies leading to surface damage. During the fretting process, a tribologically transformed structure (TTS) which has different mechanical properties and microstructure than the starting material is formed on the surface. The commonly-used Archard wear equation relating wear volume to the hardness of the worn material does not account for changes in mechanical properties induced by friction in fretting. To investigate that effect, ball-on-plane fretting tests were conducted on three engineering materials (type 316 stainless steel, pure copper, and titanium alloy Ti-6Al-4V) against an alumina ball to generate TTS layers. The evolution of mechanical properties and microstructures of TTS layers were investigated using nanoindentation and focused ion beam-scanning electron microscope (FIB-SEM). Wear volumes after different fretting cycles were measured with a white light interference microscope. Results show that the mechanical properties of TTS layers evolve differently on different materials during the fretting process. Microstructures of TTS layers also vary from one material to the other. A modified wear model that accounts for friction-induced dynamic changes in mechanical properties is proposed. In these tests the modified model was able to predict the wear volume of 316 steel and pure copper more accurately than the classical Archard model, but it was less successful in predicting wear on Ti6Al4V where there is added complexity from changing microstructure, oxidation, porosity and cracking

Micro-scale impact testing - A new approach to studying fatigue resistance in hard carbon coatings

© 2019 Elsevier Ltd Improving the fatigue resistance of DLC coatings under highly loaded repetitive contact is an important step to increasing their performance in demanding applications. The nano-impact test has been shown to be effective at highlighting differences in resistance to contact damage in thin hard carbon coatings deposited on hardened steel. A novel micro-scale rapid impact test capability capable of producing repetitive impacts at significantly higher strain rate and energy than in the nano-impact test has been developed recently enabling the study of coating fatigue with less sharp spherical indenters than in the nano-impact test. Results with the new micro-impact technique on two commercial hard carbon coatings (Graphit-iC and Dymon-iC from Teer Coatings) on tool steel are presented. The role of coating mechanical properties on the fatigue resistance and the load-sensitivity of the impact failure mechanism is discussed. The harder coating with higher sp 3 /sp 2 bonded C (Dymon-iC) was found to be significantly less durable under fatigue loading than the softer Graphit-iC. Reasons for the observed differences are discussed

Micro-scale impact resistance of coatings on hardened tool steel and cemented carbide

© 2020 Elsevier B.V. Micro-impact, a novel accelerated test method for assessing coating durability under repetitive contact, has been developed to concentrate impact-induced stresses close to the interfaces in coating systems. Test results are described for carbon coatings on hardened tool steel and nitride-based coatings on cemented carbide. At higher load it was possible to show the increasing contribution of the substrate properties (load support and ductility) to the coating system response whilst retaining high sensitivity to the coating properties. Hard and elastic carbon coatings on hardened tool steel displayed very low impact resistance under these conditions. Relatively soft carbon-based coatings with more metallic character and high plasticity (low H/E) deposited on hard but tough tool steel were resistant to radial cracking and lateral fracture at high load. Lateral fracture at high load and extensive substrate cracking was observed at higher load for hard nitrides on cemented carbide. The micro-impact test has the potential to significantly speed up the pace of coating system selection for durability under highly loaded repetitive contacts, as occur in coatings applications in engine components and in discontinuous cutting operations

Utilising H/E to predict fretting wear performance of DLC coating systems

Diamond-like carbon coatings have previously been studied as a protective coating for fretting wear protection providing low friction and low wear. H/E ratio has been used as a metric to rank coating performance in sliding wear, but this has not been applied to gross-slip fretting. Three DLC coating systems (a-C:H, Si-a-C:H, a-C:H:W top layers) on hardened M2 tool steel were studied using a bespoke electrodynamic shaker with a 10 mm 52100 steel ball as the counterface. This work has shown that H/E ratio can be used to predict wear performance in gross-slip fretting; the highest H/E ratio a-C:H performed best with low friction and wear

Plasma-sprayed high entropy alloy coating with novel MoS2 /resin hybrid sealant: tribological and corrosion characterization

Sealing treatment provides a strategy for the long-term performance of thermal spray coatings under actual working conditions. However, common sealants are mainly limited to improving the corrosion resistance of coatings, neglecting applications in more complex environments where they are subject to simultaneous corrosion and wear. Herein, a novel organic-inorganic hybrid composite sealant, composed of self-lubricating MoS2 nanoparticles and environmentally friendly waterborne silicone modified acrylic resin (WBS-ACR), was successfully prepared in the pores and micro-defects of plasma-sprayed HEA coatings by one-step hydrothermal method. The results indicate that MoS2 nanosheets are uniformly synthesized in resin materials through precursor hydrothermal reactions. The hybrid sealants are filled densely in the micro-defects of HEA coatings with a maximum penetration depth greater than 180 μm. The tribological and electrochemical results indicate that the hybrid sealant exhibits similar anti-wear performance, but two orders of magnitude lower corrosion currents than that of pure MoS2 sealant. In comparison to the pure resin sealant, the hybrid sealant retains its excellent corrosion resistance while increasing its wear resistance. The superior comprehensive performance of the novel organic-inorganic hybrid sealant could expand the application of thermal spray coatings into new fields

Tailoring the corrosion and tribological performance of Ti-modified MoS2-based films in simulated seawater

Film protection has become a crucial means to improve the corrosion and wear performance of key components in aggressive environment. In this study, the feasibility of using MoS2-based modified films in artificial seawater (3.5% NaCl solution) was evaluated by co-deposition of Ti to produce Ti-MoS2 composite and Ti/MoS2 multilayer films. The microstructure, wettability, mechanical, tribological and corrosion behavior of the Ti-modified MoS2-based films was contrasted to pure MoS2 film. The results show that the incorporation of Ti not only improves densification, but also promotes a transformation from a columnar to an amorphous film structure, leading to the improvement of mechanical properties of Ti-MoS2 composite film and Ti/MoS2 multilayer film. The friction coefficient curves of all of the three MoS2-based film in 3.5 wt% NaCl solution show stable values during the sliding process. The advantage of the preferential (002) growth orientation, improved mechanical properties and reduced hydrophobicity for both of the Ti-modified MoS2 films caused the decreased friction coefficient and wear rate in NaCl solution. The electrochemical results before and after friction show that the ranking of corrosion resistance is Ti/MoS2 multilayer > Ti-MoS2 composite film > pure MoS2 film, which is attributed to the compact microstructure and the presence of surface passive films