Preface: emergent coatings and thin films for high‑temperature energy applications

Increasing the temperature capability of mechanical devices and components is a major requirement of the energy sector. The development of new coating and thin film compositions is of strategic importance for a wide range of energy applications, which can directly influence the transport, aerospace, and manufacturing industries. This special issue covers the design and development of innovative materials related to high-temperature energy conversion, conservation, harvesting, and storage

Control over multi-scale self-organization-based processes under the extreme tribological conditions of cutting through the application of complex adaptive surface-engineered systems

This paper features a comprehensive analysis of various multiscale selforganization processes that occur during cutting. A thorough study of entropy production during friction has uncovered several channels of its reduction that can be achieved by various selforganization processes. These processes are (1) self-organization during physical vapor deposition PVD coating deposition on the cutting tool substrates; (2) tribofilm formation caused by interactions with the environment during operation, which consist of the following compounds: thermal barriers; Magnéli phase tribo-oxides with metallic properties at elevated temperatures, tribo-oxides that transform into a liquid phase at operating temperatures, and mixed action tribo-oxides that serve as thermal barriers/lubricants, and (3) multiscale selforganization processes that occur on the surface of the tool during cutting, which include chip formation, the generation of adhesive layers, and the buildup edge formation. In-depth knowledge of these processes can be used to significantly increase the wear resistance of the coated cutting tools. This can be achieved by the application of the latest generation of complex adaptive surface-engineered systems represented by several state-of-the-art adaptive nano-multilayer PVD coatings, as well as high entropy alloy coatings (HEAC)

Particle distribution, film formation and wear performance of brush plated Ni/WC

Nickel-matrix composite coatings with tungsten carbide particles were produced by brush electroplating using different current densities and materials of the brush. Non-abrasive materials and high current densities produce coatings with high particle content and non-uniform dispersion. Abrasive wear testing showed premature coating failure in areas with high particle concentrations (>21.3 at.% of W). Changes to the solution flow direction were undertaken to decrease ‘solution pooling’, as it was related to areas with excessive particle content. This, together with the use of abrasive brushes at lower current densities, gives Ni/WC coatings with a low and narrow composition range (from 13.2 ± 4.8 to 2.8 ± 0.8 at.% of W). Such optimized coatings minimized premature coating failure and improved the wear resistance to 1.8–4.4 times that of the original nickel matrix, achieving values similar to hard chrome coatings tested under the same conditions. Unlike other brush plated composite coatings, changes in coating morphology are not heavily influenced by processing parameters, but are sensitive to the presence of WC particles

Micro-impact testing of AlTiN and TiAlCrN coatings

A novel micro-scale repetitive impact test has been developed to assess the fracture resistance of hard coatings under dynamic high strain rate loading. It is capable of significantly higher impact energies than in the nano-impact test. It retains the intrinsic depth-sensing capability of the nano-impact test enabling the progression of the damage process to be monitored throughout the test, combined with the opportunity to use indenters of less sharp geometry and still cause rapid coating failure. The micro-impact test has been used to study the resistance to impact fatigue of Al-rich PVD nitride coatings on cemented carbide. The impact fatigue mechanism has been investigated in nano- and micro-scale impact tests. Coating response was highly load-dependent. A Ti0.25Al0.65Cr0.1N coating with high H3/E2 performed best in the nano- and micro- impact tests although it was not the hardest coating studied. The role of mechanical properties, microstructure and thickness on impact behaviour and performance in cutting tests is discussed

A guiding framework for process parameter optimisation of thermal spraying

Currently, most thermal spray coating service providers expect original equipment manufacturers (OEMs) to suggest the coating recipe, comprising of the right coating equipment, starting process parameters, type of inert gases, and robot program. The microstructure and mechanical properties may not comply in the first few runs. Feedback from a competent material testing service provider forms the initial step to adjust the parameters in the development journey, toward identifying the processing parameters required to obtain an acceptable coating. With the surge of interest in sustainable manufacturing, the time spent on trials in the future will shrink, and a more rigorous process needs to be applied to achieve the “right-first-time manufacturing” approach in thermal spraying. However, a framework for the systematic development of thermal spray parameter optimisation is lacking. This article provides a framework, based on a logical acumen, in selecting the right process parameters, using available data and prior knowledge about the thermal spraying process. To that end, the article summarises the extant developmental journey of thermal spray process parameters, by covering the aspects of equipment choice, robot and spray parameters, and how to minimise iterations, using diagnostic tools to get to the end solution most efficiently. This article, in its current form, will serve as a good guide for early career engineers and scientists or workers, to minimise the time processing window, by avoiding endless iterations to deposit a certain type of coating using thermal spraying. Besides, this work is also aimed at transforming academic research innovations to a robust and repeatable industrial manufacturing process

Modern coatings in high performance cutting applications

Modern, state-of-the-art, PVD coatings are required to fulfill a variety of different applications. Each metal cutting operation requires an optimal combination of various film parameters to achieve a high end cutting performance. Especially, Al-based coatings such as AlTiN- and AlCrN-coatings show very good results in high performance metal cutting applications. Wear resistance, thermal stability such as oxidation resistance and hardness at elevated temperatures are key issues within these cutting operations. In this paper the influence of these properties on Al-based nitride coatings in relation to metal cutting tests such as milling and drilling will be discussed

Probe geometry and surface roughness effects in microscale impact testing of WC-Co

Depth-sensing repetitive microimpact tests have been performed on cemented carbide cutting tool inserts with spheroconical diamond probes with end radii of 8, 20 and 100 µm. Results were strongly dependent on the probe radius and applied load. At higher load, there was a transition to a faster damage rate marking the onset of more variability in rate and in the residual depth of the impact crater when using 8 and 20 µm probes. SEM images show the breakup of the WC skeleton at the periphery of the contact zone. Lower surface roughness slowed the initial damage rate at a higher load but did not significantly influence the final crater depth. The load-dependent fatigue mechanism displayed by the cemented carbide also has implications for the study and optimization of coatings when these are deposite

Elevated temperature micro-impact testing of TiAlSiN coatings produced by physical vapour deposition

A high temperature micro-impact test has been developed to assess the fracture resistance of hard coatings under repetitive dynamic high strain rate loading at elevated temperatures. The test was used to study the temperature dependence of the resistance to micro-scale impact fatigue of TiAlSiN coatings on cemented carbide at 25–600 °C. Nanoindentation and micro-scratch tests were also performed over the same temperature range. The results of the micro-impact tests were dependent on the impact load, coating microstructure, coating and substrate mechanical properties, and their temperature dependence. At higher temperatures there was a change in failure mechanism from fracture-dominated to plasticity-dominated behaviour under the cyclic loading conditions. This was attributed to coating and substrate softening

Secondary structures on the friction surface of diamond-like coating

Peculiarities of the formation of secondary structures on the surface of a diamond-like coating are studied on the example of a friction contact between a steel ball and a diamond-like coating. The friction surface was examined in various areas; the zone of wear products (the boundary of the friction track) and the original surface outside the friction area. It is shown that secondary structures with a high content of iron, nickel, manganese, chromium, and oxygen are characteristic of areas with the highest wear resistance. Such secondary structures are formed because of the intense interaction of the diamond-like coating with the steel of the ball during dry friction

Nano- and micro-scale impact testing of zirconia, alumina and zirconia-alumina duplex optical coatings on glass

Optimising the mechanical properties of optical coatings to improve their durability will be critical if they are to be used successfully in harsh environments where they may be subject to degradation by mechanical contact. In this study zirconia, zirconia-alumina duplex and alumina experimental coatings were deposited on soda lime and borosilicate glass and their resistance to repetitive impact under different experimental conditions evaluated in nano- and micro-scale impact tests. The influence of changing probe geometry (sharp and blunt contacts) and applied load on the deformation was studied. Spheroconical indenters were found to be more suitable to study the load sensitivity of the impact response than sharp cube corner indenters. Increased resistance to plastic deformation in the coating-substrate system (H3/E2) proved detrimental to the damage tolerance to the repetitive nano- and micro-impact tests. To compare the deformation behaviour in nano-impact and nano-scratch, tests were performed using the same spheroconical probe, revealing cracking and blistering of the glass substrate in both types of test. The change in probe depth after the first impact was found to be a very useful metric to effectively compare the evolution of surface damage on continued impact in nano- and micro-impact tests at different applied load and probe geometr