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)

Teaching Wikipedia: A Model for Critical Engagement with Open Information

In this chapter, the authors describe the learning experience and goals of a class assignment to write content for Wikipedia about women in science and technology fields. The authors, a university professor and two librarians, collaboratively developed this assignment to allow students to engage in rigorous research and contribute to the visibility of women scientists by writing content for the web. The authors chose the Wikipedia platform as the means to make the students work openly available because of its ubiquity and the potential for student work to make an important impact. The assignment, used in two iterations of the course, was designed to provide students not only with a hands-on experience on working on the open web, but also with tools to assess critically the uses and abuses of open access platforms

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)

Interface-Induced Plasmon Nonhomogeneity in Nanostructured Metal-Dielectric Planar Metamaterial

Transformations of the electronic structure in thin silver layers in metal-dielectric (TiAlN/Ag) multilayer nanocomposite were investigated by a set of electron spectroscopy techniques. Localization of the electronic states in the valence band and reduction of electron concentration in the conduction band was observed. This led to decreasing metallic properties of silver in the thin films. A critical layer thickness of 23.5 nm associated with the development of quantum effects was determined by X-ray photoelectron spectroscopy. Scanning Auger electron microscopy of characteristic energy losses provided images of plasmon localization in the Ag layers. The nonuniformity of plasmon intensities distribution near the metal-nitride interfaces was assessed experimentally

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

Increasing of the carbide cutting tool life by developing the multilayer coatings

The paper presents the results of studying the structural parameters and mechanical properties of multi-element coatings based on-TiZrN, TiZrAlN, TiZrCrN, and TiNbAlN. The phase composition, the structural parameters, and the mechanical properties of such coatings are shown to depend on the design of cathode evaporators and the machine layout at the moment of application. Compared to TiN coating, multi-element coatings have higher residual compressive stress, smaller CSR, higher microdeformations of the crystal lattice, better mechanical properties, yet weaker adhesion to the tool base. Based on studying their structural parameters and mechanical properties, we have designed double-layer coatings. Use of such multi-layer coatings prolongs the tool life of carbide plates compared to TiN coating

Elevated temperature repetitive micro-scratch testing of AlCrN, TiAlN and AlTiN PVD coatings

In developing advanced wear-resistant coatings for tribologically extreme highly loaded applications such as high speed metal cutting a critical requirement is to investigate their behaviour at elevated temperature since the cutting process generates frictional heat which can raise the temperature in the cutting zone to 700–900 °C or more. High temperature micro-tribological tests provide severe tests for coatings that can simulate high contact pressure sliding/abrasive contacts at elevated temperature. In this study ramped load micro-scratch tests and repetitive micro-scratch tests were performed at 25 and 500 °C on commercial monolayer coatings (AlCrN, TiAlN and AlTiN) deposited on cemented carbide cutting tool inserts. AlCrN exhibited the highest critical load for film failure in front of the moving scratch probe at both temperatures but it was prone to an unloading failure behind the moving probe. Scanning electron microscopy showed significant chipping outside the scratch track which was more extensive for AlCrN at both room and elevated temperature. Chipping was more localised on TiAlN although this coating showed the lowest critical loads at both test temperatures. EDX analysis of scratch tracks after coating failure showed tribo-oxidation of the cemented carbide substrate. AlTiN showed improved scratch resistance at higher temperature. The von Mises, tensile and shear stresses acting on the coating and substrate sides of the interface were evaluated analytically to determine the main stresses acting on the interface. At 1 N there are high stresses near the coating-substrate interface. Repetitive scratch tests at this load can be considered as a sub-critical load micro-scale wear test which is more sensitive to adhesion differences than the ramped load scratch test. The analytical modelling showed that a dramatic improvement in the performance of AlTiN in the 1 N test at 500 °C could be explained by the stress distribution in contact resulting in a change in yield location due to the high temperature mechanical properties. The increase in critical load with temperature on AlTiN and AlCrN is primarily a result of the changing stress distribution in the highly loaded sliding contact rather than an improvement in adhesion strength

Improvement of Wear Performance of Nano-Multilayer PVD Coatings under Dry Hard End Milling Conditions Based on Their Architectural Development

The TiAlCrSiYN-based family of PVD (physical vapor deposition) hard coatings was specially designed for extreme conditions involving the dry ultra-performance machining of hardened tool steels. However, there is a strong potential for further advances in the wear performance of the coatings through improvements in their architecture. A few different coating architectures (monolayer, multilayer, bi-multilayer, bi-multilayer with increased number of alternating nano-layers) were studied in relation to cutting-tool life. Comprehensive characterization of the structure and properties of the coatings has been performed using XRD, SEM, TEM, micro-mechanical studies and tool-life evaluation. The wear performance was then related to the ability of the coating layer to exhibit minimal surface damage under operation, which is directly associated with the various micro-mechanical characteristics (such as hardness, elastic modulus and related characteristics; nano-impact; scratch test-based characteristics). The results presented exhibited that a substantial increase in tool life as well as improvement of the mechanical properties could be achieved through the architectural development of the coatings

Nanomechanical testing of thin films to 950 °C

Nanomechanical testing has been a revolutionary technique in improving our fundamental understanding of the basis of mechanical properties of thin film systems and the importance of the nanoscale behaviour on their performance. However, nanomechanical tests are usually performed in ambient laboratory conditions even if the coatings being developed are expected to perform at high temperature in use. It is important to measure nanomechanical and tribological properties of materials under test conditions that are closer to their operating conditions where the results are more relevant. We can then better understand the links between properties and performance and design advanced materials systems for increasingly demanding applications. However, high temperature nanomechanics is highly challenging experimentally and a high level of instrument thermal stability is critical for reliable results. To achieve this stability the NanoTest Vantage has been designed with (i) active heating of the sample and the indenter (ii) horizontal loading to avoid convection at the displacement sensor (iii) patented stage design and thermal control method. By separately and actively heating and controlling the temperatures of both the indenter and test sample there is minimal/no thermal drift during the high temperature indentation and measurements can be performed as reliably as at room temperature. Illustrative results are presented for TiAlN, TiFeN, DLC and MAX-phase coatings. Above 500 °C it is necessary to use Argon purging to limit oxidation of samples and the diamond indenter, although the efficiency of this decreases over 750 °C. To test at higher temperatures without indenter or sample oxidation an ultra-low drift high temperature vacuum nanomechanics system (NanoTest Xtreme) has been recently developed. Results with the vacuum system are presented up to 950 °C

Spatio-temporal behaviour of atomic-scale tribo-ceramic films in adaptive surface engineered nano-materials

Atomic-scale, tribo-ceramic films associated with dissipative structures formation are discovered under extreme frictional conditions which trigger self-organization. For the first time, we present an actual image of meta-stable protective tribo-ceramics within thicknesses of a few atomic layers. A mullite and sapphire structure predominates in these phases. They act as thermal barriers with an amazing energy soaking/ dissipating capacity. Less protective tribo-films cannot sustain in these severe conditions and rapidly wear out. Therefore, a functional hierarchy is established. The created tribo-films act in synergy, striving to better adapt themselves to external stimuli. Under a highly complex structure and non-equilibrium state, the upcoming generation of adaptive surface engineered nano-multilayer materials behaves like intelligent systems - capable of generating, with unprecedented efficiency, the necessary tribo-films to endure an increasingly severe environment