Wear and friction of TiAlN/VN coatings against Al2O3 in air at room and elevated temperatures

TiAlN/VN multilayer coatings exhibit excellent dry sliding wear resistance and low friction coefficient, reported to be associated with the formation of self-lubricating V2O5. To investigate this hypothesis, dry sliding ball-on-disc wear tests of TiAlN/VN coatings on flat stainless steel substrates were undertaken against Al2O3 at 25 C, 300 C and 635 C in air. The coating exhibited increased wear rate with temperature. The friction coefficient was 0.53 at 25 C, which increased to 1.03 at 300 C and decreased to 0.46 at 635 C. Detailed investigation of the worn surfaces was undertaken using site-specific transmission electron microscopy (TEM) via focused ion beam (FIB) microscopy, along with Fourier transform infrared (FTIR) and Raman spectroscopy. Microstructure and tribo-induced chemical reactions at these temperatures were correlated with the coating’s wear and friction behaviour. The friction behaviour at room temperature is attributed to the presence of a thin hydrated tribofilm and the presence of V2O5 at high temperature

Deposition of nanoscale multilayer CrN/NbN physical vapor deposition coatings by high power impulse magnetron sputtering

Nanoscale multilayer CrN/NbN physical vapor deposition (PVD) coatings are gaining reputation for their high corrosion and wear resistance. However, the CrN/NbN films deposited by ABS(TM) (are bond sputtering) technology have some limitations such as macrodroplets, porosity, and less dense structures. The novel HIPIMS (high power impulse magnetron sputtering) technique produces macroparticle-free, highly ionized metal plasma, which brings advantages in both surface pretreatment and coating deposition stages of the PVD process. In this study, nanoscale multilayer CrN/NbN PVD coatings were pretreated and deposited with HIPIMS technology and compared with those deposited by HIPIMS-UBM (unbalanced magnetron) and by the ABSTM technique. In all cases Cr+ etching was utilized to enhance adhesion by low energy ion implantation. The coatings were deposited at 400 degrees C with substrate biased (Ub) at -75 V. During coating deposition, HIPIMS produced significantly high activation of nitrogen compared to the UBM as observed with mass spectroscopy. HIPIMS-deposited coatings revealed a bilayer period of 4.1 nm (total thickness: 2.9 mu m) and hardness of 3025 HK0.025. TEM results revealed droplet free, denser microstructure with (200) preferred orientation for the HIPIMS coating owing to the increased ionization as compared to the more porous structure with random orientation observed in UBM coating. The dry sliding wear coefficient (K-c) of the coating was 1.8 X 10(-15) m(3) N-1 m(-1), whereas the steady state coefficient of friction was 0.32. Potentiodynamic polarization tests revealed higher E-corr values, higher pitting resistance (around potentials +400 to +600 mV), and lower. corrosion current densities for HIPIMS deposited coatings as compared to the coatings deposited by ABS or HIPIMS-UBM. The corrosion behavior of the coatings qualitatively improved with the progressive use of HIPIMS from pretreatment stage to the coating deposition step. (C) 2008 American Vacuum Society

The effect of (Ti + Al): V ratio on the structure and oxidation behaviour of TiAlN/VN nano-scale multilayer coatings

Nano-scaled multilayered TiAlN/VN coatings have been grown on stainless steel and M2 high speed steel substrates at U-B = - 85 V in an industrial, four target, Hauzer HTC 1000 coater using combined cathodic steered arc etching/unbalanced magnetron sputtering. X-ray diffraction (XRD) has been used to investigate the effects of process parameters (Target Power) on texture evolution (using texture parameter T*), development of residual stress (sin(2) psi method) and nano-scale multilayer period. The composition of the coating was determined using energy dispersive X-ray analysis. The thermal behaviour of the coatings in air was studied using thermo-gravimetric analysis, XRD and scanning electron microscopy. The bi-layer period varied between 2.8 and 3.1 nm and in all cases a {1 1 0} texture developed with a maximum value T* = 4.9. The residual stress varied between -5.2 and -7.4 GPa. The onset of rapid oxidation occurred between 628 and 645 degreesC depending on the (Ti+Al):V ratio. After oxidation in air at 550 degreesC AlVO4, TiO2 and V2O5 Phases were identified by XRD with the AlVO4, TiO2 being the major phases. The formation of AlVO4 appears to disrupt the formation of Al2O3 which imparts oxidation resistance to TiAlN based coatings. Increasing the temperature to 600 and 640 degreesC led to a dramatic increase in the formation of V2O5 which was highly oriented (0 0 1) with a plate-like morphology. At 640 degreesC there was no evidence of the coating on XRD. Increasing the temperature to 670 degreesC led to further formation of AlVO4 and a dramatic reduction in V2O5. (C) 2003 Elsevier B.V. All rights reserved

Development of superlattice CrNNbN coatings for joint replacements deposited by High Power Impulse Magnetron Sputtering

The demand for reliable coating on medical implants is ever growing. In this research, enhanced performance of medical implants was achieved by a CrN/NbN coating utilising nanoscale multilayer/superlattice structure. The advantages of the novel High Power Impulse Magnetron Sputtering technology, namely its unique highly ionised plasma were exploited to deposit dense and strongly adherent coatings on Co-Cr implants. TEM analyses revealed coating superlattice structure with bi-layer thickness of 3.5 nm. CrN/NbN deposited on Co-Cr samples showed exceptionally high adhesion, critical load values of LC2= 50 N in scratch adhesion tests. Nanoindentation tests showed high hardness of 34 GPa and Young's modulus of 447 GPa. Low coefficient of friction (µ) 0.49 and coating wear coefficient (KC) = 4.94 x 10-16 m3N-1m-1 were recorded in dry sliding tests. Metal ion release studies showed a reduction in Co, Cr and Mo release at physiological and elevated temperatures, (70 oC) to almost undetectable levels (<1 ppb). Rotating beam fatigue testing showed a significant increase in fatigue strength from 349±59 MPa (uncoated) to 539±59 MPa (coated). In vitro biological testing has been performed in order to assess the safety of the coating in biological environment, cytotoxicity, genotoxicity and sensitisation testing have been performed, all showing no adverse effects. Keywords: Orthopaedic implant, High Power Impulse Magnetron Sputtering, Superlattice coating, Corrosion, Biocompatibility

Influence of the bias voltage on the structure and the tribological performance of nanoscale multilayer C/Cr PVD coatings

Nanoscale multilayer C/Cr coatings have been deposited by utilising the combined steered cathodic arc/unbalanced magnetron sputtering technique. The coating microstructure and tribological performance have been investigated as a function of the bias voltage, ranging from U-b=-65 to -350 V. The XRD results revealed that C/Cr coatings are amorphous at low U-b, but became more crystalline when the Ub increased to -350 V. High-resolution XTEM analysis indicated coating densification and smoothening as well as formation of novel amorphous nanostructure, in which carbon-rich clusters are surrounded by a Cr-rich matrix, leading to the formation of self-organised multilayer structure as the bias voltage was increased from -65 to -350 V. An increase of the bias voltage from -65 to -350 V resulted in an increase in the hardness from 8 to 25 CiPa and Young's modulus, E from 186 to 319 GPa. A pin-on-disc test showed that the friction coefficient was reduced from 0.22 to 0.16 when the bias voltage was increased from -65 to -95 V However, a further increase in the bias voltage to -350 V led to an increase in the friction coefficient to 0.31. The lowest wear coefficient K(c)similar to6.25 x 10(-17) m(3) N-1 m(-1) was achieved at U-b = - 120 V. Standard HSS drills, 8 mm in diameter, coated with C/Cr have been tested using solution annealed AISI 304 stainless steel as the work piece material. An improvement of the lifetime by a factor of similar to9 has been achieved as compared to the uncoated tools. In this test, the C/Cr coating outperformed a number of commercially available PVD coatings, such as TiCN, TiAlCrN and showed similar performance to TiAlCrYN. (C) 2004 Elsevier B.V. All rights reserved

Substrate finishing and niobium content effects on the high temperature corrosion resistance in steam atmosphere of CrN/NbN superlattice coatings deposited by PVD-HIPIMS

The main objective of this work was to evaluate the oxidation resistance of three PVD-HIPIMS CrN/NbN coatings, studying the effect of the surface finishing of the substrate and the role of niobium content into the coating composition. CrN/NbN nano-multilayered films on P92 steel were tested at 650°C in pure steam atmosphere. The mass gain was measured at fixed intervals to study their oxidation kinetics. The morphology and thickness of nanoscales were measured by transmission electron microscopy (TEM). Characterization of coatings before and after the thermal treatment was performed by scanning electron microscopy-energy with facilities of dispersive X-ray spectroscopy (SEM–EDX) and X-ray diffraction (XRD). All coatings improved the oxidation resistance of the substrate material, but the best behaviour was exhibited by the CrN/NbN with the high niobium (Nb) content and deposited on the substrate with the finest surface finishing

Tribological properties of unbalanced magnetron sputtered nano-scale multilayer coatings TiAlN/VN and TiAlCrYN deposited on plasma nitrided steels

Unbalanced magnetron sputtered multilayer coatings TiAlN/VN and TiAlCrYN grown on pulse plasma nitriding pre-treated low alloy steel P20 have been characterised by using X-ray diffraction (XRD), scanning electron microscope (SEM), micro-indentation, scratch and pin-on-dise wear tests. A 160-mu m-thick nitrided case was formed on the steel surface containing a pure Fe3N and Fe4N compound layer and showing hardness up to 8.5 GPa, which led to improved load bearing ability and adhesion behaviour of the coating-substrate system. The coatings deposited on non-nitrided P20 showed poor adhesion and severe cracking and spalling wear. In contrast, the TiAlN/VN and TiAlCrYN deposited on nitrided substrates showed only mild polishing and oxidation wear mechanisms and extremely low wear coefficients in the scales of 10(-17) and 10(-16) m(3) N-1 m(-1), respectively. In drilling solution treated 304 austenite stainless steel, the TiAlN/VN-coated drills showed a lifetime 50% longer than TiAlN-coated drills. Plasma nitriding pre-treatment led to further increases of lifetime by 33%. (c) 2004 Elsevier B.V. All rights reserved

A MODELING-BASED CLASSIFICATION ALGORITHM VALIDATED WITH SIMULATED DATA

We present a Generalized Lotka-Volterra (GLV) based approach for modeling and simulation of supervised inductive learning, and construction of an efficient classification algorithm. The GLV equations, typically used to explain the biological world, are employed to simulate the process of inductive learning. In addition, the modeling approach provides a key advantage over the more conventional constraint and optimization-based classification algorithms, as influences of outliers and local patterns, which can lead to problematic overfitting, are auto-moderated by the model itself. We present the bare-bones algorithm and motivate the model through axiomatic postulates. The algorithm is validated using benchmark simulated datasets, showing results competitive with other cutting-edge algorithms.

Cross sectional TEM analysis of duplex HIPIMS and DC magnetron sputtered Mo and W doped carbon coatings

A FIB lift-out sample was made from a wear-resistant carbon coating deposited by high power impulse magnetron sputtering (HIPIMS) with Mo and W. TEM analysis found columnar grains extending the whole ∼1800 nm thick film. Within the grains, the carbon was found to be organised into clusters showing some onion-like structure, with amorphous material between them; energy dispersive X-ray spectroscopy (EDS) found these clusters to be Mo- and W-rich in a later, thinner sample of the same material. Electron energy-loss spectroscopy (EELS) showed no difference in C-K edge, implying the bonding type to be the same in cluster and matrix. These clusters were arranged into stripes parallel to the film plane, of spacing 7-8 nm; there was a modulation in spacing between clusters within these stripes that produced a second, coarser set of striations of spacing ∼37 nm

Characterisation of a high-power impulse magnetron sputtered C/Mo/W wear resistant coating by transmission electron microscopy

Thin films of C/Mo/W deposited using combined UBM/HIPIMS sputtering show 2–8 nm clusters of material richer in Mo and W than the matrix (found by EDS microanalysis), with structures that resemble graphitic onions with the metal atoms arranged regularly within them. EELS microanalysis showed the clusters to be rich in W and Mo. As the time averaged power used in the pulsed HIPIMS magnetron was increased, the clusters became more defined, larger, and arranged into layers with amorphous matrix between them. Films deposited with average HIPIMS powers of 4 kW and 6 kW also showed a periodic modulation of the cluster density within the finer layers giving secondary, wider stripes in TEM. By analysing the ratio between the finer and coarser layers, it was found that this meta-layering is related to the substrate rotation in the deposition chamber but in a non-straightforward way. Reasons for this are proposed. The detailed structure of the clusters remains unknown and is the subject of further work. Fluctuation electron microscopy results indicated the presence of crystal planes with the graphite interlayer spacing, crystal planes in hexagonal WC perpendicular to the basal plane, and some plane spacings found in Mo2C. Other peaks in the FEM results suggested symmetry-related starting points for future determination of the structure of the clusters