MULTILAYER COATINGS Ti/TiN Cr/CrN AND W/WN DEPOSITED BY MAGNETRON SPUTTERING FOR IMPROVEMENT OF ADHESION TO BASE MATERIALS

The paper deals with evaluation of single and multilayer layer PVD coatings based on Cr and Ti widely used in tool application. Additionally, W and WN based coating which are not so widespread were designed and deposited as functionally graded material. The coatings properties were evaluated from the point of view of hardness and adhesion. The hardness measuring was carried out using nanoindentation method. The scratch test was performed to test adhesion. Moreover, the presence of metallic interlayer in functionally graded materials further increases the coating adhesion by gradually approaching its composition to the substrate. Coatings consisting of W and WN have showed very good adhesion. With regard to the results of the scratch test, the multilayer coatings of CrN, TiN and WN have increased adhesion and can be assumed to have their protective function improved. Results will be appliedin development of functionally graded layers for functionally graded materials

Development of a semi automated dual feed unit to produce FGM coatings using the HVOF thermal spray process

The application of functionally graded materials (FGMs) is quite difficult, but thermal spray processes like Plasma spray have demonstrated their unique potential in producing graded deposits, where researchers have used twin powder feed systems to mix different proportions of powders. FGMs vary in composition and/or microstructure from one boundary (substrate) to another (top service surface), and innovative characteristics result from the gradient from metals to ceramics or non-metallic to metals. The present study investigates an innovative modification of a high velocity oxy-fuel (HVOF) thermal spray process to produce functionally graded thick coatings. In order to deposit thick coatings, certain problems have to be overcome. Graded coatings enable gradual variation of the coating composition and/or microstructure, which offers the possibility of reducing residual stress build-up with in coatings. In order to spray such a coating, modification to a commercial powder feed hopper was required to enable it to deposit two powders simultaneously which allows deposition of different layers of coating with changing chemical compositions, without interruption to the spraying process. Various concepts for this modification were identified and one design was selected, having been validated through use of a process model, developed using ANSYS Flotran finite element analysis. In the current research the mixing of different proportions of powders were controlled by a computer using LabVIEW software and hardware, which allowed the control and repeat-ability of the micro structure when producing functionally graded coatings

Elastoplastic stress analysis of functionally graded disc under internal pressure– complas XII

The study deals with elastoplastic stress analysis of a hollow disk made of functionally graded materials (FGMs) subjected to an internal pressure. The material properties of disc are assumed to vary radially according to power law function, but Poisson’s ratio is taken constant. Small deformations and a state of plane stress are presumed, and the analysis of disk is based on Von-Mises yield criterion. The materials are assumed to be linear strain hardening, isotropic and not be affected by temperature. Variation of stresses and displacements according to gradient parameters are investigated by using analytical and finite element method. The results show that gradient parameters have an important role in determining the elastoplastic stress of functionally graded disc

Elasticity analysis of sandwich pipes with functionally graded interlayers

Acknowledgements Financial support of this research by the Royal Society of Edinburgh and the Italian Academy of Sciences under International Exchanges Bilateral Programme grant is gratefully acknowledged.Peer reviewedPostprin

Interfacial adhesion of laser clad functionally graded materials

Specially designed samples of laser clad AlSi40 functionally graded materials (FGM) are made for evaluating the interfacial adhesion. To obtain the interfacial bond strength notches are made right at the interface of the FGMs. In-situ microstructural observations during straining in a field-emission gun environmental scanning electron microscopy reveal different failure modes of the FGMs and substrate. Mapping of strain fields using digital imaging correlation shows a gradual transition of deformation over the interface region and softening effects in the heat-affected zones of the FGM tracks. The strengthening of the FGM is dominated by the size of the Al halos around the particles, in accordance with a dislocation pile-up model.

Numerical modelling of functionally graded coatings

Peer reviewedPostprin

Molten salt attack on multilayer and functionally-graded YSZ coatings

Thermal barrier coatings have been extensively studied in the last years in order to increase the operational temperature of the current gas turbines as well as to improve the coating lifetime. Many coating characteristics must be met to achieve these requirements (low thermal conductivity, high thermal fatigue resistance…); therefore, complex systems have been engineered for these purposes. One of the possibilities to optimise the different properties deals with the design of multilayer or functionally-graded coatings where various types of microstructures with different characteristics are combined. One of the most important cause of gas turbines degradation relates to the attack of different type of particles which are suspended in the atmosphere (sand, fly ash…). These solid particles are molten at the operational temperatures and then, the molten salts chemically react with the coating. For this reason, the present research was focused on this type of attack. In the present work, the molten salt attack of various YSZ coatings with multilayer and functionally-graded design was addressed. Two different type of microstructures were specifically combined for this design: the APS coating microstructure obtained from conventional (microstructured) powder and a bimodal structure with nanozones obtained from nanostructured feedstock. Besides, different salts were used to simulate different attack environments (desert sand and volcanic fly ash). Findings show that nanozones act as barrier against the penetration of molten salts toward deeper layer. However, a layer formed by nanozones can detach when the salt attack is too aggressive. Hence, functionally-graded coatings, where two types of microstructures are combined through the whole coating, become ideal to diminish the molten salt attack

Deposition of Ti/TiC Composite Coatings on Implant Structures Using Laser Engineered Net Shaping

A new method of depositing hard and wear resistant composite coatings on metal-onmetal bearing surfaces of titanium implant structures is proposed and demonstrated. The method consists of depositing a Ti/TiC composite coating (~ 2.5 mm thick) on titanium implant bearing surfaces using Laser Engineered Net Shaping (LENS®). Defect-free composite coatings were successfully produced at various amounts of the reinforcing TiC phase with excellent interfacial characteristics using a mixture of commercially pure Ti and TiC powders. The coatings consisted of a mixture of coarser unmelted/partially melted (UMC) TiC particles and finer, discreet resolidified (RSC) TiC particles uniformly distributed in the titanium matrix. The amounts of UMC and RSC were found to increase with increasing TiC content of the original powder mixture. The coatings exhibited a high level of hardness, which increased with increasing TiC content of the original powder mixture. Fractographic studies indicated that the coatings, even at 60 vol.% TiC, do not fail in a brittle manner. Various aspects of LENS® deposition of Ti/TiC composite coatings are addressed and a preliminary understanding of structure-property-fracture correlations is presented. The current work shows that the proposed approach to deposit composite coatings using laser-based metal deposition processes is highly-effective, which can be readily utilized on a commercial basis for manufacture of high-performance implants.Mechanical Engineerin

Smart overlay coatings - concept and practice

Smart overlay coatings are a functionally gradient coating system designed to provide high temperature corrosion protection over a wide range of operating conditions. The SMARTCOAT design consists of a MCrAlY base, enriched first in chromium, then aluminium to provide a chemically graded structure. At elevated temperatures, above 900°C (1650°F), the coating oxidises to form a protective alumina scale. However, at lower temperatures this alumina scale does not reform rapidly enough to confer protection under type II hot corrosion conditions. The coating is therefore designed with an intermediate chromium-rich interlayer, which permits the rapid formation of chromia healing areas of type II corrosion damage. Laboratory and burner rig tests have been carried out on a series of developmental smart overlay coatings. These have shown that the development of an intermediate chromium-rich phase provides protection under low temperature hot corrosion conditions, while the aluminium-rich surface layer provides resistance to high temperature oxidation and type I hot corrosion. Thus, the single application of SMARTCOAT permits operation over a broad range of industrial and marine turbine conditio