Prevention of fretting by ion plated film

A new technological application of the ion plating technique to the prevention of fretting has been studied. Ion plating was done using gold and silver, which are commonly employed as thin metal film lubricants and also boron carbide which has extremely good wear resistance. The anti-fretting property of the ion plated film was always superior to that of the sputtered or vacuum evaporated film. The ion plated boron carbide film showed the best resistance to fretting. The better adhesion of ion plated films was responsible for the better anti-wear property. Transmission electron microscopy was used to study ion plated films.     

Humidity dependence of microwear characteristics of amorphous carbon films on silicon substrates

Influences of environmental humidity on various scanning-scratched wear characteristics, such as long-term stability of wear resistance and load dependence, scratch number dependence and scratch velocity dependence of wear depth, are evaluated by using an atomic force microscope and diamond tips. Amorphous carbon (a-C) films are deposited on silicon substrates by the electron cyclotron resonance plasma (ECR) sputtering method and the RF sputtering method combined with CVD using argon gas containing methane (CH₄) as a sputtering gas. In carbon samples with a higher hydrogen content, clear influences of the humidity on various wear characteristics are observed and their wear resistances decrease with increase of the humidity. In the ECR sputtered carbon film with low hydrogen content, wear resistance is stable during long-term exposure to an environment of high temperature and high humidity. In this film, the influences of humidity on the wear resistance and adhesion forces between the films and the substrates are not observed, since it is highly wear resistant and the wear depths are shallow in each test. Thus, amorphous carbon films with low hydrogen content are suitable as wear resistant protective overcoats from the point of view of the wear resistance, in particular the influence of the humidity on the wear resistance including its long-term stability.     

Micro-Scale Abrasive Wear Test of Thin Coated Cylindrical Surfaces

This paper is concerned with whether the micro-scale abrasive test is suitable for studying non-flat surfaces. A new micro-scale abrasion test has been developed to do studies on cylindrical shapes. A complete procedure to determine the intrinsic wear resistance of coatings is presented and discussed. The new method allows the direct characterization of small cylindrical parts, such as pins, bolts, shafts, etc. The method developed is used to study the abrasion resistance of W–Si–N sputtered coatings and electroplated chromium films.     

Effects of film thickness and contact load on nanotribological properties of sputtered amorphous carbon thin films

The nanotribological properties of amorphous carbon (a-C) films of thickness in the range of 5-85 nm sputtered on Si(1 0 0) substrates were investigated with a surface force microscope (SFM), using a Berkovich diamond tip of nominal radius of curvature approximately equal to 200 nm and contact (normal) loads between 10 and 1200 μN. The dependence of the friction and wear behaviors of the a-C films on normal load and film thickness was studied in terms of nanomechanical properties, images of scratched surfaces, and numerical results obtained from a previous analytical friction model. The increase of the contact load caused the coefficient of friction to decrease initially to a minimum value and, subsequently, to increase to a maximum value, after which, it either remained constant or decreased slightly. The dominant friction mechanism in the low-load range was adhesion, while both adhesion and plowing mechanisms contributed to the friction behavior in the intermediate- and high-load ranges. Thinner (thicker) a-C films yielded higher (lower) friction coefficients for normal loads less than 50 μN (low-load range) and lower (higher) friction coefficients for normal loads greater than 150 μN (high-load range). Elastic and plastic deformation, microcracking, and delamination of the a-C films occurred, depending on the contact load and film thickness ranges. The reduced load-carrying capacity, relatively low effective hardness (strength) obtained with thinner films, and dominant friction and wear mechanisms at each load range illustrate the film thickness and contact load dependence of the nanotribological properties of the sputtered a-C films.     

A Facile Surface Treatment to Improve the Abrasion Resistance of Photosensitive Film for Screen Printing

In this study, a facile surface treatment method was proposed to improve the abrasion resistance of photosensitive film for screen printing. Of the three silane coupling agents used in this study, 3-aminopropyltriethoxysilane (KH550) shows the best surface modification effect. The orthogonal experiments show that the concentration of KH550 solution is the most significant factor affecting the wear resistance of photosensitive films. Therefore, the surface characteristics and abrasion resistance of photosensitive films treated with various concentrations of KH550 solution were further investigated. The investigation shows that the abrasion resistance of photosensitive films treated with KH550 is improved greatly due to the existence of a coating on the surface, and it increases with the increase of KH550 concentration until a plateau is reached at a concentration of 15?wt%. The wear resistance of photosensitive films treated with 15?wt% of KH550 is increased by 34% compared with that of pure film. Moreover, surface treatment with KH550 leads to a decrease in surface roughness of photosensitive films and an increase in their hydrophobicity. Also, the hydrophobicity increases slightly with the increase of KH550 concentration, probably because KH550 concentration can only affect the thickness of surface coating, but has no effect on the surface property. This simple method is used for the first time to improve the abrasion resistance of photosensitive film, and it has the potential to be applied for large-scale production of durable screen plates.     

Adhesion Between Surfaces Separated by Molecularly Thin Perfluoropolyether Films

The relationship between the adhesion of surfaces separated by a molecularly thin liquid film and the surface energy of the film was investigated. AFM-based force–distance curves were measured on a series of carbon surfaces coated with hydroxyl-terminated perfluoropolyether (PFPE) films. The surface energy of the PFPE films was varied by altering either the total film thickness or the bonding ratio of the film by changing the concentration of the PFPE film in the solution and/or the pull-rate during dip-coating. A linear relationship between adhesion force and surface energy was observed. Adhesion was found to vanish at non-zero values of surface energy. The experimental results indicate that the adhesive force between macroscopic bodies separated by molecularly thin liquid films is linearly proportional to the excess surface energy of the film.     

Lubrication with Sputtered MoS2 Films

Sputtered MoS₂films (2000–6500 Å) were deposited on highly polished metal surfaces. These films have a low coefficient of friction (0.03–0.04) at speeds of 40–80 rpm and loads of 250–1000 grams. At loads of 250 grams the wear lives are over 0.5 million cycles, but at 1000 gram loads, it decreases to 38,000 cycles. Friction experiments and tensile tests have indicated that sputtered films have a strong adherence to metal surfaces. Electron transmission, diffraction and scanning electron microscopy show that these films have an extremely small particle size, less than 30 Å in diameter, and are very dense and free from observable pinholes. The high kinetic energy of these sputtered species, the submicroscopic particle size and the sputter-etched substrate surface is responsible for strong adhesion and cohesion of the sputtered film.     

The influence of soot and dispersant on ZDDP film thickness and friction

The effect of dispersed soot in engine oils is an increasingly important issue in terms of both engine durability and fuel efficiency. Using carbon black as a soot analogue, a study has been carried out to investigate the main factors that determine the impact of soot on friction and ZDDP film formation in formulated oils. It has been found that dispersed carbon black can rapidly remove ZDDP reaction films by abrasion. However, this removal can be prevented or limited by the choice of an optimal dispersant additive.     

Friction and Wear Properties of Graphite-Like Carbon Films Deposited on Different Substrates with a Different Interlayer Under High Hertzian Contact Stress

Four types of graphite-like carbon (GLC) films were deposited on different substrates (Ti6Al4V, WC-27CrNi) with a different interlayer (TiC/Ti, TiC/Ti/TiN) using an unbalanced magnetron sputtering system. The effect of substrate and interlayer on the microstructure and properties of the studied GLC films was then investigated using different characterization techniques. The results show that both the substrate and interlayer had an obvious influence on the tribological properties of the studied GLC films even though there was no significant structural difference between these films. Specifically, a substrate with a high hardness was propitious to achieving superior tribological behaviors for carbon film even with a different interlayer. However, the interlayer had a distinct influence on the tribological properties of the carbon film deposited on different substrates, and this effect varied with the hardness property of the substrate. For a hard substrate, the wear rate and wear life were similar irrespective of the interlayer. For a soft substrate, the addition of a TiN interlayer improved the wear life sevenfold compared to the film with only a TiC/Ti interlayer, but the wear rate for a film with and without a TiN interlayer was approximately the same. The obvious discrepancy between wear life and wear rate for a carbon film deposited on soft substrate was closely related with the film adhesion strength and plastic deformation of the substrate materials. Based on these results, it can be concluded that the wear life is a better parameter than wear rate in terms of characterization of the wear resistance of carbon film once the applied load causes the plastic deformation of the substrate.     

Effect of transfer film structure, composition and bonding on the tribological behavior of polyphenylene sulfide filled with nano particles of TiO2, ZnO, CuO and SiC

The tribological behavior of polyphenylene sulfide (PPS) filled with inorganic nano particles was studied. The fillers investigated were TiO₂, ZnO, CuO and SiC whose sizes varied from 30 to 50 nm. The polymer composites were compression molded with varying proportions of these fillers. Wear and friction tests were performed in a pin-on-disk configuration at a sliding speed of 1.0 m/s, nominal pressure of 0.65 MPa, and counterface roughness of 0.10 μm Ra. The polymer composite pins slid against hardened tool steel counterfaces. The transfer films of the composite materials formed on the counterfaces during sliding were studied by optical microscopy and X-ray photoelectron spectroscopy (XPS) and the adhesion between the transfer film and counterface was measured in terms of the peel strength. It was found that the wear rate of PPS decreased when TiO₂ and CuO were used as the fillers but increased with ZnO and SiC fillers. The optimum wear resistance was obtained with 2 vol.% CuO or TiO₂. These filled composites had the coefficients of friction lower than that of the unfilled PPS. The wear behavior of the composites is explained in terms of the topography of transfer film and adhesion of transfer film to the counterface as observed from peel strength studies. There is a good correlation observed between the transfer film-counterface bond strength and wear resistance.     

在WC-TiC-Co硬质合金基体上制备金刚石薄膜的试验研究

通过采用Cu/Ti复合过渡层在WC TiC Co硬质合金基体上制备金刚石薄膜的试验 ,研究了沉积工艺对金刚石薄膜的质量、表面粗糙度及附着力的影响。研究结果表明 ,采用Cu/Ti复合过渡层有利于提高金刚石薄膜的附着力 ;适当降低沉积温度虽然会导致金刚石薄膜中非金刚石碳含量增加 ,但有利于增强膜层附着力。     

A Method for Evaluating the Thickness of Ultrathin Films

A method for determining the thickness of ultrathin (<10 nm) films using an atomic-force microscope is described. Films were deposited onto a porous glass substrate that has smooth surface areas between the pores when the flow of the evaporated material incident on the substrate is at an angle of 20°–30° with respect to the normal to its surface. In order to obtain pores with sharp edges, the substrate surface was preliminarily sputtered by an oxygen ion beam directed at an angle of 90° to this surface. Images of such films obtained using the atomic-force microscopy technique clearly resolve the position of the pore edge–film boundary, making it possible to evaluate the film thickness by the height of the step between the pore edge and the by surface in the cross section of the surface topography.     

Evaluation of Ion-Sputtered Molybdenum Disulfide Bearings for Spacecraft Gimbals

High-density, sputtered molybdenum disulfide films (MoS₂) were investigated as lubricants for the next generation of spacecraft gimbal bearings where low torque signatures and long life are required. Low friction in a vacuum environment, virtually no out-gassing, insensitivity to low temperature, and radiation resistance of these lubricant films are valued in such applications. One hundred and twenty five thousand hours of accumulated bearing lest time were obtained on 24 pairs of flight-quality bearings ion-sputtered with three types of advanced MoS₂ films. Life tests were conducted in a vacuum over a simulated duty cycle for a space pay bad gimbal. Optimum retainer and ball material composition were investigated. Comparisons were made with test bearings lubricated with liquid space lubricants.

Self-lubricating PTFE retainers were required for long life, i.e., > 40 million gimbal cycles. Bearings with polyimide retainers, silicon nitride ceramic balls, or steel balls sputtered with MoS₂ film suffered early torque failure, irrespective of the type of race-sputtered MoS₂ film. Failure generally resulted from excess film or retainer debris deposited in the ball track which tended to jam the bearing. Both grease lubricated and the better MoS₂ film lubricated bearings produced long lives, although the torque with liquid lubricants was lower and less irregular.     

Thermal contact conductance of coated surfaces

The thermal contact resistance phenomena are increasingly important as the size of mechanical and electronic components decrease. Applying a coating material with high thermal conductivity is an effective way to enhance the thermal contact conductance. This work conducted an experimental and theoretical study to investigate the effects of diamond film coatings on the thermal contact conductance. A model based on statistical elastoplastic surface contact mechanics was developed to study the thermal contact conductance of coating material. Diamond films were sputtered on the substrate of ceramics by microwave plasma chemical vapor deposition. Test samples have different surface roughnesses, deposition times and deposition qualities. A range of test conditions was conducted to evaluate the thermal contact conductance of coated films and for comparisons with the theoretical model.     

Synthesizing diamond film on Cu,Fe and Si substrate by in-liquid microwave plasma CVD

The purpose of this study is to synthesize diamond onto Si, Cu, and Fe (SUS632J2) substrates and to analyze the effect of carbon diffusion on their surfaces. Diamond was synthesized using the in-liquid microwave plasma chemical vapor deposition (IL-MPCVD) as a novel method for synthesizing diamond on various base materials. The IL-MPCVD method is superior one due to its efficiency in terms of cost, space and speed as compared to a conventional gas phase microwave plasma CVD (MPCVD). Microwaves of 2.45 GHz generated plasma in a solution which was comprised of methanol: ethanol (M:E = 97:3). Evaluation of deposited diamond films was done by a Scanning Electron Microscope (SEM) and Raman spectroscopy. Results shows that the IL-MPCVD method can form diamond films on Cu, Si and Fe substrates. The minimum time of film formation of Cu, Si and Fe are 2.5, 3.5 and 5 min, respectively. The material that forms carbide layers such as Si is a better substrate to form diamond film by the IL-MPCVD than other metal substrates such as Cu and Fe. Synthesizing diamond directly on the Fe substrate results in poor quality layers. The effect of carbon diffusion influences diamond film nucleation and diamond growth. In order to alleviate the carbon diffusion and improve the quality of the diamond film on the Fe substrate, Si has been sputtered on the Fe substrate as an interlayer. It is found that the diamond film can be formed on a Fe substrate using a Si interlayer and that heat treatment and thickening the interlayer improve its quality.     

Morphological Growth of Sputtered MoS2 Films

Sputtered MoS₂ films from 300 Å to 20,000 Å thick were deposited on metal and glass surfaces. The substrate effects such as surface temperature, finish, pretreatment, and chemistry as they affect the film formation characteristics were investigated by optical, electron transmission, electron diffraction, and scanning electron microscopy. Substrate temperature and surface chemistry were found to be the prime variables as to the formation of a crystalline or amorphous film. The friction characteristics are strictly influenced by the type of film formed. Surface chemistry and surface pretreatment account for compound formation and corresponding grain growth, which directly affect the adhesion characteristics, resulting in poor adherence. The type of surface finish (topography) as related to scratches, impurities, inhomogeneities, etc., are favorable nucleation sites for the growth of isolated and complex nodules within the film, and various complex surface overgrowths on the film. These nodular growth features have progressively more undesirable effects on the film behavior as the film thickness increases.     

Physical properties of ultrafast deposited micro- and nanothickness amorphous hydrogenated carbon films for medical devices and prostheses

Hydrogenated amorphous carbon films with diamond-like structures have been formed on different substrates at very low energies and temperatures by a plasma-enhanced chemical vapour deposition (PECVD) process employing acetylene as the precursor gas. The plasma source was of a cascaded arc type with argon as the carrier gas. The films grown at very high deposition rates were found to have a practical thickness limit of approximately 1.5 microm, above which delamination from the substrate occurred. Deposition on silicon (100), glass, and plastic substrates has been studied and the films characterized in terms of sp3 content, roughness, hardness, adhesion, and optical properties. Deposition rates of up to 20 nm/s have been achieved at substrate temperatures below 100 degrees C. A typical sp3 content of 60-75 per cent in the films was determined by X-ray-generated Auger electron spectroscopy (XAES). The hardness, reduced modulus, and adhesion of the films were measured using a MicroMaterials NanoTest indenter/scratch tester. Hardness was found to vary from 4 to 13 GPa depending on the admixed acetylene flow and substrate temperature. The adhesion of the film to the substrate was significantly influenced by the substrate temperature and whether an in situ d.c. cleaning was employed prior to the deposition process. The hydrogen content in the film was measured by a combination of the Fourier transformation infrared (FTIR) spectroscopy and Rutherford backscattering (RBS) techniques. From the results it is concluded that the films formed by the process described here are ideal for the coating of long-term implantable medical devices, such as prostheses, stents, invasive probes, catheters, biosensors, etc. The properties reported in this publication are comparable with good-quality films deposited by other PECVD methods. The advantages of these films are the low ion energy and temperature of deposition, ensuring that no damage is done to sensitive substrates, very high deposition rates, relatively low capital cost of the equipment required, and the ease of adjustment of plasma parameters, which facilitates film properties to be tailored according to the desired application.     

Frictional properties of sputtered tin film

The structural changes and frictional properties of sputtered tin films on a glass plate were investigated as a function of the effects of film thickness and load and the influence of oxidizing, reducing and inert atmospheres. X-ray analysis of surface texturing showed that crystal rotation was a fundamental change in the structure of the surface, the rotation axis being dependent on the direction of rubbing. It was found that the coefficient of friction of tin films rubbing against SUS 304 steel decreased with decreasing ambient pressure and reached a minimum in the range 1–10 Torr.The coefficients of friction of thin films of SnO and SnO₂ were also investigated and discussed relative to the oxidation of the tin film during friction. It was concluded that the coefficient of friction of tin is controlled by gases adsorbed on the interface rather than by the formation of oxides during friction.     

The Influence of Methyl Group Content on Tribological Properties of Organo-Silica Thin Films

Solid thin films of lubricants are often used as protection coatings of working surfaces in frictional contacts. Usually, these films have to contain stable and tribologically active additives like, for example, molybdenum disulphide or graphite. In this work chemically modified silica was investigated as a potential matrix of nanocomposite lubrication films. The sol-gel technique was used with tetraethoxysilane (TEOS) and triethoxymethylsilane (TEMS) as precursors of organo-silica thin films. Dip coating was applied as the method of film formation. Introducing a methyl group into silica by adding TEMS during sol-gel synthesis of silica films strongly increases their adhesion to the coated materials, which gives possibilities for using them on steel surfaces. The chemical properties of films synthesised by the sol-gel technique were examined by FTIR spectroscopy with the use of the transmission method. The surface topography was imaged and frictional features of organo-silica films were examined by Atomic Force Microscopy (AFM).     

Electron cryo-microscopy of biological specimens on conductive titanium-silicon metal glass films

Thin films of the metal glass Ti88Si12 were produced by evaporation and characterized by AFM and conductivity measurements. Thin Ti88Si12 support films for electron microscopy were prepared by coating standard EM grids with evaporated films floated off mica, and characterized by electron imaging and electron diffraction. At room temperature, the specific resistance of a thin TiSi film was 10(6) times lower than that of an amorphous carbon film. At 77K, the specific resistance of TiSi films decreased, whereas that of carbon became immeasurably high. The effective scattering cross-section of TiSi and amorphous carbon for 120 kV electrons is roughly equal, but TiSi films for routine use can be approximately 10 times thinner due to their high mechanical strength, so that they would contribute less background noise to the image. Electron diffraction of purple membrane on a TiSi substrate confirmed that the support film was amorphous, and indicated that the high-resolution order of the biological sample was preserved. Electron micrographs of TiSi films tilted by 45 degrees relative to the electron beam recorded at approximately 4 K indicated that the incidence of beam-induced movements was reduced by 50% compared to amorphous carbon film under the same conditions. The success rate of recording high-resolution images of purple membranes on TiSi films was close to 100%. We conclude that TiSi support films are ideal for high-resolution electron cryo-microscopy (cryo-EM) of biological specimens, as they reduce beam-induced movement significantly, due to their high electrical conductivity at low temperature and their favorable mechanical properties.