Coatings for wear and lubrication

In this paper we review the recent advances in the tribological uses of r.f.-sputtered and ion-plated films of solid film lubricants (laminar solids, soft metals, organic polymers) and wear-resistant refractory compounds (carbides, nitrides, silicides). The sputtering and ion-plating potentials and the corresponding coatings formed are evaluated relative to the friction coefficient, wear endurance life and mechanical properties. The tribological and mechanical properties of each kind of film are discussed in terms of film adherence, coherence, density, grain si morphology, internal stresses and thickness and substrate conditions such as temperature, topography, chemistry and d.c. biasing. The ion-plated metallic films in addition to improved tribological properties also have better mechanical properties such as tensile strength and fatigue life.     

氧化程度对氧化石墨改性环氧树脂涂层摩擦学性能的影响

通过改变H2SO4／KMnO4氧化体系,制备出几种不同氧化程度的氧化石墨,分别对环氧树脂涂层进行填充耐磨改性。通过红外光谱和扫描电镜分析、电性能测试及摩擦磨损性能试验,研究硫酸用量、氧化石墨电阻与氧化程度三者之间的关系,考察氧化程度对氧化石墨结构及其填充改性环氧树脂耐磨涂层摩擦学性能的影响。结果表明：硫酸用量的增加引起氧化石墨电阻和氧化程度非线性增大,同时氧化石墨层状结构剥离成氧化石墨片的程度增加。氧化程度在95％以上的氧化石墨已失去固体润滑特性,导致填充改性环氧涂层摩擦性能下降,磨损增加,氧化程度约85％的氧化石墨填充改性涂层的综合性能最佳。     

Mikrostrukturieren von thermisch gespritzten Mo‐Schichten für Anwendungen im Bereich hoher Reib‐ und Verschleißbeanspruchungen

The properties of thermally sprayed coatings are dependent on many parameters such as the spraying material, substrate properties, and the injection parameters. In this study, the influence of two variable spray parameters (spraying distance and current) were investigated on molybdenum‐containing thermal spray coatings. Particularly, materials and surface characterizing properties were analyzed, and the dependence on each other was examined. The important surface parameters studied in this case are the porosity and the pore depth of the coatings. Following the correlation between spray parameters and coating properties, the influence of surface properties on the tribological behavior will be discussed, in comparison to an uncoated steel surface.     

Neue Aspekte bei der physikalischen Abscheidung kompakter Dünnschichten aus der Gasphase am Beispiel einer praxisrelevanten Festschmierstoffschicht

New aspects regarding sputter‐depositing dense coatings, in particular a solid lubricant of practical interest Using MoS₂‐based solid lubricant films as an example, this paper focuses on approaches to preventing sputter‐deposited films from attaining columnar microstructures. This is how it becomes possible to deposit tribological coatings that are characterised by a high durability. As a result of scanning electron microscopy on microstructures, texture measurements by means of XRD, and surface analysis, focusing on sputter‐deposited MoS₂ films, a concept of how to develop thick and dense MoS₂‐based solid lubricant films was generated. At an early stage of film growth a dense and flawless microstructure forms. In order to make the favourable properties of these underlayers available for tribological applications, metallic intralayers were introduced, by means of which the MoS₂ film growth was to be repeatedly interrupted.     

In-situ formation of layer-like Ag2MoO4 induced by high-temperature oxidation and its effect on the self-lubricating properties of NiCoCrAlYTa/Ag/Mo coatings

Ag-Mo-O ternary oxide has attracted growing attention because of its potential as a solid lubricant at high temperatures.This work designs and prepares NiCoCrAlYTa/Ag/Mo composite coating,performed using high velocity oxy-fuel(HVOF)spraying technology.The environment temperature plays an important role in the microstructure and phases as well as lubricant properties of NiCoCrAlYTa/Ag/Mo coatings.When the environment temperature is above 600C,the outer diffusion and oxidation of Ag and Mo lead to the formation of Ag2MoO4 on the coating surface.Layer-like Ag2MoO4 could form a continuous lubricant film at 800℃and consequently let the composite coating present the best tribological properties.Meanwhile,a small number of hard particles could play a good bearing role during friction and improve the tribological properties of the composite coating.     

WC基热喷涂金属陶瓷涂层的激光改性研究

本工作研究了CO2激光重熔处理对超音速火焰喷涂WC--Co和WC--NiCr涂层的组织结构和摩擦学行为的影响。结果表明：选定优化参数下,激光重熔可降低涂层气孔率,提高涂层显微硬度,涂层与基材之间实现冶金结合;干摩擦条件下,涂层经过激光重熔处理耐磨性能显著提高;但润滑条件下劣于未经重熔处理涂层,这可能与未重熔涂层含有较多的气孔,可存储润滑油较好地发挥润滑效果有关。     

Surface roughness, mechanical and tribological properties of ultrathin tetrahedral amorphous carbon coatings from atomic force measurements

Atomic force microscope (AFM), lateral force microscope and AFM-based scratch and wear testing techniques were used to evaluate and compare the surface roughness, tribological and mechanical properties of thin (2.7-43 nm) tetrahedral amorphous carbon coatings prepared by pulsed cathodic arc discharge. It was found that surface roughness of ultrathin (2-8 nm) coatings was mainly determined by the roughness of the Si substrate and their average density strongly depended on their thickness. Poor friction, mechanical properties of thinner (2.7-15 nm) coatings can be associated with their low average density. The dense coatings (>15 nm) had lower friction coefficient, better scratch and wear resistance properties that were independent of their thickness. It appears that the over 15-nm coatings studied are feasible for some wear-resistant and tribological applications.     

热处理对冷喷涂Cu-20%Al_2O_3复合涂层耐磨损性能的影响研究

利用冷喷涂技术制备Cu-20%(质量分数)Al2O3复合涂层,并在氩气保护气氛下对该复合涂层进行300℃、500℃和700℃退火热处理。采用常温干摩擦试验评价热处理对冷喷涂Cu-20%(质量分数)Al2O3复合涂层耐磨损性能的影响,并利用扫描电镜(SEM)观察涂层表面磨痕形貌。结果表明,复合涂层经退火热处理后发生了再结晶现象,涂层显微硬度降低。冷喷涂态和退火态复合涂层磨损机制不同:冷喷涂态复合涂层和低温退火热处理(300℃和500℃)下复合涂层磨损主要为磨粒磨损,700℃退火态复合涂层主要表现为疲劳磨损。     

Formation mechanisms of zinc,molybdenum, sulfur and phosphorus containing reaction layers on a diamond-like carbon (DLC) coating

Diamond-like carbon (DLC) coatings are nowadays successfully applied on industrial components like pistons, piston rings and bearings in lubricated tribological contacts due to friction and wear reducing effects. In contradiction thereto, todays lubricants and additives are designed for tribological steel/steel contacts, whereby the knowledge on tribochemical layer formation on steel surfaces is comprehensive in contrast to the physical-chemical interactions between diamond-like carbon coatings, lubricants and additives. Therefore the formation mechanisms of zinc, molybdenum, sulfur and phosphorus containing reaction layers on a zirconium modified diamond-like carbon coating a-C : H : Zr (ZrC_g) in lubricated tribological contacts were analyzed by means of pin-on-disc (PoD) tribometer by varying the distances from s = 200 m–3,000 m under boundary and mixed friction conditions at T = 90 °C and a contact pressure p = 1,300 MPa regarding the application of diamond-like carbon coatings on gears. The base lubricant poly-alpha-olefin (PAO) was formulated using the anti-wear (AW) and extreme pressure (EP) additive zinc dialkyldithiophosphate (ZnDTP) and the friction modifier (FM) additive molybdenum dialkyldithiophosphate (MoDTP). The chemical composition of the tribochemical reaction layers by means of and Raman spectroscopy and x-ray photoelectron spectroscopy (XPS) as well as for the thickness differ significantly by varying the additivation.     

氮离子注入浓度对弹条钢基体Cr/CrSiN复合涂层的摩擦学性能影响研究

在轨道用扣件弹条钢(60Si2Cr)上注入不同浓度的氮离子,用电弧离子镀技术沉积了Cr过渡层,并在其上制备了CrSiN/Cr复合涂层。在UMT-3多功能摩擦磨损机上对复合层进行了法向载荷为20N的摩擦磨损实验,探讨了经不同氮离子注入浓度后Cr/CrSiN复合涂层摩擦磨损行为和损伤机理,研究发现,经氮离子注入后,复合涂层表面硬度明显的增加,随着离子注入浓度的升高涂层的耐磨性逐渐提高,其磨损机制主要为剥落和磨粒磨损。     

新型固体润滑及油品添加剂-硫代钼酸盐的制备

研究了在水溶液中合成新型固体润滑兼油品添加剂一ＮｉＭｏＯ_２Ｓ_２及其原料（ＮＨ_４）_２ＭｏＯ_２Ｓ_２的条件,其最佳参数为ｐＨ＝４～５,温度为３０℃左右和ｐＨ＝７～９;温度为－５～０℃．还对产品的组成、结构及形貌进行了分析观察,并验证了ＮｉＭｏＯ_２Ｓ_２作为油品添加剂和固体润滑剂从２０～６００℃的减摩性能;证实硫代钼酸镍是一种宽温度范围的润滑剂．     

Growth defects in PVD hard coatings

In PVD coatings, various growth defects typically appear during the deposition. Such defects are drawbacks in coating application. In order to improve the tribological properties of PVD hard coatings it is important to minimize the defect density. Various PVD hard coatings were prepared by evaporation using a thermionic arc and by sputtering using unbalanced magnetron sources. Coating topography was analyzed using a 3D stylus profilometer and other analytical techniques (SEM, FIB). We studied the influence of different types of substrate materials, the substrate position in the vacuum chamber, pre-treatment and deposition parameters on defect density.     

Funktionale Oberflächen auf Duplex‐Stahl durch Laserfeinbeschichten

Functional surfaces on duplex stainless steel by lasercladding The product‐lubricated axial and radial bearings installed in multistage high‐pressure pumps inevitably encounter severe mixed friction conditions as the pumps start and stop. This leads to extremely high tribological loads on the bearing components, compounded by the effects of a highly corrosive pumped fluid. The present paper describes a laser cladding process which produces near‐net‐shape coatings of new, highly corrosion and wear resistant functional layers which can be deposited directly on high‐alloy stainless steels without requiring additional buffer layers and without affecting the mechanical properties and corrosion resistance of the substrate. The results cover the solidification behaviour of the coatings as well as the microstructure resulting from various heat treatment conditions. In addition, the technological properties of the coatings and the resulting composites are discussed. The coating systems are tested as to their corrosion resistance and tribological characterization in a pump‐specific tribological system.     

Nanoparticle dispersion-strengthened coatings and electrode materials for electrospark deposition

Advanced electrode compositions were developed using self-propagating high-temperature synthesis (SHS). Electrospark deposition (ESD) was applied to produce tribological coatings which were disperse-strengthened by incorporation of nanosized particles. Nanostructured electrodes of cemented carbides were produced using powder metallurgy technologies. They allow increasing the coatings density, thickness, hardness, Young's modulus and wear resistance. Positive effects of the nanostructure of electrodes on the deposition process and structure and properties of the coatings are discussed. In that case the tungsten carbide phases become predominant in the coatings. A mechanism of the dissolution reaction of WC with Ni at the contact surface of electrode was proposed. It was shown that the formation of the coating structure starts on the electrode and is accomplished on the substrate.     

Chemical vapour deposition of chromium

The chemical vapour deposition of chromium and the partial transformation of chromium into chromium carbide on carbon-containing substrates such as tool steels was investigated.The process using CrCl₂ as the reactive gas is described. Of the different process parameters studied, the substrate composition was found to have an important influence on the nature and properties of the chromium layer. In the early stages of deposition the reaction is controlled by the exchange of Fe from the substrate for Cr. As the H₂ reduction process becomes increasingly important, a nearly linear relationship exists between the growth rate and the deposition time. The composition, structure, thickness, hardness, roughness, corrosion resistance and tribological properties of the coatings are described. Some applications of chromium coatings are also given.     

钛合金表面耐磨润滑微弧氧化膜的研究进展

综述了钛合金微弧氧化膜的摩擦学性能研究以及提高膜层耐磨性能和润滑性能所采用的方法,旨在对改善钛合金微弧氧化膜摩擦学性能的研究现状有一个系统全面的认识,并在此基础上展望了未来钛合金微弧氧化膜摩擦学研究的发展趋势和方向。     

Friction and wear reduction with tribological coatings

The basic requirements for a good tribological surface are (1) low sliding friction, (2) good resistance to scuffing, wear and abrasion, (3) long contact fatigue life and (4) adequate subsurface strength to provide dimensional stability. Coatings have inherent deficiencies. The major problem is failure at the interface between the coating and the substrate, which results in flaking, peeling or spalling of the coating under the repetitively applied contact stresses.Three types of coatings which employ different mechanisms to improve the tribological properties and to maintain coating integrity are described in this paper. Nitrocarburizing represents a class of coatings in which the elements are allowed to diffuse into the surface of the structural material to form an alloy with the substrate. Diffusion provides compositional gradients which result in hard wear-resistant surface and which at low shear strengths avoid the interfaces that frequently exist between coatings and substrates. Chemically vapor-deposited chromium and titanium carbides represent a class of coatings in which a chemically distinct layer is grown on top of the substrate and is bonded to the substrate by diffusion. In the third type of coating, hard particles are suspended in a soft matrix. The hard particles provide the wear and abrasion resistance and the soft matrix both bonds the particles together and provides the low friction. Although the bond strength of this coating to the substrate is lower than that provided by diffusion in the other coatings, the soft matrix will yield without flaking under the shear stresses which are developed at the interface.     

Schichtentwicklung für die schmiermittelfreie Umformung von hochfesten Aluminiumwerkstoffen

Development and evaluation of coatings for lubricant free forming of high strength aluminium Many applications in light weight construction require massive formed high strength aluminium parts. For economical and ecological reasons the use of lubricants for massive forming has to be avoided. Both, lubricant free forming and processing of high strength materials are big challenges that can be realized by using coated tools with functional surfaces that show high wear resistance, low friction and low adhesion to aluminium [1–7]. For goal‐oriented surface engineering different coating technologies, such as Physical Vapour Deposition (PVD) and Chemical Vapour Deposition (CVD) have been used for the preparation of specimens. The coating properties are evaluated by mechanical tests and numeric simulation to investigate the massive forming processes and the coating‐substrate‐behaviour. On the base of TiCN‐, TiC‐TiN‐ and DLC‐coatings on steel it is shown how relevant coating properties like Young’s Modulus, crack behaviour and hardness can be analyzed with regard to small coating thicknesses. In order to scale up the results to industrial conditions, finally the simulation is correlated to real deforming.     

Einfluss der Mikrostruktur auf das Verschleiß‐ verhalten der hartanodisierten Aluminium‐legierungen EN AW‐6082 und EN AW‐7075

Microstructural effect on the wear behaviour of the hard‐anodised aluminium alloys EN AW‐6082 and EN AW‐7075 The suitability of hard‐anodising of high‐strength Al alloys (EN AW‐7075‐T651) for the fabrication of protective coatings which are also applicable on screws was investigated. A medium‐strength AlSi1MgMn alloy (AA60682‐T6), generally rated as applicable for anodising, was used as reference material. After possible setting phenomena of a screw joint, the load‐bearing surface of the screw can be subjected to an oscillating relative movement. The damaging tribological load was simulated in an oscillation wear test. The resulting wear appearances have revealed that the untreated oxide coatings on the EN AW‐6082 substrate are not capable of providing protection against tribological load. Since hot‐water sealing increases the hardness of the coating but also contains the technology‐induced risk of softening the substrate material, other tribological protection methods have been looked for. The analysis of the tribological tests (characterisation of the structure and the resulting properties of the material, measurement of the wear amount and analysis of the wear appearance) have shown that the films sealed with wax emulsion on both substrate materials are the most promising candidates for the application of devices under oscillation wear. The obtained roughness, friction coefficients and hardness values confirm the positive behaviour of the anodically oxidised EN AW‐7075‐T651 alloy under the chosen tribological load.     

固体自润滑涂层的研究进展

随着科学技术的发展,各种摩擦副所受到的载荷、运转速度、温度等也在急剧增加,传统的润滑油脂已不能完全满足苛刻工况下的使用要求,固体自润滑涂层是解决上述问题的有效途径之一。综述了固体自润滑涂层的材料体系、涂层结构及其制备工艺的新进展,并展望了其发展趋势。