Nanocrystalline CVD diamond coatings for drilling of WC-Co parts

Drilling of pre-sintered cemented carbide parts is a challenging task due to the high hardness and abrasive nature of the WC grains. This operation is commonly done using uncoated cemented carbide drill bits but the tool life is very limited requiring tool re-sharpening after a few holes. A solution for the improvement of the tool performance is here exploited by the use of nanocrystalline diamond (NCD) films as high abrasion resistant coatings. These coatings were grown in a hot filament chemical vapor deposition (HFCVD) reactor. Filament temperatures in the range of 1940-1980 °C were crucial to obtain highly adherent and very uniform coatings at the cutting edge and on the surfaces of the flutes. The performance of the coated tools was evaluated in through-hole drilling of a pre-sintered cemented carbide showing outstanding cutting efficiency when compared to that of an uncoated tool: maximal 940 mm/min infeed rates (app. 1 s to drill 17 mm) instead of 20 mm/min for the latter; absence of tool wear in contrast to a flank wear of about 50 μm in the uncoated tool after only 4 holes; hole edge integrity even at the highest infeed rates while grain decohesion at the hole edge takes place when using bare drill bits.     

The effect of polypyrrole coatings on the adhesion and structure properties of UHMWPE fiber

To improve the adhesion between ultrahigh molecular weight polyethylene (UHMWPE) fiber and polymer matrix, pyrrole is oxidatively polymerized on the UHMWPE fiber surface continuously. The micro-composite of polypyrrole (PPy)-coated fiber/epoxy was prepared and the fiber was studied by interfacial shear strength (IFSS) through a single fiber pull-out method. Compared with the UHMWPE fiber as-received, the mean value of IFSS between PPy-coated UHMWPE and epoxy increased from 1.06 MPa to 5.72 MPa. In addition, the surface morphology and structure of PPy-coated UHMWPE fiber were studied by SEM, FT-IR, DSC and DMA. The results showed that PPy-coated UHMWPE fiber surface was observed with some particles attached. Although there is no chemical interaction between PPy and UHMWPE chains, PPy has some interaction with UHMWPE molecular chains according to the results of DMA. The PPy coatings have an effect on the adhesion may be associated with the roughened surface of the fiber and upon intermolecular interaction.     

Certain peculiarities of Zr?Cr?N coatings on steel blades of a gas-turbine engine compressor

The properties of compressor blades of a helicopter gas-turbine engine with an experimental ionplasma coating Zr−Cr−N, are compared to those with Ti−Zr−N basic composition. It is shown that, due to the structural properties, the experimental coatings make the blades more corrosion-resistant, and mitigate the dependence of their residual properties on the amplitude and the temperature of the preliminary vibrotempering.     

Formation of structure and properties of coatings deposited by microarc oxidizing on parts fabricated from aluminum alloys

The laws governing the effect of the oxidizing parameters and additional treatment on the phase composition, structure, and properties of coatings are investigated, which makes it possible to change them in a wide range. New techniques are suggested for depositing coatings with improved characteristics. Translated from Metallovedenie i Termicheskaya Obrabotka Metallov, No. 10, pp. 34 – 38, October, 2000.     

钎焊金刚石耐磨涂层制备及其磨损性能

为提高农机刃具类零件的抗磨粒磨损性能,提出一种钎焊金刚石耐磨涂层制备方法,在Q235钢基体上制备了不同粒径及镀覆状态的金刚石耐磨涂层,并与65Mn钢的摩擦磨损和抗磨粒磨损性能进行对比。采用扫描电镜(SEM)对涂层表面、涂层与钢基体界面、涂层磨损后的表面微观形貌进行表征,并分析涂层的磨损规律及机理。结果表明:钎焊金刚石涂层与钢基体结合良好,金刚石在涂层中均匀分布,涂层厚度约370 μm。钎焊金刚石涂层的耐磨性优于65Mn钢的,且随着金刚石粒径减小钎焊金刚石涂层的摩擦系数降低,涂层的耐磨性增大;钎焊镀钨金刚石涂层的抗摩擦磨损和磨粒磨损性能均高于钎焊未镀覆金刚石涂层的。      

微米、纳米及微/纳米复合金刚石涂层的切削性能研究

利用化学气相沉积(chemical vapor deposition,CVD)法在硬质合金上制备纳米、微米以及微/纳米复合金刚石涂层,并进行了切削对比试验。通过测试已加工材料的表面粗糙度和金刚石涂层刀具前、后刀面磨损,对比分析了不同金刚石涂层的切削性能,同时总结了CVD金刚石涂层刀具的失效形式及机理。结果表明:纳米金刚石涂层刀具切削加工后的表面粗糙度值最小,Ra=0.942μm;微米金刚石涂层刀具切削加工表面粗糙度值最大,Ra=1.631μm;纳米涂层刀具的后刀面磨损最大,约为微米涂层的2倍,复合涂层的5倍;微/纳米复合金刚石涂层刀具膜/基结合力高,前、后刀面的金刚石涂层没有出现脱落,且刀具的磨损量较少;金刚石涂层刀具的主要失效形式是涂层的过早脱落,其失效主要是由金刚石涂层的残余应力大、涂层化学纯度低、内部产生微裂纹多,以及切削时表面粗糙度高、切削力大和刀具积屑瘤普遍等原因引起的。     

The structure and mechanical and tribological properties of TiBCN nanocomposite coatings

TiBCN nanocomposite coatings were deposited in a closed field unbalanced magnetron sputtering system using pulsed magnetron sputtering of a TiBC compound target with various Ar/N₂ mixtures. TiBCN coatings were characterized using X-ray diffraction, X-ray photoelectron spectroscopy, transmission electron microscopy, nanoindentation, Rockwell C indentation and ball-on-disk wear tests. The coatings with a nitrogen content of less than 8 at.% exhibited superhardness values in the range of 44–49 GPa, but also showed poor adhesion and low wear resistance. Improvements in the coating adhesion, H/E ratio and wear resistance were achieved together with a decrease in the coating hardness to 35–45 GPa as the N content in the coatings was increased from 8 to 15 at.%. The microstructure of the coatings changed from a nano-columnar to a nanocomposite structure in which 5–8 nm nanocrystalline Ti(B,C) and Ti(N,C) compounds were embedded in an amorphous matrix consisting of BN, free carbon and CN phases. With a further increase in the N content in the coatings to levels greater than 20 at.%, the inter-particle spacing of the nanocrystalline compounds increased significantly due to the formation of a large amount of the amorphous BN phase, which also led to low hardness and poor wear resistance of the TiBCN coatings.     

The effect of pulsed magnetron sputtering on the structure and mechanical properties of CrB2 coatings

CrB₂ thin films possess desirable combinations of properties (high hardness, wear resistance, chemical inertness, high thermal and electrical conductivity), which are attractive for a wide range of potential applications. Pulsed magnetron sputtering (PMS) of loosely-packed blended powder targets has allowed the deposition of stoichiometric chromium diboride coatings. The structure and properties of these coatings were found to be strongly dependent on the deposition process parameters; therefore investigation of the coating structures could explain certain differences between them and provide important information about the characteristics of the deposition process. In this study, characterization of the CrB₂ films was performed by scanning and transmission electron microscopy (SEM and TEM) techniques. The microstructures and properties of coatings deposited with different parameters are compared and changes that resulted from the variation of these parameters (particularly the pulsing duty cycle and the substrate biasing conditions) are discussed. The results show that besides the pulsing frequency, the target pulsing duty cycle is an important parameter of the PMS process, which is able to affect such coating properties as hardness, thickness and stress. Coating thickness measurement results suggest more intense bombardment of a growing film by energetic ions at lower values of duty cycle. Structural TEM analysis revealed two extremely different types of coating microstructures, obtained at quite similar substrate biasing conditions, i.e. floating (∼ − 15 V) and negatively biased (− 30 V). It appears that the structures of the coatings deposited at the negatively biased substrate are significantly affected by high-energy ion bombardment, which is a peculiarity of PMS that can modify film growth conditions. These conditions are not present when the substrate is allowed to float.     

Friction analysis of thermally sprayed coatings finished by ball burnishing and grinding

Thermally sprayed coatings offer a promising approach as efficient method to increase the wear-resistance of sheet metal forming tools. However, the roughness of thermally sprayed surfaces is quite high. The use of these coatings for deep drawing tools results in poor sheet surface qualities and low drawing ratios. Because it is suspected that high friction is the reason for the low drawability, hard metal coatings (WC–12Co), deposited by high velocity oxygen fuel flame-spraying, were machined by grinding and ball burnishing to improve their friction behavior and the accuracy of the tool shape. The investigation was conducted by plane strip drawing tests. Strips of high strength steel were mated with these novel and effective coatings at different normal contact pressures and drawing velocities. Uncoated friction elements made of C60 steel were considered as reference during the analysis. The results revealed that coated but unmachined friction elements showed high friction values, which led to scratch marks on the sheet surface after drawing. Applying the finishing processes, the friction coefficient could be reduced significantly. Additionally, deep drawing tests were carried out to determine the drawing ratio for coated, unmachined as well as for processed, coated dies. Thermally sprayed and ball burnished as well as thermally sprayed and ground coatings are feasible for deep drawing. Due to the post treatment, the drawing ratio β = 1.8 was increased to 2.0. This is consistent to the results of the friction tests.     

多弧离子镀沉积温度对TiN涂层性能的影响

在多弧离子镀设备上沉积了ＴｉＮ涂层,研究了不同沉积温度下ＴｉＮ涂层的表面硬度及与基体的结合力。实验结果表明,在保证基体材料不过热的前提下提高沉积温度,有利于提高ＴｉＮ涂层的性能。     

Electrochemical properties and structure of vanadium-based conversion coatings on electro-galvanised steel

The corrosion resistance of vanadium-based conversion coatings on electro-galvanised steel (EG) was examined in terms of the different valence species V⁵⁺ and V⁴⁺ as the raw material in the treatment solution. The effects of mixing phosphoric acid with the vanadium-based conversion coating have also been investigated. Corrosion performance was tested by neutral salt spray test and the mechanism of corrosion resistance was analysed by electrochemical impedance spectroscopy and X-ray photoelectron spectroscopy. It was found that conversion coatings formed from V⁵⁺ or V⁴⁺ did not clearly show different corrosion behaviour, but that the addition of phosphoric acid to the solution including V⁵⁺ improved corrosion protection. These results indicate that mixing phosphoric acid lowers the pH of the solution and improves corrosion resistance. The role of phosphoric acid is also explained by the formation of hydrogen bonds at the interface between the vanadium species and EG substrate.     

The effect of the nature and structure of organic components of copper-plating sulfate bath on the electroplating kinetics,structure, and physicomechanical properties of coatings

The rate and kinetics of electrochemical reduction of Cu²⁺ ions in aqueous and aqueous methylpyrrolidone electrolytes are found to depend on the structure of organic additives, which were derivatives of N-(2′-hydroxybenzyl)aniline with electron-donating or electron-withdrawing substituents. An increase in the content of cyclic lactam in the electrolyte is shown to result in the efficiency of all the additives studied, especially Cl-substituted compound. Electron microscopic studies revealed the substantial improvement of the microstructure of deposits obtained from aqueous methylpyrrolidone electrolytes containing aniline derivatives. Tribological and elastic characteristics of the coatings are improved, and microhardness increases in certain cases.     

Annealing effect and irradiation properties of HFCVD diamond films

The post-growth treatment of a [ 100]-oriented diamond film was performed to improve the film quality. The characteristic of post-growth film was investigated by using the RAMAN spectrum and the capacitance-frequency curve. The results show that the resistivities and frequency response enhance after the post-treatments in solution of H2SO4 and H2O2 and an annealing under N2 atmosphere at 500℃ for 60 min. Under a bias voltage of 100 V, the net photocurrent is obtained under ^55Fe（5.9 keV） X-rays and ^241Am （5.5 MeV） α particles radiation, respectively. The photocurrent increases rapidly at first and becomes stable for the ＂pumping＂ effect with the radiation time.     

等离子喷涂生物活性涂层的梯度结构表征

采用自动控制的等离子喷涂系统,在钛合金基体上制备出生物活性梯度涂层,利用纳米硬度计、扫描电镜等对生物活性涂层的梯度结构进行分析.实验结果表明:金属基体与陶瓷界面区域的弹性模量和硬度呈梯度变化;生物活性功能涂层表面分布着不同尺寸范围的孔洞,具有典型的多孔结构特征,整个涂层沿垂直基体方向从底层致密结构向表面层多孔结构过渡;涂层成分底层生物稳定性至表面层生物活性呈梯度变化,涂层表面成分为生物活性的羟基磷灰石.涂层的这种结构特征有利于改善生物活性涂层的综合性能,提高涂层与基体的结合强度,根据ASTM C633-79测试生物活性涂层与基体的结合强度,结合强度达到48.6 MPa.     

The effect of microstructure and composition on mechanical properties in thick-layered nanocomposite Ti-Si-C-N coatings

Recently great emphases have been placed on material characteristics, such as hardness and toughness in development of protective hard coatings. This work aims to investigate the microstructures and mechanical properties of rather thick Ti-Si-C-N coatings, deposited by a plasma enhanced magnetron sputtering (PEMS). It has been evidently proved that Ti-Si-C-N coatings can effectively enhance hardness due to nanocomposite structure. The composition of the Ti-Si-C-N coatings was quantitatively measured with an electron probe microanalyzer (EPMA). Detailed microstructure of the Ti-Si-C-N coatings was performed by a transmission electron microscopy (TEM). The X-ray diffractometry (XRD) was also used to further identify microstructures. The results indicated that the hardness and microstructures of thick Ti-Si-C-N coatings were strongly affected by the Si contents. A nanocomposite coating with nano grains embedded in amorphous matrix was revealed.     

Study of the mechanism of the burnishing process with cylindrical polycrystalline diamond tools

It is widely recognized that the chipless finishing process–the burnishing process can be used efficaciously to reduce the surface roughness and increase the surface hardness of a workpiece. But most of previous works published on the burnishing process concentrated on experimental researches in the last few years. The mechanism of the burnishing process which is very important for spreading the burnishing process has been explored based on contact mechanics. The simulation curve is obtained from a theoretical model. Theoretical results are compared with the experiments in which aluminum alloy LY12 was selected as material for making the specimens and a new cylindrical polycrystalline diamond tool developed by us was used for the burnishing process. The comparison shows that the theoretical model is basically correct in describing the burnishing process.