柔性衬底直流磁控溅射ZnO基高性能透明导电薄膜的制备及性能研究

采用直流磁控溅射法,以柔性PET(聚对苯二甲酸乙二醇酯)为基底,通过参数优化以求在室温下制备高性能ZnO/Ag/ZnO多层薄膜。实验中,使用X射线衍射仪(XRD)、原子力显微镜(AFM)、紫外-可见分光光度计、四探针电阻测试仪等仪器分别对ZnO/Ag/ZnO多层薄膜的微观结构、表面形貌、透过率及方块电阻进行测试及表征。结果表明,随着Ag层厚度增加,薄膜方块电阻急剧下降,通过改变ZnO层厚度,可有效调节薄膜光学性能,随着ZnO层厚度增加,可见光区平均透过率先增大后减小。引入品质因子FTC作为评价指标可知,当依次沉积ZnO、Ag、ZnO厚度为50nm、8nm、50nm时,薄膜光电性能最佳,其在可见光平均透过率为82.3%、方块电阻为2.8Ω/、禁带宽度为3.332eV。     

Experimental evaluation of coating delamination in vinyl-coated metal forming

In this paper, a new evaluation and prediction method for coating delamination during sheet metal forming is presented. On the basis of the forming limit diagram (FLD), the current study evaluates the delamination of PET coating by using a cross-cut specimen, dome test, and rectangular-cup drawing test. Dome test specimens were subjected to biaxial, plane strain, and uniaxial deformation modes. Rectangular cup-drawing test specimens were subjected to the deep-drawing deformation mode, and compression deformation mode. A vinyl-coated metal (VCM) sheet consists of three layers of polymer on the sheet metals: a protective film, a PET layer and a PVC layer. The areas with coating delamination were identified, and the results of the evaluation were plotted according to major and minor strain values, depicting coating delamination. The constructed delamination limit diagram (DLD) can be used to determine the forming limit of VCM during the complex press-forming process. ARGUS (GOM) was employed to identify the strain value and deformation mode of the delaminated surface after the press forming. After identifying the areas of delamination, the DLD of the PET coating can be constructed in a format similar to that of the FLD. The forming limit of the VCM sheet can be evaluated using the superimposition of the delamination limit strain of the coating onto the FLD of VCM sheet. The experimental results showed that the proposed test method will support the sheet metal forming process design for VCM sheets. The assessment method presented in this study can be used to determine the delamination limit strain under plastic deformation of other polymer coated metals. The experimental results suggested that the proposed testing method is effective in evaluating delamination for specific applications.     

Tio2—Ag—Cr红外高反射膜系光学特性研究

本文介绍红外反射膜系的设计、光学特性计算和实验研究。探索了一种新的膜系TiO_2Ag-Cr,即膜厚分别为72nm、14nm和10nm时,在波长大于900nm的红外区,透射率小于10％,而对可见光则平均透射年为50％,透射主峰在550nm。这种膜镀覆在窗玻璃表面上,室内有夏凉冬暖之感,镀覆于白炽灯泡玻壳表面上,有节能和提高光效的作用。     

Tribological Properties of DLC Coatings in Helium

The aim of this research work was to investigate tribological properties of low-friction DLC coatings when operating in helium atmosphere. Two commercial DLC coatings (a-C:H and Me-C:H) were included in the investigation and compared to reference PTFE-based coatings, normally used on components operating in helium. Coatings were deposited on hardened 100Cr6 bearing steel discs and tested against uncoated steel balls in low-load pin-on-disc contact configuration. Investigation was focused on the effect of substrate roughness (R _a ?=?0.05?C0.2???m) and contact conditions, including contact pressure (150?C350?MPa) and sliding speed (0.2?C0.4?m/s) on the coefficient of friction of DLC coatings operating in helium. Results of this investigation show that for low-load sliding contact DLC coatings provide low friction in helium atmosphere, similar to soft PTFE-based coatings. At the same time DLC coatings investigated were found to substantially reduce wear of the coated surface. However, while the wear of the coated part has been more or less eliminated, application of DLC coating prolongs running-in and increases wear of the steel counter-part. Furthermore, also in helium atmosphere tribolgical behaviour of DLC coatings showed dependence on the coating type and contact conditions.     

High resolution biological scanning electron microscopy: A comparative study of low temperature metal coating techniques

Structural information on the surface of biological specimens can be resolved within molecular dimensions by “in-lens” field emission scanning electron microscopes when cryo-methods are used to adequately preserve the native state of the specimen. The visual definition of molecular surface structures depends largely on the metal coating. The thickness of the coating, as well as the temperature at which it is deposited, are among the most important parameters affecting visual definition. These were evaluated on T4 polyheads and T4D phages using chromium double-axis rotary shadowing (DARS). Micrographs of optimally DARS coated T4 polyheads and T4D phages were compared with chromium planar-magnetron sputtering (PMS) and unidirectional shadowing with platinum/carbon. Metal deposition was carried out at low temperatures during all three procedures. Optimal visual definition of structural details on the surface of DARS coated T4 polyheads and T4D phages (capsomeres of T4 polyheads and their subunits with diameters of 8 and 3 nm; T4D phage tail fibres with a thickness of 3 nm) is achieved at a thickness of the chromium film greater than the minimum required for metal film coalescence. Chromium DARS coating at room temperature resulted in poor structural definition, whereas DARS at specimen temperatures of ?85°C and ?150°C, with the chromium thickness optimized for each temperature, yielded good visual detail of polyhead substructures. The visual definition was slightly reduced when DARS coating was carried out at a specimen temperature of ?250°C. Adequate structural visibility of T4D phage and T4 polyhead surface structures was achieved with the three coating techniques tested. Smaller filamentous structures, however (e.g., phage tail fibres), were more clearly identified after chromium DARS coating or unidirectional platinum/carbon shadowing than after optimized PMS with chromium. Each method has its own merits.     

Optical characteristics of silver film on the moth-eye structure

The development of coating optics to lower the reflected light and thereby to increase the optical efficiency of an optical system has been a very important issue for many years. Conventional solutions to this, such as multilayered alternation of high and low refractive index layers, often lead to an expensive coating process. Recently, the use of antireflection structured (ARS) surface, which is called “moth-eye structure”, has been proposed as an applicable option based on both the theoretical and experimental studies. In the current study, the experimental results of the reflectance and transmittance of two different thicknesses of silver films deposited on the moth-eye structure were carried out. The moth-eye structure arrays were fabricated by holographic exposure and photolithographic processes on the polymer film. The structure arrays were consisted of periodic length of about 300 nm, with the diameter of about 250 nm and the height of 150 nm. Compared with the silver coating film on the flat PET substrate, the optical property of the silver coating film on the moth-eye structure showed a better result for the anti-reflection application. The 25 nm-thick silver film on the moth-eye structure is suggested to be applied for the car window glass of antireflective films to obtain the high performance of heat insulation with acceptable transparency in the visible range.     

Electron microscopic studies of CuS nanocrystals formed in Langmuir-Blodgett films

The morphology and structure of CuS crystals formed during sulfidation of copper behenate films obtained by the Langmuir-Blodgett (LB) method have been studied using high resolution electron microscopy. The average size of these crystals is about 3 nm and increases by a factor of approximately 2.2 after annealing at a temperature of 150 °C or above. Analysis of interplanar distances has shown that in the range of annealing temperatures of 150–200 °C, CuS nanocrystals have a P6_3/mmc hexagonal crystal lattice with parameters a = 0.38 nm and c = 1.64 nm. At annealing temperatures of 250 °C or above, the Cu₂S crystalline phase begins to form, in addition to CuS nanocrystals. The proportion of this phase increases with increasing annealing temperature. Cu₂S nanocrystals have a hexagonal crystal lattice type with the P6_3/mmc spatial group and unit cell parameters a = 0.39 nm and c = 0.68 nm. Quantitative evaluation of copper and sulfur in individual CuS and Cu₂S nanocrystals was performed by local analysis of characteristic X-ray spectra.     

Experimental study of mechanical properties and scratch resistance of ultra-thin diamond-like-carbon (DLC) coatings deposited on glass

To improve the mechanical and tribological properties of glass, an ultra-thin diamond-like-carbon (DLC) coating of 2.2 nm thick was deposited on the surface of glass, using the linear ion beam deposition technique. The coated glass showed significant improvement in scratch resistance against severe damage, such as cracking, delamination, and chipping. To understand the mechanism, an experimental study was carried out. It was found that the major contribution to the significantly improved scratch resistance attributable to the compressive stress, which was yielded during the deposition process and resides in the coating, as well as the top layer of glass substrate.     

Fabrication of 3D random microlens array composite optical film with self-assembly

A method for fabricating a microlens array composite optical film by a seamless roller mold of self-assembly is presented. The roller with a lot of random cavities is used to produce a polyethylene terephthalate (PET) composite optical film with 3D random microlens arrays using the ultraviolet (UV) roll-to-roll printing. The luminance gain and haze are 1.247 and 86 %, respectively, giving the PET composite optical film the properties of a brightness enhancement film and a diffuser. Solid glass beads (SBs) are used for parameter testing for self-assembly. Then, 3 M glass bubble beads (BBs) are used to fabricate a seamless roller mold. The optimal parameters of the self-assembly process for the SB are a coating speed of 135 mm/h with a 39 % volume ratio, and those for the BB are a coating speed of 30 mm/h with a 3 % volume ratio. Finally, the PET optical film is used in the green energy lighting testing of a commercial bicycle light-emitting diode (LED). The results show increased lighting angle and light uniformity, making it similar to traditional tungsten light.     

On the bending of architectural laminated glass

As a result of its numerous environmental qualities, laminated safety glass is being used to an increasing extent in the field of architectural glazing. Its use in the manufacture of aircraft and automobile windscreens is well established, and the impact resistance of such laminates has been extensively studied. However, little work appears to have been done on the response of architectural laminated glass to normal structural loading. In this context, an architectural laminate is defined as comprising two glass layers of arbitrary thickness together with an adhesive plastic interlayer.The aim of the present work is to provide an insight into the fundamental behaviour of architectural laminated glass in bending. To this end, theoretical and experimental studies have been made concerning the action of laminated glass beams in four-point bending. Closed-form expressions are derived for the interfacial shear traction and central deflexion, and relevant numerical values are given. Experimental results are also presented; these relate to a series of tests on small laminated glass beams subjected to both transient and sustained loading at various ambient temperatures.In general, the degree of coupling between the two glass layers is shown to be chiefly dependent upon the shear modulus of the interlayer, which in turn is found to be a function of both the ambient temperature and the duration of loading; in this connexion, basic data are given on interlayer shear stiffness which can be utilized in subsequent structural analyses of architectural laminates.     

Experimental examination of the wear behaviour of the VAlN tool coating by strip drawing process

Resistance to wear, and therefore the lifetime of forming tools, can be increased by surface functionalisation using novel, multifunctional coatings. Thereby, the tribological requirements on the coating are an essential factor. Within the scope of the research work presented here, tribological examinations were carried out on a metastable vanadium aluminium nitride (VAlN) tool coating when drawing the high-strength sheet metal material DP 800. It was shown that the wear of the VAlN tool coating can already be determined at stable frictional behaviour (μ?<?0.085). The wear analysis was carried out considering the topography and change in hardness of the tool surface during the drawing path of 110,000?mm under a contact stress of 150?MPa.     

Rhenium-iridium coating effect of tungsten carbide mold for aspheric glass lens

Recently, with increasing lightness and miniaturization of high resolution camera phones, the demand for aspheric glass lens has increased because plastic and spherical lenses are unable to satisfy the required performance. An aspheric glass lens is fabricated by high temperature and pressure molding using a tungsten carbide molding core; so precision grinding and coating technology for the molding core surface is required. In this paper, Aspheric glass lens for 5 megapixel 4 time zoom camera phone modules was developed. The grinding condition of the tungsten carbide molding core was found after applying design of experiments (DOE). Also, the ultra-precision grinding process was investigated under this condition by experiment. Rhenium-iridium (Re-Ir) coating was applied on the ground surface of the tungsten carbide molding core. The influence of Re-Ir coating was compared and evaluated. The surface roughness of the molding core were improved by application of Re-Ir coating on the surface of the tungsten carbide molding core. Aspheric lenses were also molded with the non-coated molding core and the Re-Ir coated molding core. The surface roughness of the aspheric glass lens improved by about 0.4 nm (aspheric surface) and 0.5 nm (plane surface).     

汽车高强钢纵梁热冲压实验研究

通过在自主研制的热冲压实验线上开展汽车纵梁热冲压实验,探明并对比了无涂层和不同润滑条件下Al-Si涂层22MnB5板对复杂零件热冲压成形质量和组织性能的影响。结果表明：①相比于无涂层板,涂层板能有效改善氧化脱碳现象,但涂层中形成的孔隙和裂纹容易导致零件在成形时产生破裂;采用水基石墨润滑不能消除破裂;采用玻璃润滑能有效避免破裂。②无涂层板的抗拉强度和屈服强度较高,无润滑和石墨润滑涂层板次之,玻璃润滑涂层板的抗拉强度和屈服强度较低;无涂层板的延伸率较涂层板的延伸率大。③玻璃润滑涂层板的表面粗糙度较小,无涂层板次之,无润滑和石墨润滑涂层板的表面粗糙度较大。     

Chromium oxide coatings applied to magnetic tape heads for improved wear resistance

This paper reports on an investigation of the wear of chromium oxide based very thin films. Linear data tape Advanced Digital Recording (ADR™) heads coated with 20- and 40-nm thick chromium oxide films have been tested subject to temperature/humidity matrix of 10 to 40°C/10 to 80% in order to assess the wear behaviour of the coating as a function of environment. The tested heads were analysed at various stages of wear, by use of optical microscopy (OM), atomic force microscopy (AFM) and Auger electron spectroscopy (AES). The results show that the most severe damage occurs at the highest relative humidity (80% RH) and for a given humidity, at the lowest temperature (10°C). Inversely, stain transferred from the tape to the head surface predominates at the lowest humidity (10% RH). Stain therefore appears to protect the coating against wear with the degree of protection increasing with the temperature.The wear process differs according to the coating thickness. This is attributed to the location of the maximum subsurface stress with respect to the coating/substrate interface. It is shown that this maximum stress occurs below the interface for 20 nm and at the interface for 40 nm thick coatings. This correlates to different observed wear modes.     

Anti-oxidant mechanism of TiAlN/SiN decorative films on borosilicate glass by magnetron sputtering

The black TiAlN decorative film was prepared on the borosilicate glass by the magnetron sputtering in equipment with multiple vacuum chambers. The transparent SiN protective layer was deposited on the surface of the TiAlN film to keep the black color invariant at the high temperature. The structure of the TiAlN/SiN film was characterized by scanning electron microscope (SEM), X-ray diffraction (XRD), and high-resolution transmission electron microscopy (HRTEM). The coating adhesion was measured by scratch tester. The TiAlN film has a columnar crystal structure with a thickness of 200 nm, and the top SiN layer is amorphous with a thickness of 100 nm. The coated borosilicate glass with the TiAlN/SiN films still retains the black color after oxidation at 600 °C in atmosphere. While the oxidation temperature elevates to 700 °C, the color of the TiAlN/SiN films begins to change. The top SiN layer plays a role as the barrier against oxygen diffusion into the inner TiAlN layer. The thin self-formed aluminum oxide layer was generated on the surface of the SiN layer and it contributes to the improvement of anti-oxidant property of the inner TiAlN layer. However, the thick self-formed aluminum oxide layer leads to the color change of the black TiAlN film. The thermal oxidation benefits the improvement of the adhesion for the TiAlN/SiN films with glass substrate.     

Surface durability of WC/C-coated case-hardened steel gear

The purpose of this study is to investigate the influence of tungsten carbide/carbon (WC/C) coating on the surface durability of casehardened steel gear. Two kinds of WC/C coatings were deposited on the ground gear pair made of chromium molybdenum steel with carburizing and quenching. One is the conventional WC/C coating, and the other is WC/C coating with about 1 μm CrN interlayer. Here, the WC/C-coated test pinion and the WC/C-coated one with CrN interlayer are represented by WT and ST, respectively. Non-coated test pinion is represented by NT. The surface roughness along the tooth profile direction of WT and ST was almost the same as that of NT. A spur gear test was carried out with an IAE power circulating type gear test rig under EP gear oil lubricating condition. The fatal failure mode of the test pinions was pitting due to surface cracking. The fatigue life of WT was longer than that of NT under a maximum Hertzian stress p _max=1700 MPa. On the other hand, under p _max=1900 MPa, that of WT was as long as that of NT due to the peeling occurrence of the coated layer. Under the comparatively low load condition without peeling occurrence, the surface roughness of WT decreased with the increasing number of cycles, and their fatigue life became longer than that of NT. On the contrary, in the case of ST, the peeling of the coated layer occurred at a comparatively early stage of the gear test, and the dedendum was worn by tens of micrometers. Therefore, in the case of ST, the effect of the WC/C coating disappeared at a comparatively small number of cycles.     

喷涂功率对碳/碳复合材料表面羟基磷灰石涂层抗剪强度的影响

采用等离子喷涂技术在碳／碳复合材料表面制备了羟基磷灰石（HA）涂层,采用自制装置测定了不同喷涂功率下涂层与基体的抗剪强度,采用扫描电镜观察了涂层表面、横截面和剪切断裂表面的微观形貌,并分析了涂层与基体的剪切断裂失效形式。结果表明：在40kw喷涂功率下,涂层与基体的抗剪强度最高,约为10MPa,其剪切断裂失效方式主要为涂层内部失效。     

Tribological Behavior of TiC/a-C:H-Coated and Uncoated Steels Sliding Against Phenol–Formaldehyde Composite Reinforced with PTFE and Glass Fibers

Tribological experiments on phenol–formaldehyde composite reinforced with polytetrafluoroethylene (PTFE) and glass fibers were performed against 100Cr6 steel and TiC/a-C:H thin film-coated 100Cr6 steel. In both cases, the coefficient of friction increases with increasing sliding distance until a steady-state value is reached. Although the steady-state values of the coefficient of friction are very close and ultralow, the wear rate of the PTFE composite liner at a long sliding distance (1,000 m) is reduced when the steel ball is coated with the TiC/a-C:H coating. This behavior is mainly attributed to the smoother surface after long sliding and the improved wear resistance of TiC/a-C:H coating. PTFE transfer films are evident on the surfaces of the hard counterparts. The average thickness of the transfer film on TiC/a-C:H-coated surfaces is about 3.8 nm. On the surface of uncoated steel ball, a continuous but non-uniform transfer film of around 13.9 nm average thickness was found.     

Effect of elastic-plastic behavior of coating layer on drawability and frictional characteristic of galvannealed steel sheets

During a galvannealed sheet metal forming, the failures of coating layers (powdering, flaking and cracking) frequently affect the strain state of sheets and deteriorate the frictional characteristic between sheets and tools. Two FE-models in this study were suggested to investigate the effects of the mechanical behavior of coating layers on the formability and friction of the coated steel sheets in FE analysis; the first is one-layer model to express the coated sheet as one stress-strain curve and the second is a multiple-layer model which is composed of substrates and coating layers, separately. First, the frictional properties and the formability of the coated sheets were experimentally investigated using a cup deep-drawing trial. After, the drawing process was simulated by FE analysis of the two models. In the multiplelayer model, the mechanical behavior of the coating is defined as a stress-strain curve which was determined using the nanoindentation test of the coating, its FE analysis and artificial neural network method. The result showed that the multiple-layer model provides more accuracy predictions of drawing loads than the one-layer model in the FE analysis, compared to the actual cup drawing test.

     

Finite element analysis of coating adhesion failure in pre-existing crack field

Abstract

The influence of a pre-existing crack field on coating adhesion failure in a steel surface coated with a 2 μm thick titanium nitride (TiN) coating was investigated by finite element method modelling and simulation. The stress and strain fields were determined in contact conditions with a spherical diamond tip sliding over the coated surface at a loading of 8 N. One crack in or at the coating increased the maximum tensile stresses with six times from 82 to 540 MPa when the crack was vertical through the coating or L shaped and with nine times when the crack was horizontal at the coating/substrate interface. A simulated multicrack pattern relaxed the tensile stresses compared to single cracks. The results indicate that a cracked coated surface needs to have about five to nine times higher adhesive and cohesive bonds to resist the same loading without crack growth compared to a crack free surface. For optimal coated surface design, the strength of the adhesive bonds between the coating and the substrate in the vertical direction needs to be 50% higher than the cohesive bonds within the coating and the substrate in the horizontal direction. The first crack is prone to start at the top of the coating and grows vertically down to coating/substrate interface, and there it stops due to the bigger cohesion within the steel material. After this, there are two effects influencing that the crack will grow in the lateral direction. One is that steel cohesion is normally bigger than the coating/interface adhesion, and the second is that there are higher tensile stresses in the horizontal than in the vertical cracks. Several vertical cracks can stop the horizontal crack growth due to stress relaxation.