Determining elasticity characteristics for protective coatings

A method is proposed for determining the elastic modulus and Poisson's ratio for a protective coating in static uniaxial tension. The difference in Poisson's ratio between the substrate and the coating results in additional stresses, and the coating is in a planar state of stress. Formulas are derived for the coating's elasticity characteristics in terms of a single test on a coated specimen. That method has given the elastic modulus and Poisson's ratio for gas- plasma coatings.Translated from Problemy Prochnosti, No. 7, pp. 48–51, July, 1995.     

Effects of differences in elastic characteristics between substrate and coating on the stress and strain state in a composite. 1. Estimating tensile stresses in the coating

A differential equation is derived for the tensile stress in the coating on uniaxial stretching in the substrate, which incorporates the difference in Poisson's ratio between the substrate and the coating. Additional stresses arise in the coating because of this. An expression is derived for the stress distribution in the coating. A graph is proposed indicating the distribution of that stress in the plane of the adhesive contact.Translated from Problemy Prochnosti, No. 9, pp. 37–43, September, 1995.     

On the Reduction of Residual Stresses in Plasma-Vacuum-Deposited Coatings

Residual stresses in a plasma-vacuum-deposited titanium-nitride coating, which vary between –780 and –2800 MPa depending on the coating thickness, have been determined. It has been shown that deposition of a pure-chromium sublayer and substitution of a discontinuous (discrete) coating for a continuous one allow residual stresses to be reduced appreciably. It has been found that residual compression stresses can affect favorably the characteristics of strength of both the coating itself and the coated part as a whole.     

The Effect of Hard Coating Properties on Substrate Stresses Under Tribological Loads

A study has been carried out using finite element methods to investigate the influence of hard coatings on substrate stresses under tribological and thermal loads. The study was performed under a uniform distribution of traction (normal and tangential pressure) and temperature. The stresses have been calculated in terms of the ratio of the modulus of elasticity between coating and substrate and the ratio of the coating thickness to the loading strip length at different coefficients of friction and temperatures. The heat transfer problem was solved with regard to a variety of coating properties and the output temperature applied as a thermal load in the structure problem. It is shown that altering the coating modulus of elasticity and coefficient of friction in the presence of a temperature change affects the maximum equivalent stress in the substrate and changes its location. The simulations carried out are discussed in terms of the potential benefits of plasma-based surface coatings and treatments in improving tool performance and the requirements for coating design specifications which will allow design engineers to build surface treatments into new tool designs.     

Elasto-optics in double-coated optical fibers induced by axial strain and hydrostatic pressure

Stresses, microbending loss, and refractive-index changes induced simultaneously by axial strain and hydrostatic pressure in double-coated optical fibers are analyzed. The lateral pressure and normal stresses in the optical fiber, primary coating, and secondary coating are derived. Also presented are the microbending loss and refractive-index changes in the glass fiber. The normal stresses are affected by axial strain, hydrostatic pressure, material properties, and thickness of the primary and secondary coatings. It is found that microbending loss decreases with increasing thickness, the Young's modulus, and the Poisson's ratio of the secondary coating but increases with the increasing Young's modulus and Poisson's ratio of the primary coating. Similarly, changes in refractive index in the glass fiber decrease with the increasing Young's modulus and Poisson's ratio of the secondary coating but increase with the increasing Young's modulus and Poisson's ratio of the primary coating. Therefore, to minimize microbending loss induced simultaneously by axial strain and hydrostatic pressure in the glass fiber, the polymeric coatings should be suitably selected. An optimal design procedure is also indicated.     

Fatigue behavior of AA7075-T6 aluminum alloy coated with ZrN by PVD

The present investigation has been conducted in order to study the effect of the deposition of a ZrN coating, of 3 μm in thickness, on the static mechanical properties and fatigue behavior of a 7075-T6 aluminum alloy substrate. It has been determined that the coating deposition process gives rise to a significant decrease in such properties, which is not fully compensated for the presence of the film. When fatigue tests were carried out in a 3 wt.% NaCl solution at low alternating stresses, the ZrN film partially compensated for the decrease in fatigue properties of the coated substrate. Extensive delamination of the coating from the substrate was observed under the action of cyclic stresses greater than approximately 220 MPa. Below this stress and in the presence of NaCl, the behavior of the coated material approached that of the uncoated alloy, which highlighted the good corrosion resistance of the ZrN coating and its ability to protect the substrate when it remained adhered to the latter.     

Effect of the Elastic Modulus of a Coating on the Serviceability of the Substrate–Coating System

We study the effect of the elastic modulus of a coating on its strength and strain characteristics, as well as on the residual stresses in it. The tangential and normal stresses that occur in the substrate and coating depend on the elastic modulus of the latter. It has been concluded that when designing substrate–coating systems, one should try to seek the optimum ratio of their elastic properties. An original approach has been proposed to the deposition of protective structurally inhomogeneous coatings, in which, unlike functionally gradient materials, not the composition but the structure is varied continuously.     

PVD‐CrN Beschichtungen auf Magnesium AZ91hp und Stahl 100Cr6 – Untersuchung des Substrateinflusses auf die Schichteigenschaften

PVD‐CrN coated magnesium alloy AZ91hp and steel 100Cr6 – Investigation on the influence of the substrate material on coating properties PVD‐chromium‐nitride coated samples of substrates of the magnesium alloy AZ91hp and the roller and ball bearing steel 100Cr6 were investigated regarding structure, mechanical characteristics, adhesion and internal stresses. For the coatings the parameters layer thickness and substrate BIAS voltage were varied. Both substrate materials were coated in one lad. Results of the x‐ray analysis of the internal stresses show significant differences between the coated magnesium and the coated steel substrates. In the case of the variation of the substrate BIAS voltage, for the coated steel a dependency of the internal stresses to coating parameters could be obtained. For the coated magnesium no dependency was recognizable. The coating structure was examined with scanning electron microscopy. Element depth profiles of the coated samples were performed with SIMS.     

Durability of nanosized oxygen-barrier coatings on polymers

Research on silicon oxide thin films developed as gas-barrier protection for polymer-based components is reviewed, with attention paid to the relations between (i) coating defects, cohesive strength and internal stress state, and (ii) interfacial interactions and related adhesion to the substrate. The deposition process of the oxide from a vapor or a plasma phase leads in both cases to the formation of covalent bonds between the two materials, with high adhesion levels. The oxide coating contains nanoscopic defects and microscopic flaws, and their respective effect on the barrier performance and mechanical resistance of the coating is analyzed. Potential improvements are discussed, including the control of internal stresses in the coating during deposition. Controlled levels of compressive internal stresses in the coating are beneficial to both the barrier performance and the mechanical reliability of the coated polymer. An optimal coating thickness, with low oxygen permeation and high cohesive strength, is determined from experimental and theoretical analyses of the failure mechanisms of the coating under mechanical load. These investigations are found relevant to tailor the interactions and stress state in the interfacial region, in order to improve the reliability of the coating/substrate assembly.     

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.     

Effect of thick DLC coating on fatigue behaviour of magnesium alloy in laboratory air and demineralised water

Rotating bending fatigue tests have been performed using Diamond‐like carbon (DLC) coated specimens of a wrought magnesium alloy, AZ80A, in laboratory air and demineralised water and the effect of DLC coating on fatigue and corrosion fatigue behaviour was studied. Three film thicknesses of 3.5 μm, 13 μm, and 25 μm (two‐layer film) were evaluated and particular attention was paid to the role of thick DLC coating. In laboratory air, the fatigue strengths of the DLC‐coated specimens were higher than that of the substrate specimen and increased with increasing film thickness. This was because hard DLC coating with good adhesion suppressed the crack initiation due to cracking of inclusions or cyclic slip deformation on the substrate surface. In demineralised water, the fatigue strength of the 3.5‐μm DLC‐coated specimen was the same as that of the substrate specimen due to the penetration of the water through pre‐existing film defects, while the 13‐μm and 25‐μm DLC‐coated specimens showed increased corrosion fatigue strength with increasing film thickness and also exhibited nearly the same fatigue strength as in laboratory air except for a few premature failed specimens, indicating a potential of thick DLC coating or two‐layer coating for complete improvement of corrosion fatigue strength in aqueous environments.     

Plasma Sprayed Copper-Nickel-Indium Coatings on Titanium Alloys

Copper-nickel-indium coatings were deposited on the surface of titanium alloy specimens by plasma spraying. The structure and properties of the coatings were studied thoroughly using optical and scanning electron microscopy. The mechanical behavior of the Cu-Ni-In coated titanium substrates was examined. The coating was found to decrease the tensile strength of the titanium alloy substrate. The elastic modulus and the ultimate tensile strength of the coated system were found to decrease with increasing coating thickness. The residual stresses of the coated system were also calculated.     

残余应力对涂覆Al2O3涂层的ZrO2陶瓷的强度和裂纹扩展阻力的影响

本研究在ZrO₂基体表面涂覆一薄层Al₂O₃涂层, 利用基体与涂层之间热膨胀系数不匹配, 在Al₂O₃-ZrO₂预应力陶瓷(简称A_CZ_S预应力陶瓷)表层引入压应力。采用维氏压痕法评价残余应力对A_CZ_S预应力陶瓷的表层和基体中裂纹扩展阻力的影响。理论分析结合实验结果表明: 表层的压应力使得A_CZ_S预应力陶瓷的裂纹扩展阻力增大, 最终导致强度和损伤容限提高; 且A_CZ_S预应力陶瓷表层的压应力和裂纹扩展阻力随着基体截面积与涂层截面积比值的增加而增大。当ZrO₂基体表层的Al₂O₃涂层厚度为40 μm时, 表层压应力使A_CZ_S预应力陶瓷的弯曲强度达到(1207±20) MPa, 相比于同种工艺下制备的ZrO₂陶瓷强度提高了32%, 同时也是Al₂O₃强度的3倍。此外, A_CZ_S预应力陶瓷也表现出很好的抗热震性能。     

Fatigue resistance of PECVD coated steel alloy

The thin hard coating deposition techniques CVD and PVD have been used for a long time in industry. Such coatings prove very effective in improving the tribological and corrosive resistant properties of the substrate. It was shown that the compressive residual stresses are introduced on the surface layer from the PVD deposition process that helps to increase the fatigue limit of coated structural components. The aim of this work is to evaluate the effect of a SiO_x coating, deposited by means of PECVD technique, on the fatigue resistance of a quenched and tempered alloy steel (39NiCrMo3). Rotating bending fatigue tests were carried out to assess its fatigue limit and characterize any possible variation between the coated and the uncoated material. Fracture surface observations were made using SEM on fracture surfaces, and scratch tests were performed on samples to assess the coating-substrate interface delamination.     

Stress analysis of a substrate coated by nanomaterials with vacancies subjected to uniform extension load

In this study, a stress analysis of a substrate coated by nanomaterials with a vacancy under uniform extension load is investigated. The behavior of the coated substrate is modeled with the behavior of a two-layered beam, in which one of the layers is elastic and described by the continuous medium and the second layer consists of a nanomaterial with damage of a vacancy. The extension of the coating is carried out by stretching of the first layer, which lies on the substrate and by the cohesive forces between the layers. It is assumed that vacancies do not vary along the width of the substrate. The constitutive equations of the first layer (i.e., an elastic substrate) are given in the framework of Hooke’s law and the constitutive equations of the second layer; that is, the coating is carried out by taking into account discreteness of the nanomaterial with a vacancy. The expressions for the determination of the contact pressure and stresses of the substrate with a nanocoating that have vacancies are obtained. In addition, damage conditions for the substrate and nanocoating are determined. Finally, carrying out some computations, effects of the characteristics of a nanocoating with and without vacancies on the values of contact pressure and stresses of the coated substrate have been studied.     

Variables affecting the fatigue resistance of PVD-coated components

The effect of intrinsic properties of CrN coatings on fatigue behaviour was studied in this paper. The coating layer microhardness and the residual stresses characterising the surface film were measured and the obtained results were introduced in a numerical modelling predicting fatigue life procedure of coated components. The effect of a CrN monolayer film deposited on bulk samples, produced in 2205 duplex stainless steel, H11 tool steel or 6082 aluminium alloy was investigated. The fatigue limit of coated and uncoated samples was experimentally determined while the development of FEM models, confirmed by means of experimental tests, represents a powerful tool to predict fatigue life of coated components. The effects on the fatigue strength of coating and bulk material defects like droplets and non-metallic inclusions were considered along with the residual stress gradient characterising the coating and evaluated by means of X-ray measurements. The influence of the substrate material plastic deformation on the integrity of the coating was evaluated too.     

Effects of elasticity differences between substrate and coating on the state of stress and strain in a composite. Part 2. Coating tensile stress distribution

An expression is given for the tensile stress in the coating in uniaxial stretching of the substrate, which incorporates the differences in Poisson's ratio for the substrate and coating. The tensile stress is dependent on the substrate strain, the elastic characteristics of substrate and coating, and also on the geometric parameters. A graph is given for the stress distribution for a gas-thermal coating in the plane of adhesive contact. Translated from Problemy Prochnosti, No. 5, pp. 63–67, May, 1996.     

Fatigue behavior of a 7075-T6 aluminum alloy coated with an electroless Ni–P deposit

An investigation has been carried out in order to study the fatigue and corrosion–fatigue behavior of a 7075-T6 aluminum alloy coated with an electroless Ni–P (EN) deposit, in the as-plated condition, of approximately 38–40 μm in thickness and a high P content, of approximately 18 wt%. The results obtained, show that the EN coating can give rise to a significant improvement in the fatigue and corrosion–fatigue performance of the substrate, depending on the testing conditions. When the coated system is tested in air, it is observed that the increase in fatigue properties decreases as the alternating stress applied to the material increases. At stresses of the order of 0.4 σ_0.2% the increase in fatigue life is more than about 100%. However, as the stress increases to values in the range of 0.7 σ_0.2%, no improvement in the fatigue performance of the system is observed and the behavior is similar to that of the uncoated substrate. Under corrosion–fatigue conditions, the fatigue life is observed to increase between approximately 60% and 70%, depending on the stress applied. It is shown that fatigue cracks are associated with nodular-like defects present on the surface of the coated samples. The deleterious effect of such defects seems to be more pronounced as the alternating stress applied to the material increases. A crude estimate of the yield strength of the EN coating from tensile measurements indicates that such a parameter is in the range of 3.8 GPa, in agreement with the computation of the absolute hardness of the deposit, of about 4 GPa, by means of Meyer’s law. It is also shown that the EN deposit has a very good adhesion to the substrate even when the system is subjected to tensile stresses greater than the yield strength. Such characteristics as well as the higher mechanical properties of the EN coating in comparison with the aluminum alloy substrate and the preservation of its integrity during fatigue testing contribute to the better fatigue performance of the coated system.     

Strength analysis for three-dimensional fiber reinforced composites

Three-dimensional fiber reinforced composite materials produced by impregnating resin into woven fabric have superior interlaminar and impact strength and are capable of being formed into complex shapes. Consequently it is expected in the future that they will be used for various structural members which have to date been difficult to make with conventional composite materials. With the growth in their fabrication technoloy, the development of a strength analysis method is being demanded. This paper describes a strength analysis method for three-dimensional composite materials on the basis of a micro-mechanical analysis of a unit cell. The unit cell is a small geometrical unit of fiber architecture. A feature of the present analysis method is to represent a unit cell as a rigid frame structure constructed of fiber-beam elements and matrix-beam and matrix-rod elements. Strength analyses are made for orthogonal weave and 5-axial weave three-dimensional carben/epoxy composite materials; the tensile, compressive, and shear moduli and strengths, and Poisson's ratio are calculated. The analytical results show fairly good agreement with experimental results; 11%, 21%, and 20% differences between them on the average for elastic moduli, strengths, and Poisson's ratios, respectively. It is also understood that the present idealized analysis model cannot accurately predict the characteristics of undulated fiber composites, especially in respect to the compressive strength.     

任意负泊松比超材料结构设计的功能基元拓扑优化法

基于拓扑优化方法,提出了设计具有任意负泊松比超材料及结构的功能基元拓扑优化法。针对功能基元的不同初始拓扑基结构,包括矩形和三角形初始拓扑基结构,以指定的负泊松比值作为约束条件,以功能基元柔顺度最大化为目标函数,建立了任意负泊松比超材料拓扑优化模型并求解。提取拓扑优化得到的功能基元最优构型,经周期性分布从而形成负泊松比结构。建立优化得到的超材料结构有限元模型,验算了功能基元的泊松比,计算分析了该超材料试件的静、动力学特性。结果表明,该负泊松比效应超材料试件具有较好的承载能力,且在中低频段有较好的减振效果。