The influence of multilayer structure on mechanical behavior of TiN/TiAlSiN multilayer coating

Nitride coatings have been generally applied on light alloys like titanium and aluminium to promote their multiple performances, including hardness, thermal stability and wear resistance. In this work, TiAlSiN/TiN multilayered (ML) coating and TiAlSiN single-layer (SL) coating were deposited on TC18 (Ti5Al5Mo5V1CrFe) alloy by Multi-arc ion plating technique. The microstructure and chemical composition of the coatings were evaluated by SEM, XRD and XPS. Additionally, hardness, adhesion and wear resistance were measured through nanoindentation, scratch spectrometer and ball-on-disk tribometer. The results present that both ML and SL coating contain three main phases of TiN, Al₂O₃ and Si₃N₄. Nevertheless, the adhesion of ML coating is 62.4 N, compared to that of the SL coating is 51.8 N. The parameter H³/E² as an indication of plastic deformation to evaluate wear resistance shows that the ML coating has high hardness and high toughness concurrently. The tribological study indicated that the wear rate of the ML coated specimen was 1/7 of the SL coated counterpart.     

Friction and wear properties of Si3N4-hBN ceramic composites using different synthetic lubricants

This paper presents a tribological investigation of Si₃N₄-hBN composite ceramics using synthetic lubricants. The friction and wear properties of Si₃N₄-hBN ceramic composites sliding against TC4 titanium alloy (Ti6Al4V) were investigated via pin-on-disc tests. An axial compressive load of 10?N was applied with a sliding speed of 0.73?m/s. Three different lubrication conditions including simulated body fluid (SBF), physiological saline (PS) and bovine serum (BS) were used. For SBF lubrication, the friction coefficients and wear rates of Si₃N₄-hBN/Ti6Al4V pairs were varying with the increase of hBN contents. When using 20?vol% hBN, the average friction coefficient and wear rate of Si₃N₄ (0.28 and 3.5?× 10^?4 mm³ N^?1 m^?1) were as good as that of the pure Si₃N₄ (0.34 and 3.69?× 10^?4 mm³ N^?1 m^?1). Meanwhile, the processability of the Si₃N₄ material would be improved by adding hBN. It was worth to mention that when using 30?vol% hBN, the tribological performance of bearing combination deteriorated with extensive wear from the ceramic pin. This may due to the reduction of mechanical property caused by adding hBN and the occurring of tribochemical reaction. According to the worn surface examination and characterization, the main wear mechanism was abrasive and adhesion wear. Scratch grooves were observed on the metal disc, and metallic transform layers were seen on the ceramic pin. Moreover, surface lubrication film consisting of TiO₂, SiO₂·nH₂O, Mg(OH)₂, and H₃BO₃ were formed on the metal disc when using SBF lubrication and 20?vol% hBN content. Among the three lubrication conditions, SBF generally led to the best tribological performance. No surface lubrication film was found during BS and PS lubrications. This may be resulted from the absence of essential ions to promote the formation of surface lubrication film (PS lubrication) and the formation of a protein barrier on the surface of the metal disc (BS lubrication).     

Optimized a-C coatings by doping with zirconium for tribological properties and machining performance

In this study, a-C:Zr_x% coatings with various levels of zirconium (Zr) addition are deposited on cemented tungsten carbide (WC-Co) substrates using a medium frequency twin magnetron sputtering and unbalanced magnetron sputtering system. The tribological properties of the coatings are investigated by conducting wear tests against an AISI 1045 steel counterbody under a cylinder-on-disk line contact wear mode using an oscillating friction and wear tester system. The machining performance of coated turning cutters and micro-drills is then evaluated by performing turning tests and high-speed through-hole drilling tests using AISI 1045 steel counterbodies and printed circuit board workpieces, respectively. The experimental results reveal that the fabricated a-C:Zr_x% coatings not only have improved tribological properties, but also yield an enhanced machining performance. For sliding against the AISI 1045 steel counterbody under loads of 10 N and 100 N, respectively, the optimal tribological properties are provided by the a-C:Zr_13%coating. However, the optimal turning and drilling performance is obtained using the a-C: Zr_45% coating.     

Wear behavior of plasma sprayed hydroxyapatite bioceramic coating in simulated body fluid

To investigate the wear behavior of bioceramic coating, two-body abrasive wear of air-plasma sprayed (APS) hydroxyapatite (HA) coating was studied in different conditions including: i) in simulated body fluid (SBF) and in dry conditions, and ii) sliding on Al₂O₃ abrasive paper, HA, polycarbonate (PC) and polyurethane (PU), as well as iii) on different applied loads. Cross-sectional microstructures and worn surface morphologies of the coating were examined by scanning electron microscopy (SEM). Phase constitutions were analyzed by X-Ray diffraction (XRD). Microhardness, elastic modulus, fracture toughness and bond strength of the coating were investigated. It was revealed that, under the load of 20?N and sling on different counterpart materials, the wear rates of the coating varied from 24.09?×?10^?2to 0.25?×?10^?2 mg/Nm in SBF and varied from 13.54?×?10^?2 to 0.05?×?10^?2 mg/Nm in dry condition, respectively. The accumulated weight loss of the coating sliding on HA in SBF increased from 3.1 to 7.9?mg as the applied load increased from 5?N to 20?N. As sliding on Al₂O₃ in dry condition and/or under high load, the abrasive wear of the coating dominantly occurred in the form of ploughing and peeling off of splats. As sliding on PC, PU and HA in SBF, the adhesive wear of the coating mainly occurred in the form of exfoliation.     

Wear behavior of graded Cr-CrN-Cr(1−x)Al(x)N coatings synthesized by closed-field unbalanced magnetron sputtering for advanced machining operations

Graded Cr-CrN-Cr_(1?x)Al_(x)N coatings were synthesized onto M42 HSS substrates used in advanced machining operations by closed-field unbalanced magnetron sputtering (CFUBMS). The tribological behavior of these graded coatings was explored in detail by advanced electron microscopy, confocal laser scanning microscopy, nanoindentation and dry sliding wear tests. The presence and magnitude of residual stresses in these coatings were determined by the XRD – sin²ψ method, which revealed increasing compressive stresses with increasing Al content. The coating surface morphology, mechanical properties were determined prior to dry sliding wear by atomic force microscopy (AFM) and nanoindentation methods, which yielded decreasing surface roughness (R_a) as well as enhancement of hardness and modulus along with increase in H/E and H³/E² ratios with increasing Al content. Tribological investigation was performed with a pin-on-disc arrangement by keeping the sliding velocity (0.2?ms^?1) and normal axial load (10?N) constant and varying the sliding distance. Specific wear rates of the order ~ 10^–17 m³ N^?1 m^?1 were encountered for all coatings with the wear rates increasing as the Al content increased implying a decrease of wear resistance of the coatings. Abrasive wear has been found to be the dominant wear mechanism during dry sliding wear. Increasing modulus mismatch between coating and substrate can be mainly attributed to a decrease in wear resistance of the coatings.     

AlCrN/Cr3C2–NiCr duplex coating towards high load-bearing and dry sliding antiwear applications

In this study, experimental analysis and finite element modeling (FEM) were employed to investigate the microstructure and mechanical properties of duplex coatings composed of a Cr₃C₂–NiCr interlayer and a top AlCrN film in comparison with these of a single AlCrN film. Results showed a significant improvement in the adhesive strength, load-bearing capacity, H/E, and H³/E² ratios, and hardness of the AlCrN/Cr₃C₂–NiCr duplex coatings compared to the single AlCrN film, especially the wear resistance that increased by nearly eight times under heavy loads. Moreover, FEM analysis revealed that the duplex design reduced the stress concentration area on the surface of AlCrN film and kept it far away from the contact interface during load-bearing.     

Microstructure,bonding strength,and friction–wear performance of AlCrN/nitrided layer composite coating on H13 hot work mould steel

An AlCrN/nitrided layer (NL) composite coating was fabricated on H13 hot work mould steel using a cathode arc ion plating and low temperature plasma nitriding. The surface and cross-section morphologies, chemical composition, phases, and roughness of AlCrN/NL coating were analyzed using a scanning electron microscope (SEM), energy dispersive spectrometer, X–ray diffractometer (XRD), and atomic force microscope, respectively, the friction–wear performances of AlCrN/NL coatings at 400, 500, and 600°C were investigated using a high-temperature wear test. The results show that the AlCrN/NL coating with the surface roughness of 76.8 nm forms the AlN phase, which increase its hardness from 1088 HV of NL to 2381 HV. The average coefficients of friction (COFs) of AlCrN/NL coating at 400, 500, and 600°C are 0.70, 0.55, and 0.56, respectively, and the corresponding wear rates are 1.59 × 10⁻⁵, 9.77 × 10⁻⁵, and 3.93 × 10⁻⁵ mm³/N/m, respectively, as a result, the lowest average COF and wear rate are at 500 and 400°C respectively. The wear mechanism of AlCrN/NL coating at 400°C is primary abrasive wear, accompanied by adhesive wear, while those at 500 and 600°C are primary adhesive wear, accompanied by abrasive wear.     

Scratch and wear resistance of hydrophobic CeO2-x coatings synthesized by reactive magnetron sputtering

CeO_2-x coatings were deposited under variable oxygen flow ratios (%f_O2) onto Si substrates by reactive magnetron sputtering. Nanoindentation testing revealed an increase in the hardness, elastic modulus, H/E and H³/E² ratio with increasing oxygen flow ratio, which in turn increased the adhesion and tribological performance of the coatings. Scratch testing yielded the highest critical load (L_C2 = 28.8 N) and CPR_S = 103 for the coating deposited with the highest oxygen flow ratio (57 %f_O2). Cracking events during scratch testing were initiated by tensile forces behind the scratch stylus, which led to the formation of semi-circular ring cracks. As the normal load increased, transverse cracks emerged extending outwards from the scratch track towards the edge causing the exposure of substrate. Beyond L_C2, severe spallation of the CeO_2-x coatings led to coating failure. Furthermore, the specific wear rates of the CeO_2-x coatings were determined to be within the ~10⁻¹⁵ m³/Nm range influenced by three-body abrasive wear. In-depth analyses from scratch and wear data indicates that these coatings possess good adhesion and durability.     

Surface Characterization and Biocompatibility of Selenium‐Doped Hydroxyapatite Coating on Titanium Alloy

Selenium‐doped hydroxyapatite (HA) was biomimetically coated on Ti6Al4V plates with the aim of combining the anticancer and antibacterial properties of selenium with the biocompatibility and bioactivity of HA. For the coating process, the composition of 1.5 × SBF (solution with ion concentrations at 1.5 times that of simulated body fluid, SBF) was modified to include 0.15 mM selenate (SeO₄^2?) ion. The selenium‐doped HA coating was characterized by several methods, such as scanning electron microscopy, X‐ray diffraction, and Fourier transform infrared spectroscopy. The cytotoxicity of selenium on osteoblast and osteosarcoma cells was determined. The coating was shown to inhibit the growth of Staphylococcus epidermidis.     

Study on the tribological performance of ceramic coatings on titanium alloy surfaces obtained through microarc oxidation

Through microarc oxidation, a ceramic coating is directly formed on the surface of Ti6Al4V alloy, by which its surface property is greatly improved. Microstructure, phase composition and tribological performance of the coatings were characterized. The results showed that the coating with 10-μm thickness is compact in the inner layer and porous in the surface layer. The coating is mainly composed of rutile and anatase TiO₂. The tribological behavior of the microarc oxidation ceramic coating under dry sliding against SAE52100 steel was evaluated on a ball-on-disc test rig. The Ti6Al4V alloy was characterized by adhesion wear and scuffing under dry sliding against the steel, while the polished ceramic coating experienced much abated adhesion wear and scuffing under the same testing condition. The polished ceramic coating showed good friction-reducing and fair antiwear ability in dry sliding against the steel. This is attributed to the smooth surface and rutile TiO₂.     

The post-annealing effect on tribological and corrosion behaviors of CrN/AlCrN multilayered coating applied by CAE-PVD

The present study investigated the wear and electrochemical behaviors of CrN/AlCrN multilayered coatings post-annealed at 300, 450, and 600°C temperatures. The cathodic arc evaporation technique has been utilized to deposit the coatings. Scanning electron microscope, field emission SEM, energy-dispersive X-ray, grazing incidence X-ray diffraction, and Rockwell-C indenter methods were used to characterize the coatings and to investigate the interdiffusion between the multilayered CrN/AlCrN and the H13 base metal. The results showed that the sharp interface of the CrN and AlCrN layers was blurred by the annealing process supporting the interdiffusion of the layers. The reciprocating wear test and the microhardness tester were used to evaluate the coatings’ mechanical behavior. The hardness and roughness of the coatings were increased by increasing the post-annealing temperature. The smallest wear rates were observed for the samples treated at 300 and 450°C, which were approximately 17 times and 12 times smaller than the wear rate of the sample annealed at 600°C. Electrochemical testing was used to study the corrosion behavior of the coatings. The results showed that by increasing annealing temperature, corrosion resistances of the coatings are improved. As a result, the corrosion current density of the 600°C annealed coating was approximately 434 times smaller than as-deposited coatings.     

Nanoindentation study on nanomechanical characteristics of a-CN film deposited by shielded arc ion plating

Mechanical properties of the a-CN films including elastic modulus (E_r), hardness (H), elastic recovery (R), contact stiffness (S) and deformation energies were measured by a nanoindentation system. We also evaluated wear resistant behavior of the layered a-CN films in nanometer scale by the same nanoindentation system. All the a-CN films, irrespective of V_b, showed better wear-resistance characteristics than sapphire and quartz. The a-CN (− 300 V)/Si sample showed the best wear-resistance, although its hardness was lower than the a-CN (− 300 V)/a-C (− 100 V)/Si. The wear resistant characteristic of the films can be understood by considering the other mechanical properties including that of R, hardness-to-elastic modulus ratio (H / E_r), and elastic deformation energy (W_e) obtained from the nanoindentation. These various nanomechanical properties certainly govern the wear-resistance of the film.     

In vitro biocompatibility of a nanocrystalline β-Ta2O5 coating for orthopaedic implants

To improve the durability and bioactivity of Ti–6Al–4V alloy used for medical implants, the β-Ta₂O₅ nano-crystalline coatings were introduced using double cathode glow discharge technique. The coating microstructure was characterized using X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM) and high-resolution transmission electron microscopy (HRTEM). The coating exhibits an assembly of near-equiaxed grains, locally aligned normal to the coating surface. The β-Ta₂O₅ coating exhibits strong adhesion to substrate and a strong resistance to deformation and cracking under applied loads. Cells culture tests showed that the coating is more beneficial to the adhesion and proliferation of NIH-3T3 cells as compared to the uncoated alloy. In-vitro bioactivity was evaluated by immersion of the coating in simulated body fluids (SBF) for different periods up to 14 days at 37 °C. The results indicated that bioactivity of Ti–6Al–4V was dramatically improved after the deposition of β-Ta₂O₅, since the coating has a higher apatite forming ability than the Ti–6Al–4V substrate. Finally, the electrochemical behavior of the β-Ta₂O₅ coating after soaking in SBF at 37 °C for 0, 3, 7, and 14 days was studied through potentiodynamic polarization and electrochemical impedance spectroscopy (EIS). EIS measurements also confirm that the presence of a hydroxyapatite layer on the coating becomes thicker and denser during soaking in SBF. Moreover, the coating exhibits better corrosion resistance than the bare alloy. Hence, the β-Ta₂O₅ coating is a promising candidate coating for protection of orthopedic implants with enhanced bioactivity and corrosion resistance.     

Effects of ceramic-based CrN,TiN, and AlCrN interlayers on wear and friction behaviors of AlTiSiN+TiSiN PVD coatings

In this study, the wear and friction behavior of cathodic arc physical vapor deposited AlTiSiN+TiSiN coatings on H13 tool steels were investigated by using CrN, TiN and AlCrN interlayers with tribometer tests both under unlubricated and boundary lubricated conditions. 6 mm alumina balls were used as counter surfaces to test ceramic hard coatings. Surface coatings were characterized through nanoindentation, scanning electron microscopy coupled with an energy-dispersive X-ray spectrometer (SEM/EDXS), optical profilometry, and atomic force microscopy (AFM) techniques. The results showed that especially AlTiSiN+TiSiN coating with TiN interlayer resulted in a much more enhanced tribological performance of the tool steels at both unlubricated and the boundary lubricated conditions even at elevated contact pressures.     

Preparation,biomimetic apatite induction and osteoblast proliferation test of TiO2-based coatings containing P with a graded structure

TiO₂-based coatings containing P (T–P) were prepared on Ti6Al4V by microarc oxidation (MAO) with applied voltages of 200–400 V in an electrolyte containing (NaPO₃)₆ and NaOH. The surfaces of the T–P coatings became rough and the thickness increased with increasing the applied voltage. Above 200 V, anatase was found on the surface, and rutile was observed at 400 V. With increasing the coating thickness, the O and P concentrations increase; while Ti and Al concentrations decrease. Ti, O and P elements display a uniform distribution character around the micropores on the surface of the T–P coating formed at 300 V. However, the inner of the micropores exhibits a high Ti concentration and low O and P concentrations due to the graded distributions of Ti, O and P elements in the T–P coating. The apatite-forming ability of the T–P coating formed at 300 V was evaluated by immersing in a simulated body fluid (SBF) for 28 and 56 days. The results indicate that biomimetic apatite was formed on the surface of the T–P coating after immersion in SBF for 56 days. And the further cell experiment indicates that the T–P coating can provide surface suitable for the MG63 cell proliferation.     

Wear assessment of Cr2O3-/TiAlN-coated DAC-10 tool steel against steel and Al2O3 counterbodies

TiAlN film was deposited on Cr₂O₃-coated plasma-nitrided DAC-10 tool steel to obtained multilayer Cr₂O₃/TiAlN coating layer using cathodic arc deposition technique. The structural make-up of the coating was characterized using Atomic Force Microscopy (AFM) and X-ray diffraction methods, and the mechanical properties were evaluated using nanoindentation and nanoscratch test. The structural phases of the coating indicated the presence of crystalline CrO structure and cubic TiAlN phases. The coating showcased improved hardness (38 GPa), elastic modulus (387 GPa), and adhesion along with appreciable H/E (0.09) and H³/E² (0.366 GPa) attributes. Further, friction-induced wear behavior of the coating was investigated against steel and Al₂O₃ counterbodies under dry sliding conditions. The wear behavior of the coating was greatly influenced by its hardness and deformation properties and frictional behavior of the counterbodies. More spikes and fluctuation were observed in the frictional curve against Al₂O₃ counterbody attributed to the emanation of TiO₂, Cr₂O₃, and Al₂O₃ compounds due to dry sliding leading to the formation of flakes and delamination induced debris. Against the steel counterbody, the coating mainly formed a typical smooth glossy surface ascribed to the formation of Fe₂O₃ compound on the worn surface.     

Investigation of the tribological and biomechanical properties of CrAlTiN and CrN/NbN coatings on SST 304

This study examines the influence of thin layer coatings of CrAlTiN and CrN/NbN, deposited via physical vapor, on the biocompatibility, mechanical, tribological, and corrosion properties of stainless steel 304. The microstructure and morphology of the thin CrAlTiN and CrN/NbN layers were characterized by scanning electron microscopy (SEM), EDX, and X-ray diffraction. The pin on disc wear test was performed on bare and metal-nitride coated SST 304 under a 15 N load at 60 rpm and showed that the wear rates of the thin CrAlTiN and CrN/NbN film coatings were lower than the bare substrate wear ratio. The coefficients of friction (COFs) attained were 0.64, 0.5, and 0.55 for the bare substrate, CrN/NbN coating, and CrAlTiN coating, respectively. Nano indentation tests were also performed on CrAlTiN-coated and CrN/NbN-coated SST 304. The nanohardnesses and Young's moduli of the coated substrates were 28 GPa and 390 GPa (CrN/NbN-coated) and 33 GPa and 450 GPa (CrA1TiN-coated), respectively. For comparison, the nanohardness and Young's modulus of the uncoated substrate were 4.8 GPa and 185 GPa, respectively. Corrosion tests were conducted, and the behaviors of the bare and metal nitride-deposited substrates were studied in CaCl₂ for seven days. The corrosion Tafel test results showed that the metal-nitride coatings offer proper corrosion resistance and can protect the substrate against penetration of CaCl₂ electrolyte. The CrN/NbN-coated substrates showed better corrosion resistance compared to the CrAlTiN-coated ones. In evaluating the biocompatibility of the CrAlTiN and CrN/NbN coatings, the human cell line MDA-MB-231 was found to attach and proliferate well on the surfaces of the two coatings.     

Design of cycle structure on microstructure,mechanical properties and tribology behavior of AlCrN/AlCrSiN coatings

AlCrN/AlCrSiN coatings with cycle structure, composed of fcc-CrN, hcp-AlN and amorphous Si₃N₄ phases, were fabricated to protect high speed steel (HSS) tools by high energy ion source enhanced multi-arc ion plating technology with Al₇₀Cr₃₀ and Al₆₀Cr₃₀Si₁₀ alloying targets. With the increasing cycle structure, the crystal grains of AlCrN layers was refined from 60–110 nm to 8–15 nm, and the growth behavior transformed from (200)fcc to the coexistence of both (200)fcc and (111)fcc preferred orientation as demonstrated by GIXRD spectrum, calculated texture coefficient and HRTEM results. The HRTEM results investigated that the inter-planar spacing of CrN(111) was basically equal to that of AlN(0002) with parallel orientation relationship and the interface-1 between the substrate and adhesion layer with a semi-coherent appearance presented a specific orientation relationship. The coating with two cycle structure (Cycle 2) possessed better adhesion strength (HF1 grade, 62.7±1.3 N of Lc2), higher hardness (30.2±1.7 GPa), better fracture toughness (0.099 of H/E, 0.29 GPa of H³/E² and 9.8±0.3 MPa m^1/2 of K_IC under 20 kgf loading), lower friction coefficient (0.54), less wear rate (4.2 × 10^?16 m³/N·m) and longer service life (7.4 m).     

Influence of the substrate nature on the properties of nanocrystalline diamond films

Nanocrystalline diamond/amorphous carbon (NCD/a-C) nanocomposite films have been deposited by microwave plasma CVD from CH₄/N₂ mixtures on a variety of substrates such as polycrystalline diamond, cubic boron nitride, silicon, titanium nitride, and Ti–6Al–4V. The study aimed to investigate the influence of the chemical nature of the substrate, the surface roughness, and the pretreatment of the substrate on the nucleation, the bulk structure, and the mechanical and tribological properties of the NCD/a-C films. The present paper is especially devoted to the bulk structure of the films. By means of X-ray diffraction (XRD), Raman spectroscopy and X-ray photoelectron spectroscopy (XPS) it is shown that the bulk properties of the films are not affected by the properties of the substrate although these have a strong influence on the nucleation behaviour. XRD measurements show that – irrespective of the substrate used – the films contain diamond nanocrystallites of 3–5 nm diameter. From the Raman spectra it can be inferred that the crystallite/matrix ratio does not vary. The XPS measurements, finally, show that there are no great changes in the sp²/sp³ ratio of the matrix. These findings are discussed in view of possible growth mechanisms of NCD/a-C nanocomposite films.     

Electrochemical and structural evaluation of functionally graded bioglass-apatite composites electrophoretically deposited onto Ti6Al4V alloy

Titanium and its alloys are widely used as materials for implants, owing to their corrosion resistance, mechanical properties and excellent biocompatibility. However, clinical experience has shown that they are susceptible to localised corrosion in the human body causing the release of metal ions into the tissues surrounding the implants. Several incidences of clinical failures of such devices have demanded the application of biocompatible and corrosion resistant coatings and surface modification of the alloys. Coating metallic implants with bioactive materials is necessary to establish good interfacial bonds between the metal substrate and the bone. Hence, this work aimed at developing a bioglass-apatite (BG-HAP) graded coating on Ti6Al4V titanium alloy through electrophoretic deposition (EPD) technique. The coatings were characterized for their properties such as structural, electrochemical and mechanical stability. The electrochemical corrosion parameters such as corrosion potential (E_corr) (open circuit potential) and corrosion current density (I_corr) evaluated in simulated body fluid (SBF) have shown significant shifts towards noble direction for the graded bioglass-apatite coated specimens in comparison with uncoated Ti6Al4V alloy. Electrochemical impedance spectroscopic investigations revealed higher polarisation resistance and lower capacitance values for the coated specimens, evidencing the stable nature of the formed coatings. The results obtained in the present work demonstrate the suitability of the electrophoretic technique for the preparation of graded coating on Ti6Al4V substrates.