Hybrid magnetron sputtering of ceramic superlattices for application in a next generation of combustion engines

Bruno César Noronha Marques De Castilho,Haroldo Cavalcanti Pinto,Gelmires De Araújo Neves,Raíra Chefer Apolinario,Pedro Renato Tavares Avila,Romualdo Rodrigues Menezes,Tamires De Souza Nossa,Magdalena Walczak,Alisson Mendes Rodrigues,Jucielle Veras Fernandes

doi:10.1038/s41598-022-06131-9

Abstract

A hybrid magnetron sputtering process (dcMS/HiPIMS) was developed to manufacture nanostructured CrN/Cr1-xAlxN multilayers, motivated by improving the low-emission efficiency when applied on gas-nitrided diesel piston rings of a next-generation of combustion engines. In order to improve the mechanical, tribological, and corrosion behavior of the multilayers, the hybrid dcMS/HiPIMS process was designed by selecting the optimal sputtering procedure applied to AISI 440 base steel. The effect of substrate bias and carousel rotational speed on the phase composition, crystallographic texture, residual stresses, surface roughness, coating periodicity and densification, instrumented hardness, elastic modulus, as well as wear and corrosion resistance was determined. The results have demonstrated that hybrid magnetron sputtering produces multilayers with a superlattice structure, which outperforms commercial PVD coatings of CrN for diesel piston rings manufactured by cathodic arc evaporation. Also, multilayer periodicities in the range of 5 to 10 nm yield the best tribological performance under bench tests for the piston ring/cylinder liner system.

Highlights

IntroductionA hybrid magnetron sputtering process (dcMS/high power impulse magnetron sputtering (HiPIMS)) was developed to manufacture nanostructured chromium nitride (CrN)/Cr1-xAlxN multilayers, motivated by improving the low-emission efficiency when applied on gas-nitrided diesel piston rings of a next-generation of combustion engines
A hybrid magnetron sputtering process was developed to manufacture nanostructured chromium nitride (CrN)/Cr1-xAlxN multilayers, motivated by improving the low-emission efficiency when applied on gas-nitrided diesel piston rings of a next-generation of combustion engines
Internal combustion engines are at the center of this discussion since the consumption of fossil fuels, in particular petroleum diesel, results in the generation of nitrogen oxides (NOx), hydrocarbons and particulate matter, which contribute to the greenhouse effect, deteriorating air quality and thereby putting the health of humankind at risk[1,2]

Summary

Introduction

A hybrid magnetron sputtering process (dcMS/HiPIMS) was developed to manufacture nanostructured CrN/Cr1-xAlxN multilayers, motivated by improving the low-emission efficiency when applied on gas-nitrided diesel piston rings of a next-generation of combustion engines. In order to improve the mechanical, tribological, and corrosion behavior of the multilayers, the hybrid dcMS/HiPIMS process was designed by selecting the optimal sputtering procedure applied to AISI 440 base steel. The results have demonstrated that hybrid magnetron sputtering produces multilayers with a superlattice structure, which outperforms commercial PVD coatings of CrN for diesel piston rings manufactured by cathodic arc evaporation. Lower sulfur content negatively affects the lubricity of combustion residues, demanding novel coatings to minimize wear and fuel consumption while maintaining low friction in adverse working conditions. One of the main objectives of piston rings is to seal the combustion chamber, and as the piston ring is worn out, more oil from the engine will be Mechanical and Metallurgical Engineering, Escuela de Ingeniería, Pontificia Universidad Católica de Chile, Vicuña

Methods

Results

Conclusion