Pulsed-laser deposition of particulate-free TiC coatings for tribological applications

Abstract

Hybrid bearings comprising ceramic or ceramic-coated steel balls and steel raceways can provide good fatigue life and resistance to wear. One of the coating materials that has received serious consideration in hybrid systems is titanium carbide (TiC). At present, the commercially available process for the deposition of TiC involves the heating of steel substrates to fairly high temperatures (>900 °C). The high-temperature process involves considerable costs and complexities that are associated with the post-deposition heat treatment and repolishing of the coated steels for bearing applications. Pulsed-laser deposition (PLD) is ideally suited to deposit TiC coatings on bearing steels at room temperature. However, it is well known that codeposition of particulates has been one of the most challenging problems of PLD. This is especially of concern when dealing with hard coatings for tribological applications. Here we describe a novel and extremely simple method of depositing high-quality, particulate-free TiC coatings on bearing steel surfaces that uses PLD. The method relies on a new non-line-of-sight deposition that uses a permanent magnet and prevents particulates from arriving at the substrate. The surface roughness of TiC films deposited on steels by way of this technique has an extremely low root mean square value of 1.6 nm. The TiC films have been extensively characterized for their morphology, chemical composition, and mechanical properties with scanning electron and atomic force microscopy, X-ray diffraction, transmission electron microscopy, X-ray photoelectron spectroscopy, and nanoindentation. Time-resolved emission has been used for the in situ characterization of the laser-ablated TiC plume and has resulted in the identification of various plume species as a function of laser parameters. The spectroscopic results are correlated to film growth and to our modified PLD method.