Deposition Of Carbide Research Articles

Effects of zirconium diboride addition on porosity reduction in laser metal deposition of tungsten carbide–cobalt cermet material

Laser metal deposition of tungsten carbide–cobalt (WC-Co) cermet material is a promising means of improving the wear resistance of metal products. However, laser metal deposition of WC-Co has constraints on its practical use because a clad bead of WC-Co often includes numerous gas pores. Earlier studies have found CO gas generation in a molten pool by reaction of carbon and oxygen to be the main cause of gas porosity in a WC-Co clad bead. Preventing the gas reaction is important to obtain clad beads with few pores. The addition of elements with strong affinity for oxygen, such as aluminum, was found to be effective for porosity reduction in a clad bead. However, the addition of highly reactive pure aluminum particles on WC-Co powder presents some difficulties for industrial use. For this study, zirconium diboride (ZrB2), a chemically stable compound, was used as an additive to WC-Co powder. After WC-Co powder with adhered ZrB2 particles was prepared using a wet granulation process, laser metal deposition was conducted. Zirconium stemming from the dissolution of ZrB2 in the molten pool was found to have the effect of trapping oxygen elements as solid zirconium oxides. Consequently, gas generation in the molten pool by the reaction of carbon and oxygen was restrained. Clad beads having few pores and fine microstructures were obtained. Observations of the molten pool behavior taken using a high-speed camera indicated that ZrB2 addition drastically improves process stability compared to processes using conventional WC-Co powder.

Investigation of shaft and segment failure in co-rotating twin-screw extruder

This research is focused on identifying the reasons behind the failure of the shaft and screw segment associated with the ABS plastic material co-rotating twin-screw extruder. These steel parts failed during production and after only 12 days of operation. To understand the failure causes, their chemical composition was examined initially. The results showed that the chemical composition of the analyzed parts meets the design and standard of BS EN 4957 (2018). Subsequently, a detailed study of the fracture cross-section of both pieces was conducted, along with microscopic and mechanical tests, to gather comprehensive information on the failure reasons. The findings indicate that the initiation of the cracks is linked to the presence of coarse carbide deposits, leading to micro-cracks on the surface of the shaft. Under torsional-bending cyclic loading, these cracks expanded as low-cycle fatigue fractures. When the fatigue crack reached its critical extent, rapid and abrupt crack propagation and failure ensued. Furthermore, defects like holes and coarse sediments within the segment also contributed to the conditions conducive to rapid crack growth and failure. In conclusion, to prevent future accidents and issues with comparable equipment, various safety measures and recommendations were introduced.

Exploring the machined surface characteristics of Haynes 25 superalloy: Cost mitigation and quality enhancement perspective

The current study investigates the surface characteristics and machining cost of electrical discharge machining (EDM) of Haynes 25 superalloy using tools made by additively manufactured CuCr1Zr, pure copper and graphite. Before assessing machinability, the workpiece and tool materials were characterized using Energy Dispersive Spectroscopy (EDS), X-ray Diffraction (XRD) and evaluations of tensile strength, micro-hardness, density and thermal conductivity. The effects of current (I), voltage (V), pulse duration (Ton), duty cycle (τ) and flushing pressure (Fp) is analyzed on surface characteristics viz. surface roughness (SR), surface crack density (SCD), recast layer thickness (RCT), heat-affected zone (HAZ), micro-hardness (MH) and machining cost (MC). Post machining XRD analysis revealed the formation of cobalt oxides like (CoO and Co3O4) affecting the micro-hardness of the machined surface. Alongside, a field emission scanning electron microscopy (FESEM) is carried out which confirms, the deposition of metal carbides and oxides on the EDMed surface. Current and pulse-on-time significantly influenced performance, with optimal EDM parameters identified and validated through confirmative experiments, resulting in a mean error of ∼2.84 %. It is seen that the use of additively manufactured CuCr1Zr tools resulted in improved machined surface characteristics and a more cost-effective approach for producing intricate profiles with minimal surface defects.

Chemical Vapor Deposition of Tantalum Carbide in the TaBr5–CCl4–Cd System

The tantalum carbide coatings were deposited on substrates made of 12Kh18N10T steel, ZhC6 alloy, and molybdenum by reduction of TaBr5 and CCl4 vapors with cadmium vapors at temperatures of 950–1000 K. The average deposition rate of coatings on molybdenum was ~5 μm/h, on ZhC6 alloy was ~6 μm/h, and on 12Kh18N10T steel was ~8 μm/h. The coatings were formed as columnar grains on the substrate surface and as a diffuse layer in the substrate material. The surface layers contained mainly tantalum monocarbide TaCy (y = 0.72–0.86) and a small fraction of tantalum. The coatings on the surface of ZhC6 alloy and 12Kh18N10T steel flaked off with increasing thickness, which was due to different thermal expansion of the coating and substrate, as well as concentration inhomogeneity and phase transitions in the substrate material during coating deposition and during the heating and cooling processes.

Growth of stable SiC2N2-Si2CN4 phases during nitrogen incorporated sputter deposition of silicon carbide

The incorporation of nitrogen during sputtering of silicon carbide (SiC) target facilitates formation of different technologically significant phases. The bonding nature in these phases serve as the means of enhancing the hardness and toughness of the overall film getting deposited as shown by nanoindentation tests. Raman spectra gives the carbonaceous point of view based on existing models. A heterogenous crystallization was evident from getting a G-peak doublet. The experimental evidence of theoretically predicted SiC2N2 and Si2CN4 phases as per the phase diagram were found and confirmed by EDAX studies. These stable phases provided enhanced mechanical properties of the coatings

SiC Detector Thickness Optimization for Enhanced Response Variability

Neutron spectroscopy is a crucial point in several nuclear applications. Accurately measuring fast neutron energy distributions in high-flux conditions reveals a significant technology gap, hindering the acquisition of precise energy fluence distributions. This project investigates the potential of machine learning to bridge this gap, focusing on neutron energies from 100 keV to 20 MeV and fluence rates from 1010 n/cm2s to 1012 n/cm2s using solid detectors such as Silicon Carbide (SiC) and Chemical Vapor Deposition (CVD) diamonds. This paper details the simulation design phase of our project, emphasizing the exploration of optimal SiC solid detector thickness to introduce crucial variability for machine learning training.

Oscillating energy deposition of 17-4 PH alloy reinforced with tungsten carbide particles

17-4 PH is a martensitic precipitation-hardening stainless steel, renowned for its exceptional strength and high-temperature resistance, making it extensively employed in the fabrication of aircraft engines and flight control systems. The strengthening method of this alloy involves precipitation strengthening through thermal treatment. However, it is also susceptible to grain growth, which can diminish the alloy's mechanical properties and corrosion resistance. This research proposes to use circular oscillating laser deposition of 17-4 PH alloy reinforced with tungsten carbide (WC) and compares it with Gaussian laser deposition. The research findings indicate that the circular oscillating laser induces a stirring effect on the molten pool, facilitating the transformation of columnar dendrites into equiaxed grains and thereby refining the grain size. The convection, intensified by the high temperature and stirring effect, promotes the melting and diffusion of WC particles. The reaction between W, C elements, and 17-4 PH alloy facilitates the precipitation of hard phase carbides. Compared to Gaussian laser deposition, the microhardness of the 7 wt% WC/17-4 PH material prepared by circular oscillating laser deposition increased by 21.25 %, and the wear rate decreased by 70.06 %. The electrochemical test results have revealed that the 7 wt%WC/17-4 PH composite material fabricated using Gaussian laser exhibits optimal corrosion resistance. The circular oscillating laser induces carbide deposition at grain boundaries, resulting in the formation of microcells and exacerbating the corrosion.

Organomorphic Silicon Carbide Reinforcing Preform Formation Mechanism

Development of the organomorphic ceramic-matrix composites (CMCs), where the reinforcing preform is built using polymer fibers subject essentially to hot pressing, was motivated by a desire to obtain much higher structural uniformity as well as to reduce the number of the process steps involved in the production of CMCs. This paper addresses the peculiarities of the organomorphic silicon carbide preform formation process. Using X-ray phase analysis, tomography, mass and IR spectroscopy, and thermomechanical and X-ray microanalysis, both the properties of the initial fibers of polycarbosilane (PCS)—the silicon carbide fiber precursor—and their transformation in the preform while heated to 1250 °C under constant pressing at 10–100 kPa were studied. Analysis of the data obtained showed the organomorphic SiC preform relative density at a level of 0.3–0.4 to be ensured by self-bonding of the silicon carbide preform, resulting from the fact that during the low-temperature part of pyrolysis, easily polymerizing substances are released leaving a high coke residue, thus cementing the preform. Another possible factor of SiC framework self-bonding is the destruction of the polymer fibers during pyrolysis of various PCS preforms differing in their methylsilane composition (for example, dimethylsilane), where deposition of silicon carbide on the contacting fibers starts as early as at 450–500 °C.

Superhydrophobic self-extinguishing cotton fabrics for electromagnetic interference shielding and human motion detection

• Multifunctional cotton fabric has been prepared via a layer-by-layer method. • Cotton-10BL-Si shows superhydrophobic and self-extinguishing behaviors. • Cotton-10BL-Si has great potential in EMI shielding and motion sensors. • Cotton-10BL-Si shows satisfying washability and durability. Multifunctional intelligent fire-safe cotton fabric promises next-generation fire-fighting uniform and sensor applications. However, cotton fabrics' hygroscopicity and intrinsic flammability significantly impede their potential applications in industries. Herein, we report a superhydrophobic fireproof cotton fabric (PEI-APP-PEI-MXene) generated via sequential layer-by-layer deposition of polyethyleneimine (PEI), ammonium polyphosphate (APP), and titanium carbide (MXene), followed by hydrophobic treatment with silicone elastomer. Compared to untreated cotton, the treated cotton fabric with 10 polymolecular layers exhibits ∼43% and ∼42% reductions in the peak heat release rate and total heat release, respectively, a desired UL-94 V-0 rating, and a high limiting oxygen index (LOI) value of 39.5 vol.%. In addition to that, the treated fabrics displayed improved electromagnetic interference (EMI) shielding and motion-sensing abilities. The presented work provides a facile and effective surface modification approach to generate multifunctional cotton fabrics with promising practical applications.

Модернизация CVD-установки для осаждения карбида хрома на внутренних поверхностях корпуса распылителя форсунки дизельных двигателей

Fuel injector nozzle parts tend to wear out due to abrasive particles of quartz and aluminum oxide penetrating into the fuel. The hardness of quartz abrasive particles exceeds the hardness of work surfaces in 1.4 times, and that of aluminum oxide – in 2.7 times. Strengthening one part of the fuel injector nozzle does not increase the service life sufficiently, so it is necessary to harden both parts of the precision pair. The CVD method is the most promising technology of wear-resistant coating deposition on steel machine parts. It produces carbide-chrome coating with microhardness up to 19 GPa (in vacuum conditions of 100 to 0.001 Pa) at temperatures above 200°C. The analysis of available devices and the review of patents of known solutions on the coating deposition from a steam phase have shown the impossibility of using these devices for restoration of the nozzle body. In this respect, the author developed a new reactor design and a scheme of the CVD unit for the coating deposition on the inner hard-to-reach surfaces of the nozzle body. The developed CVD unit takes into account the factors affecting chromium carbide deposition: thermodynamic conditions, reagent feed, deposition duration, unit parameters, adhesion and coating properties. The CVD unit upgrade results in making chromium carbide coating on the inner surfaces of the nozzle sprayer body, achieving thermodynamic equilibrium of chemical reaction of chromium hexacarbonyl decomposition at temperatures below 200°C (below the low tempering level of 18Х2Н4ВА, 12Х2Н4А and 40ХН2МА steel), and ensuring a controlled supply of a reaction medium to hard-to-reach areas, where refractory metal coatings are formed.

Conformal chemical vapor deposition of boron-rich boron carbide thin films from triethylboron

We report conformal chemical vapor deposition (CVD) of boron carbide (BxC) thin films on silicon substrates with 8:1 aspect-ratio morphologies, using triethylboron [B(C2H5)3] as a single source CVD precursor. Step coverage (SC) calculated from the cross-sectional scanning electron microscopy measurements shows that films deposited at ≤450 °C were highly conformal (SC = 1). We attribute this to the low reaction probability at low substrate temperatures enabling more gas phase diffusion into the features. The chemical state of the material, determined by x-ray photoelectron spectroscopy, shows as a carbide with B–B, B–C, C–B, and C–C chemical bonds. Quantitative analysis by time-of-flight elastic recoil detection analysis reveals that films deposited at 450 °C are boron-rich with around 82.5 at. % B, 15.6 at. % C, 1.3 at. % O, and 0.6 at. % H, i.e., about B5C. The film density as measured by x-ray reflectometry varies from 1.9 to 2.28 g/cm3 depending on deposition temperature.

The effect of heat treatment on oxygen content and microstructure of near-surface areas of titanium hydride coated with tungsten carbide

The article proposes a method of magnetron vacuum deposition of tungsten carbide coatings on spherical hydride granules. The article also illustrates the features of the microstructure and the uniformity of the resulting coating. The effect of heat treatment on the oxygen content in the near-surface areas of titanium hydride coated with tungsten carbide is investigated. The features of the coating structure were studied using by scanning electron microscopy (SEM) with a built-in energy dispersion spectrometer. Comparative data on thermal oxidation of uncoated spherical granules and granules coated with tungsten carbide are presented.

Conformal and superconformal chemical vapor deposition of silicon carbide coatings

The approaches to conformal and superconformal deposition developed by Abelson and Girolami for a low-temperature, low-pressure chemical vapor deposition (CVD) setting relevant for electronic materials in micrometer or submicrometer scale vias and trenches, are tested here in a high-temperature, moderate pressure CVD setting relevant for hard coatings in millimeter-scale trenches. Conformal and superconformal deposition of polycrystalline silicon carbide (SiC) can be accomplished at deposition temperatures between 950 and 1000 °C with precursor partial pressure higher than 20 Pa and an optional minor addition of HCl as a growth inhibitor. The conformal deposition at low temperatures is ascribed to slower kinetics of the precursor consumption along the trench depth, whereas the impact of high precursor partial pressure and addition of inhibitor is attributable to surface site blocking. With the slower kinetics and the site blocking from precursor saturation leading the growth to nearly conformal and the possibly preferential inhibition effect near the opening than at the depth, a superconformal SiC coating with 2.6 times higher thickness at the bottom compared to the top of a 1 mm trench was achieved.

Leveraging computational thermodynamics to guide SiC-ZrC chemical vapor deposition process development

Using the CALPHAD approach to understand zirconium carbide deposition, a series of phase equilibria were calculated from a custom thermodynamic database based on a literature source, and the equilibria were used to explore the potential chemical vapor deposition (CVD) processing space in the ZrCl4-CH3SiCl3-CH4-H2 system as a function of pressure, temperature, and gas composition. Several gas ratios were considered. At a given ZrCl4:CH3SiCl3 ratio within the range studied, the most important factor was found to be the ratios of CH4:ZrCl4, wherein the nature of the composition – carbide vs. silicide – could be controlled. A pure binary composition of ZrC and SiC is expected to form by increasing the initial amount of methane and decreasing the amount of hydrogen from values predicted purely based on thermodynamic equilibrium. Rietveld analysis of the x-ray diffractograms from corresponding experimental depositions confirmed that increasing the CH4:ZrCl4 ratio increased the fraction of carbon-containing species (SiC, ZrC) and decreased the fraction of non-carbides (ZrSi, ZrSi2, etc.), as predicted from the CALPHAD results.

Promoted MoxCy‐based Catalysts for the CO2 Oxidative Dehydrogenation of Ethane

AbstractThe CO2 oxidative dehydrogenation reaction has the potential to play a role in the advancement of CO2‐utilizing catalytic reactions, co‐activating CO2 and short‐chained alkanes. Transition metal carbides are promising catalysts for this reaction, in particular MoxCy, however catalytic stability is a major challenge. In this study, the addition of a promoter (Fe, K, Ni or Pt) has shown to significantly influence the crystal structure of the carbide system as well as the acid‐base characteristics. K promotion decreased the number of acid sites, limiting ethane activation and the removal of the oxygen surface species formed in CO2 activation. The catalysts deactivate due to oxidation to MoOx. Fe decreased the initial activity, but it increased the stability of the oxygen surface species, which enhanced the stability of the catalyst and ethylene selectivity to outperform the unpromoted sample. Oxidation of the carbide and carbon deposition during the reaction could not be prevented. Ni promotion increases the number of basic sites, enhancing the CO2 activation, shown by the highest activity obtained during the reverse water‐gas‐shift experiments. At higher CO2 content in the feed the dry‐reforming reaction becomes the dominant reaction pathway. Pt suppressed the dry‐reforming reaction, but instead increased the direct dehydrogenation activity, accompanied by a high degree of carbon deposition. No oxidation to MoOx was observed at a stoichiometric CO2 to C2H6 feed ratio.

Effects of tool coating and tool wear on the surface quality and flexural strength of slotted CFRP

Machining of carbon fibre reinforced polymer (CFRP) is abrasive and causes significant tool wear. The effect of tool wear on static flexural strength is investigated, using edge trimming with uncoated carbide and chemical vapour deposition (CVD) diamond coated burr style tools. Edge rounding (ER) criteria along with flank wear are used to observe tool degradation with ER shown to preferentially wear allowing the tool to become cyclically sharper and duller, corresponding to fluctuating dynamometer readings, a novelty for CFRP machining. Areal surface metrics degraded for an uncoated tool due to changes in cutting mechanism, whilst for up to 16.2 m of linear traverse, the coated tool showed limited changes. Tool wear, caused by edge trimming 7.2 m of CFRP, using an uncoated carbide tool, provided a flexural strength reduction of up to 10.5 %, directly linking tool wear to reduced mechanical strength.

Machining of Zircaloy-2 using progressive tool design in EDM

ABSTRACT Zircaloy-2 is used in nuclear and biomedical industries therefore required high accuracy and precision, and achieved by application of electrical discharge machine (EDM). In this study, a new horizon of tool design is investigated for improvement in the performance of EDM. To measure the effect of tool design, Zircaloy-2 is machined with EDM using progressive Cu tool and measured the response parameters (MRR, TWR, radial overcut (Roc ), radial undercut (Ruc ), taper angle (Φ), and surface roughness). The progressive tool with varying design parameters of rake angle (0°, 45°, and 60°), flat land (2 mm), trunk diameters (10, 8, and 6 mm), and relief angle (0°, 45°, and 60°) are used to perform rough and finish machining in single EDM operation. MRR and SR are increased with increase in rake angle due to reduction in oxide and carbide deposition on the machined surface. Best combination for maximum MRR (1.131 × 10−3 mm3/min), minimum SR (4.313 µm), and minimum taper angle (2.17°) is obtained when machining is performed using T7. Multiresponse optimization (R-method) gives highest rank to progressive tool T7. Tool design improved TWR and significant reduction in radial overcut over conventional tool.

Oil-in-water emulsion separation: Fouling of alumina membranes with and without a silicon carbide deposition in constant flux filtration mode

Ceramic membranes have drawn increasing attention in oily wastewater treatment as an alternative to their traditional polymeric counterparts, yet persistent membrane fouling is still one of the largest challenges. Particularly, little is known about ceramic membrane fouling by oil-in-water (O/W) emulsions in constant flux filtration modes. In this study, the effects of emulsion chemistry (surfactant concentration, pH, salinity and Ca2+) and operation parameters (permeate flux and filtration time) were comparatively evaluated for alumina and silicon carbide (SiC) deposited ceramic membranes, with different physicochemical surface properties. The original membranes were made of 100% alumina, while the same membranes were also deposited with a SiC layer to change the surface charge and hydrophilicity. The SiC-deposited membrane showed a lower reversible and irreversible fouling when permeate flux was below 110 L m−2 h−1. In addition, it exhibited a higher permeance recovery after physical and chemical cleaning, as compared to the alumina membranes. Increasing sodium dodecyl sulfate (SDS) concentration in the feed decreased the fouling of both membranes, but to a higher extent in the alumina membranes. The fouling of both membranes could be reduced with increasing the pH of the emulsion due to the enhanced electrostatic repulsion between oil droplets and membrane surface. Because of the screening of surface charge in a high salinity solution (100 mM NaCl), only a small difference in irreversible fouling was observed for alumina and SiC-deposited membranes under these conditions. The presence of Ca2+ in the emulsion led to high irreversible fouling of both membranes, because of the compression of diffusion double layer and the interactions between Ca2+ and SDS. The low fouling tendency and/or high cleaning efficiency of the SiC-deposited membranes indicated their potential for oily wastewater treatment.

Experimental and Numerical Study on Friction and Wear Performance of Hot Extrusion Die Materials.

For the aluminium alloys produced by the hot extrusion process, the profile is shaped according to the bearing at the exit of the extrusion die. The tribological process has significant effects on the die service life, profile dimensional tolerances, and profile surface finish. Recently, new technologies have been introduced to the hot extrusion die, such as cemented carbide insert die and surface coating. However, under hot extrusion working conditions, quantitative studies on their friction and wear performances are lacking. In this work, the friction and wear performances of three typical extrusion die materials, traditional hot tool steel (H13), cemented carbide (YG8), and chemical vapour deposition (CVD) coating, were studied. Macro and nano hardness tests, Pin-on-disk friction and wear tests, optical profiler and SEM observations, and experiments and simulations of hot extrusion were conducted. The results show that the coefficients of friction of CVD coatings and H13 hot work tool steel specimens were smaller under the hot extrusion condition than at room temperature. The wear mechanisms of H13, YG8, and CVD coatings at 500 °C are adhesion, abrasive, and fatigue, respectively. Moreover, the tribology results were validated by the extrusion experiments and the finite element analysis of hot extrusion. The conclusion of this manuscript is useful not only for the numerical simulation of the hot extrusion process but also for the surface finishing of the extrusion profile.

Gas‐phase kinetic of boron carbide chemical vapor deposition using BCl3+CH4+H2 mixture

AbstractA detailed chemical kinetic mechanism consisting of 472 reactions and 61 species for the gas‐phase thermal decomposition of BCl3+CH4+H2 mixtures is used to model the chemical vapor deposition (CVD) of boron carbide. The mechanism is constructed using a reaction mechanism generator (RMG), which is automatic and requires no or less human intervention. New functionality, considerable thermodynamic and kinetic data have been added to RMG to account for boron chemistry. The model considers all necessary reactions in the reaction pathways and reasonably predicts the experimental data available from the literature. The sensitivity analysis identifies crucial species responsible for boron carbide formation. Besides, a reduced mechanism (15 species and 26 reactions) is derived from a detailed mechanism, which could be used to expedite an effective CVD reactor design through numerical simulations. The performance of the reduced model is also evaluated concerning the complete mechanism, which shows that the reduced model can predict the reactor behavior reasonably well.