Cathodic Arc Evaporation Method Research Articles

The effect of roughness and top layer in solid particle impingement erosion of multilayer nanostructured nitride PVD coatings

The effect of the surface roughness of the coating and the composition of the upper layer on the solid particle erosion of multilayer nanostructured coatings applied via cathodic arc evaporation (CAEPVD) method was investigated. CrN/TiN nanostructured multilayer coating (TiN as the upper layer) and TiN/CrN nanostructured multilayer coating (CrN as the upper layer) were applied on 410 stainless steel through the CAEPVD method with the following architecture. 1) a bottom layer of Cr and CrN deposited on the substrate, 2) nanolayers of TiN and CrN deposited on the bottom layer alternately and 3) an upper layer of CrN or TiN deposited on the nanolayers. After applying the coating, half of the samples were polished to obtain smooth surfaces, while the other half remained unpolished, resulting in rough surfaces. Surface morphology, phases identification, adhesion, mechanical, and erosion behavior of the coatings were characterized using SEM, XRD, Rockwell adhesion measurements, nanoindentation test, and solid particle impingement, respectively. The nano-scale indentation results demonstrated that the hardness, Young's modulus, H/E, and H3/E2 of the CrN/TiN coating were 5.57, 1.42, 3.86, and 85.39 times larger than those of the substrate. For the TiN/CrN coating, the values were 4.04, 1.13, 3.53 and 51.68 times greater than those of the substrate. The results of the erosion test showed that the erosion mass loss for the CrN/TiN and TiN/CrN coatings decreased up to 73% and 67%, respectively. Additionally, surface smoothing improved erosion resistance by 40% for both coatings. This shows that the smoothed CrN/TiN nanostructured multilayer coating is an excellent candidate for increasing the erosion resistance due to the higher ratios of H/E and H3/E2 and smoother surface.

Dry machining characteristics of coated inserts and multi response optimization through DEAR‐Taguchi method

AbstractThe primary intent of the proposed research work is to investigate the effectiveness of the titanium aluminium nitride/tungsten carbide‐carbide coated insert during dry turning structural stainless steel. The aim of the study is to simultaneously optimise machining variables like spindle speed, depth of cut and feed for several responses like flank wear, material removal rate and surface roughness. Titanium aluminium nitride/tungsten carbide‐carbide is coated on the surface of carbide tool by cathodic arc evaporation method. The characterization studies have been conducted to ensure the existence of coating material. Micro hardness of coated and pure inserts was tested, which confirms that titanium aluminium nitride/tungsten carbide‐carbide coated insert possesses 17.43 % augmented hardness over pure inserts. The machining was performed by adopting Taguchi experimental design. A multi‐response optimization approach was applied in this study that included ranking methodology based on data development analysis and Taguchi's design. The performance index for multiple responses was measured and mathematically analysed for their effect on processing parameters. The combination of parameter such as spindle speed: 2000 min−1; cutting depth: 0.45 mm and feed rate: 0.16 mm rev−1 was experimental as optimal machining parameters.

THE PROCEDURE OF SELECTING THE VALUES OF THE WORK CONDITION PARAMETERS OF THE BALL-CRATERING METHOD FOR THE ASSESSMENT OF RESISTANCE TO ABRASIVE WEAR

In the example of the CrN coating deposited by the cathodic arc evaporation (CAE) method on two differently prepared substrates, the procedure for selecting the values of the work condition parameters of the ballcratering method was presented. The procedure was developed thanks to applying an individual experiment design from Taguchi's approach and has not been used to determine the values of the parameters of the operating conditions of the test friction node for tribological tests. The procedure, according to Taguchi, allowed us to determine the values of the parameters for assessing the abrasion resistance of anti-wear coatings, with the use of a much smaller number of tests, compared to the methods used so far and a repetitive wear mechanism. The starting point of the presented procedure was selecting the area of the permissible values of the operating parameters, in the ball-cratering method, in which optimal values were searched for to minimise the relative error in determining the diameters of wear marks craters. After determining the area of limit values, an experiment plan was generated in which the variables were: load, rotational speed, minimum friction path, and maximum friction path. The results of abrasive wear tests performed with the ball-cratering method, in accordance with the developed test procedure for the CrN coating – were deposited on the substrate after heat treatment and the substrate after the nitriding process had been successfully verified.

EFFECT OF NITROGEN PRESSURE ON THE STRUCTURAL AND MECHANICAL PROPERTIES OF V-Mo-N COATINGS DEPOSITED BY CATHODIC ARC EVAPORATION

The coatings of the V-Mo-N system were deposited by the cathodic arc evaporation method from the unfiltered plasma of two V and Mo cathodes. Electron microscopy, energy dispersive analysis, X-ray diffractometry, nanoindentation, and adhesion testing have been used to study the effect of nitrogen pressure during deposition on surface morphology, composition, structure, and mechanical properties of coatings. It was found that at a nitrogen pressure of 1 Pa the V29Mo21N50 coating formed with a predominantly cubic c-(V,Mo)N structure and an insignificant fraction of hexagonal h-(Mo,V)N. With an increase in the pressure of the reaction gas to 2…3 Pa, a gradual increase in the concentration of nitrogen up to 54 at.% and molybdenum up to 26 at.% is observed, which leads to a slight increase in the hexagonal phase concentration. All coatings are characterized by a fairly good surface quality, high hardness of 30…32 GPa and adhesion to the steel substrate. The c-(V,Mo)N coating has better resistance to crack propagation, correlates with a maximum H3/E2 – 0.18, and combines high hardness and ductility.

Tailoring the scratch adhesion strength and wear performance of TiNiN nanocomposite coatings by optimising substrate bias voltage during cathodic arc evaporation

The tribological properties of TiN-based coatings can be substantially influenced by the choice of substrate bias employed during physical vapor deposition. However, the effects of applied substrate bias voltages during cathodic arc evaporation on to the scratch adhesion strength and wear resistance of TiNiN coatings have not been previously studied. In this present work, a series of TiNiN coatings were fabricated onto tool steel (M2) substrates using the cathodic arc evaporation method by applying a range of bias voltages to the substrate. The aim of this study is to investigate the scratch response and wear performance of these coatings along with an investigation of the deformation mechanisms in operation during scratch and wear tests. The best scratch adhesion strength (i.e., greater LC1, LC2 and CPRs values) was noted for the coating prepared at a bias voltage of −100 V, which was ascribed to the synergistic responses arising from superior mechanical properties, the influence of a high compressive residual stress and a fine, equiaxed nanocomposite structure, that acted to promote effective resistance against cohesive and adhesive failure. Further, the failure mechanisms under progressive loading conditions were also investigated through observation of the complex crack patterns generated, compressive residual stress values and the coatings' hierarchical design. An approximately 85 % enhancement in wear resistance for these TiNiN coatings was achieved as the bias voltage was increased from 0 V to −100 V. This −100 V coating exhibited the highest values of H/Er (>0.1) and We (>60 %), as well as the highest Ni concentration (~ 4 at.%).

Comparative analysis of cavitation erosion of Cr-C carbide coatings depending on the carbon content

The aim of the study was to conduct a comparative analysis of the cavitation erosion resistance of thick (up to 20 μm) Cr-C coatings by means of the rotating-disk testing method. An experimental study was carried out of the process of cavitation destruction of Cr18Ni10Ti stainless steel samples with Cr-C thick coatings depending on the carbon concentration in the coating. Nanocrystalline thick coatings of Cr-C were deposited by using the cathodic arc evaporation (Arc PVD) method. The results showed that the erosion rate of the coated samples was more than four times less than that of the uncoated sample. The Cr-C samples coated with 28.8 at % carbon content demonstrated less surface damage compared to the other coated samples and the reference samples.

Detection and Analysis of Corrosion and Contact Resistance Faults of TiN and CrN Coatings on 410 Stainless Steel as Bipolar Plates in PEM Fuel Cells.

Bipolar Plates (BPPs) are the most crucial component of the Polymer Electrolyte Membrane (PEM) fuel cell system. To improve fuel cell stack performance and lifetime, corrosion resistance and Interfacial Contact Resistance (ICR) enhancement are two essential factors for metallic BPPs. One of the most effective methods to achieve this purpose is adding a thin solid film of conductive coating on the surfaces of these plates. In the present study, 410 Stainless Steel (SS) was selected as a metallic bipolar plate. The coating process was performed using titanium nitride and chromium nitride by the Cathodic Arc Evaporation (CAE) method. The main focus of this study was to select the best coating among CrN and TiN on the proposed alloy as a substrate of PEM fuel cells through the comparison technique with simultaneous consideration of corrosion resistance and ICR value. After verifying the TiN and CrN coating compound, the electrochemical assessment was conducted by the potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS) tests. The results of PDP show that all coated samples have an increase in the polarization resistance () values (ranging from 410.2 to 690.6 ) compared to substrate 410 SS (230.1). Corrosion rate values for bare 410 SS, CrN, and TiN coatings were measured as 0.096, 0.032, and 0.060 , respectively. Facilities for X-ray Diffraction (XRD), Scanning Electron Microscope (FE-SEM, TeScan-Mira III model and made in the Czech Republic), and Energy Dispersive X-ray Spectroscopy (EDXS) were utilized to perform phase, corrosion behavior, and microstructure analysis. Furthermore, ICR tests were performed on both coated and uncoated specimens. However, the ICR of the coated samples increased slightly compared to uncoated samples. Finally, according to corrosion performance results and ICR values, it can be concluded that the CrN layer is a suitable choice for deposition on 410 SS with the aim of being used in a BPP fuel cell system.

Effect of a Gas Medium on the Mechanical, Tribological, and Anticorrosion Properties of Cr–Ni–Al–C–N Coatings Deposited by the Pulsed Cathodic Arc Evaporation Method

Effect of a Gas Medium on the Mechanical, Tribological, and Anticorrosion Properties of Cr–Ni–Al–C–N Coatings Deposited by the Pulsed Cathodic Arc Evaporation Method

STRUCTURE AND PROPERTIES OF FeCr, CrAl AND FeCrAl COATINGS DEPOSITED BY CATHODIC ARC EVAPORATION

Protective coatings with different compositions of Fe, Cr, and Al were deposited by cathodic arc evaporation method on fragments of Zr1Nb alloy fuel claddings. The influence of the composition and structural state of the developed coatings on their physical and mechanical properties (microhardness, resistance to corrosion and cavitation and abrasive wear) has been studied. It is shown that the optimal combination of mechanical properties and high resistance to oxidation from a series of studied coatings FeCr, FeCrAl, and CrAl have coatings of the FeCrAl system with a concentration of Cr ~ 22 at.% and Al ~ 14.3 at.%. It was found that protective coatings such as FeCr, FeCrAl, and CrAl with a thickness of ~ 12 μm significantly increase the resistance to oxidation and prevent the destruction of fuel claddings under oxidation in air at a temperature of 1150 °C for 1 h.

Irradiation resistance of chromium coatings for ATFC in the temperature range 300–550°C

Within the accident tolerant fuel cladding (ATFC) concept, chromium coatings appear to be promising for protecting zirconium alloys from high temperature oxidation. The effects of high energy heavy ion irradiation in the temperature range of 300–550°C on the structure of chromium coatings deposited on Zr-based (E110) alloy substrate by the cathodic arc evaporation method were studied. Isotropic growth of the grain size in chromium coatings from the initial 250 nm to 476 nm at 550°C is caused by irradiation with 1.4 MeV argon ions to the dose of 25 displacements per atom (dpa). Maximum swelling up to 1.6 % was observed under the irradiation temperature of 500°C.

Wear Resistance of (Ti,Al)N Metallic Coatings for Extremal Working Conditions

The article includes research results for the functional properties achieved for a wide range of sintered tool materials, including sintered carbides, cermets and three types of Al2O3 oxide tool ceramics ((Al2O3 + ZrO2, Al2O3 + TiC and Al2O3 + SiC(w)) with (Ti,Al)N coating deposited in the cathodic arc evaporation (CAE-PVD) method and comparison with uncoated tool materials. For all coated samples, a uniform wear pattern on tool shank was observed during metallographic analysis. Based on the scanning electron microscope (SEM) metallographic analysis, it was found that the most common types of tribological defects identified in tested materials are: mechanical defects and abrasive wear of the tool side, crater formation on the tool face, cracks on the tool side, chipping on the cutting edge and built-up edge from chip fragments. Deposition of (Ti,Al)N coating on all tested substrates increases the wear resistance and also limits the exceeding of critical levels of permanent stresses. It even increases the tool life many times over. Such a significant increase in tool life results, among other things, from a large increase in microhardness of PVD coated materials compared to uncoated samples, increased resistance to thermal and chemical abrasion, improved chip formation and removal process conditions. Use of hard coatings applied to sintered tool materials is considered to be one of the most important achievements in improving the functional properties of cutting tools and can still be developed by improving the coating structure solutions (sorted and nanocrystalline structures) and extending the range of coating applications (Ti,Al)N in a variety of substrates.

In Vitro Corrosion and Tribocorrosion Performance of Biocompatible Carbide Coatings

The present study aims to explain the corrosion and the tribocorrosion performance in simulated conditions of the human body by the level of stress, adhesion of coating to substrate, roughness, and hardness. The coatings were synthesized by the cathodic arc evaporation method on 316L stainless steel substrates to be used for load bearing implants. Structure, elemental, and phase compositions were studied by means of energy dispersive spectrometry and X-ray diffraction, respectively. The grain size and strain of the coatings were determined by the Williamson–Hall plot method. Tests on hardness, adhesion, roughness, and electrochemical behavior in 0.9% NaCl solution at 37 ± 0.5 °C were carried out. Tribocorrosion performances, evaluated by measuring the friction coefficient and wear rate, were conducted in 0.9% NaCl solution using the pin on disc method at 37 ± 0.5 °C. TiC and ZrC exhibited a (111) preferred orientation, while TiNbC had a (200) orientation and the smallest crystallite size (8.1 nm). TiC was rougher than ZrC and TiNbC; the lowest roughness was found for TiNbC coatings. The highest hardness and adhesion values were found for TiNbC, followed by TiC and the ZrC. All coatings improved the corrosion resistance of 316L steels, but TiNbC showed the best corrosion behavior. TiNbC had the lowest friction coefficient (1.6) and wear rate (0.99 × 10−5 mm3·N−1∙m−1) values, indicating the best tribocorrosive performance in 0.9% NaCl at 37 ± 0.5 °C.

Nanoscale Multi-Layer Thin Film Fabricated by Cathodic Arc Evaporation (CAE) Method

In the present study, TiN and CrN single-layer and TiN/CrN nanoscale multi-layer thin films have been deposited on 420C stainless steel (SS) substrate using a cathodic arc evaporation (CAE) method. The nanoindentation test showed that hardness of TiN/CrN nanoscale multi-layer thin film was 30 GPa that is harder than TiN (HTiN = 23 GPa) and CrN (HCrN = 19 GPa). Ball-on-disk tribometer and Rockwell-C indentation methods showed respectively better sliding wear performance for TiN/CrN nanoscale multi-layer coating and better adhesion strength for CrN single-layer coating in comparison to all samples. Finally it was found that the TiN/CrN nanoscale multi-layer thin film can be used for tribological applications on 420C SS where high hardness and wear resistance and low friction coefficients are essential.

Corrosion Behavior of TiN/CrN Nanoscale Multi-layered Coating in Ringer's Solution

In this article, corrosion behavior of the single-layered TiN, single-layered CrN and multi-layered TiN/CrN coatings have been fabricated on 420C stainless steel (SS) by Cathodic Arc Evaporation (CAE) method in Ringer's solution was studied. The electrochemical appraisal was done by the Potentiodynamic Polarization (PDP) and Electrochemical Impedance Spectroscopy (EIS) tests. Results of PDP test revealed that all coated specimens have an increment in the polarization resistance (Rp) values (ranges from 438.2 to 593.6Ω.cm2) compared to bare SS (268.1Ω.cm2). Corrosion rate values for bare 420C SS and CrN, TiN and multi-layered TiN/CrN coatings were measured 0.086, 0.042, 0.050 and 0.068mpy, respectively. Furthermore, EIS results were showed that the single-layer CrN coating well depicted by an equivalent circuit with three time constants and has larger impedance and maximum logarithmic variation of C2. Finally, the corrosion performance results confirmed that single-layered CrN coating is an appropriate choice for deposition on 420C SS with the aim of application in general surgical instruments.

Improving wear and corrosion resistance of AISI 304 stainless steel by a multilayered nanocomposite Ti/TiN/TiSiN coating

In this paper, to simultaneously enhance the wear and corrosion resistance of AISI 304 stainless steel, a multi-layer nanocomposite Ti/TiN/TiSiN coating is deposited on this alloy utilizing cathodic arc evaporation method. The results show that the deposited coating has a multi-layered structure including layers of Ti, TiN and TiSiN with the thicknesses of 0.71, 1.84 and 0.68 μm, respectively. The coating has a nanocomposite-type microstructure consisting of TiN nanocrystallines with size of 5.6 nm embedded in an amorphous matrix of SiNx. The graded architecture of Ti/TiN/TiSiN coating, as well as the plasma nitridation of the substrate, contribute to improving the adhesion strength of the deposited layer. The deposition of Ti/TiN/TiSiN layer on AISI 304 stainless steel decreases its coefficient of friction from about 0.5 to 0.1 and remarkably increases wear resistance against Al2O3 ball about 18.7 times which is directly related to the high hardness of the coating (~3700 HV0.01). The electrochemical investigations in an aerated 3.5 wt.% NaCl aqueous solution reveal that the deposition of Ti/TiN/TiSiN coating on AISI 304 stainless steel increases its corrosion resistance by blocking the penetration of corrosive species and preventing the exposure of the substrate to these destructive agents.

Microstructure, Properties, and Titanium Cutting Performance of AlTiN–Cu and AlTiN–Ni Coatings

In this study, three kinds of coatings, AlTiN, AlTiN–Ni, and AlTiN–Cu were deposited via the cathodic arc evaporation method. The microstructure, mechanical properties, oxidation resistance, and cutting behavior of these coatings were then investigated. The incorporation of Cu(Ni) into AlTiN eliminated its columnar structure and led to an increase in the growth defects of its macroparticles. The addition of Cu and Ni decreased the hardness of the coatings, their elastic moduli, and their friction coefficients. All of the AlTiN, AlTiN–Ni, and AlTiN–Cu coatings presented sufficient adhesion strength values. The oxidation resistance of these three coatings was determined to be in the following order: AlTiN > AlTiN–Ni > AlTiN–Cu. Titanium turning experiments indicated that the cutting force was reduced and the tool life was improved through doping with Cu(Ni) elements, dependent on cutting speed. The AlTiN–Ni coating showed the best performance at a high cutting speed, whereas the AlTiN–Cu coating was more successful at a lower cutting speed.

THE EFFECT OF TiN, TiAlN, CrAlN, AND TiAlN/TiSiN COATINGS ON THE WEAR PROPERTIES OF AISI H13 STEEL AT ROOM TEMPERATURE

TiN, TiAlN, CrAlN and TiAlN/TiSiN films were deposited on AISI H13 hot work steel substrate by cathodic arc evaporation method. Each coating was optimized in laboratory conditions and the highest hardness and wear resistance coatings were taken into consideration for this study. Morphological properties, chemical compositions, crystallographic structure, nano hardness and adhesion strength of coatings were analyzed with SEM, AFM, EDS, XRD, nano indentation and scratch resistance tester. Wear experiments were performed using ball-on-disk tribometer against Al2O3 ball of 6[Formula: see text]mm diameter and wear volume of coatings were measured using optical profilometer. Wear experimental results revealed that all coated samples showed higher wear resistance and hardness than uncoated AISI H13 steel substrate. The highest wear and scratch resistances as well as nano hardness were attained for CrAlN coating. TiAlN coating has the lowest scratch resistance and wear resistance. Adhesive wear mechanism was the dominant wear mechanism for CrAlN coatings which is the highest wear resistant coating. Abrasive wear mechanism was the dominant wear mechanism for TiAlN coatings which is the lowest wear resistant coating.

Self-Cleaning Properties of TiN/CrN Nanoscale Multi-layer Deposited on Surgical 420C Stainless Steel

The present paper focuses on the investigation of self-cleaning properties based on studding of water repellency and blood repellency for TiN- and CrN single-layer and TiN/CrN nanoscale multi-layer coatings deposited via Cathodic Arc Evaporation (CAE) method on medical grade 420C stainless steel substrate. X-ray diffraction (XRD) method and Field Emission Scanning Electron Microscope (FESEM) was used to characterize microstructure. Surface roughness parameters were measured by using Taylor-Habsson method. Blood contact angle and water contact angle measurements test were applied to characterize the self-cleaning properties of the specimens. The analysis of sample data shows that coated specimens have more water contact angle values in comparison to bare steel. Among the coated samples, CrN single-layer has the highest water contact angle (80°) due to its lower surface roughness (Ra=0.189µm) among the other samples. Moreover, the findings of the paper prove that samples had inverse behavior against blood and water in the contact angle measurement test. Bare steel has higher blood contact angle (76.1°) and more blood repellency than the coated specimens. It seems that the different behavior of samples against water and blood in contact angle tests is due to the nature of two fluids. TiN/CrN multi-layer coating results had minor differences in water and blood contact angle tests (67.3° and 62.2° respectively).

Tribological properties of different types of coating materials deposited by cathodic arc-evaporation method on Ni-Cr dental alloy

Wear can be regarded as one of the most essential factors in determining as well as controlling the long-term clinical performance of a metallic biomaterial, also nano-indentation is one of the most precise ways of comparing and determining the mechanical properties of restorative materials. This paper is simply considered as a report of how the tribological wear properties and nano-indention of uncoated and coated nickel chromium dental alloy are examined. Tests were undertaken in the study on the following coating materials: TiN/CrN multilayer, and TiN, CrN monolayer. The tribological tests were performed in artificial saliva so that wear factor and the friction coefficient can be determined. After that, scanning electron microscope (SEM) can help ascertaining the traces of wear. The results show that wear rate and friction coefficient of coated samples (TiN, CrN, and TiN/CrN) were lower than those of uncoated dental alloy (0.448, 0.339, 0.43, and 0.705) respectively, while hardness values for TiN-monolayer (25.378 GPa), CrN-monolayer (22.138 GPa), and TiN/CrN-multilayer (28.54 GPa) of coated samples were higher than those of uncoated dental alloy (4.24 GPa) respectively.

Al-Mn based coatings deposited by cathodic arc evaporation for corrosion protection of AISI 4140 alloy steel

Aluminum alloy coatings were deposited on AISI 4140 steel substrates by cathodic arc evaporation method using the following cathodes: Al0.9Mn0.1, Al0.8Mn0.2, Al0.5Mn0.5, Al0.8Mn0.1Si0.1 and Al0.7Mn0.2Si0.1. Evaluation of corrosion resistance of the substrate-coating systems was performed in 3 wt% NaCl solution by means of potentiodynamic polarization tests. Based on the polarization curves, the parameters such as corrosion potentials, corrosion current densities and corrosion rates, breakdown potentials and protection potentials were determined. Furthermore, the samples were characterized, before and after electrochemical measurements, by scanning electron microscopy and energy dispersive X-ray spectroscopy. The polarization tests have revealed that all deposited coatings constitute the cathodic protection for the AISI 4140 steel substrate. Susceptibility of the substrate-coating systems to pitting corrosion and rates of anodic reactions are resultants of three factors i.e. manganese content, silicon presence and surface morphology of the coatings. It has been found that the coating obtained from Al0.8Mn0.1Si0.1 alloy exhibits the best protective properties in relation to the AISI 4140 steel substrate in the corrosive environment used. This substrate-coating system is characterized by the lowest value of the corrosion rate, stable passive range, the highest value of the breakdown potential and high ability to pits repassivation. The system has also lasted 1000 h of the aerated salt test (5 wt% NaCl) without apparent red rust spots at the sample surface. This result confirms the excellent anticorrosive properties of the coating in relation to the AISI 4140 alloy steel and the possibility of the coating practical application in the chloride-rich environments.