Multi-arc Ion Plating Research Articles

The Cr/Cr2N multilayer coating with high load-bearing capacity and thermal shock resistance

By utilizing the multi-arc ion plating (MAIP) technique, multilayer coatings with varying Cr/Cr2N ratios and uniform thicknesses were deposited onto a nitrided Cr–Ni–Mo–V steel substrate. The evolution of microstructure and mechanical properties was characterized using scanning electron microscopy, X-ray diffraction, and micro-Vickers hardness testing. The load-bearing capacity of the multilayer coatings with varying modulation ratios was comprehensively evaluated through Vickers indentation tests with a 10-kgf load, Rockwell hardness testing with a 150-kgf load, and scratch tests with loads of 60 and 100N. The coating with a Cr/Cr2N layer modulation ratio of 0.2/0.4 μm exhibited a hardness of 1385 HV and an adhesion strength of 91N. Under a 10kgf load, this coating also demonstrated excellent fracture toughness, and did not exhibit any radial cracks in the Vickers indentation. Subsequently, a thermal shock test, involving quenching from 900°C water to 25°C, was conducted on the coating with the best comprehensive performance. The multilayer coating with high load-bearing capacity could withstand 52 thermal shock cycles before delamination occurred. Failure analysis further confirmed that the multilayer coating with enhanced load-bearing capacity effectively resisted thermal shock.

Quantitative characterization on influence of surface particles on corrosion behavior of multiarc ion plated CrAlN coatings

Surface particles on multiarc ion plated coatings are common defects, and their influence on the service performance of coatings is rarely defined. The CrAlN coatings were deposited on the tungsten steel (YG8) substrates using multiarc ion plating. The effects of the substrate bias voltages and nitrogen flow rates on the quantity of the surface particles were investigated, and the influence of the surface particles on the corrosion resistance of the coatings is quantitatively characterized. The morphology of surface particles was characterized using a scanning electron microscope. The quantity of the surface particles was counted by image software. The corrosion resistance of the coatings was evaluated through an electrochemical workstation. The results show that the quantity of surface particles decreased with the increase in the substrate bias voltage and nitrogen flow rate. The corrosion resistance of the coatings showed a positive correlation with the quantity of the surface particles, and it decreased dramatically when the quantity of the surface particles exceeded 111/10 000 μm2. The corrosion mechanism of the coatings was attributed to the defect-induced pitting corrosion.

Thermal Corrosion Properties of Composite Ceramic Coating Prepared by Multi-Arc Ion Plating

In this study, a NiCr/YSZ coating was applied to a γ-TiAl surface using multi-arc ion plating technology to enhance its high-temperature performance and explore the mechanisms of high-temperature oxidation and thermal corrosion. The thermal corrosion properties of the γ-TiAl matrix and NiCr/YSZ coating were investigated at 850 °C and 950 °C using a constant-temperature corrosion test in a 75% Na2SO4 + 25% NaCl mixture. The results indicate that after 100 h, the thermal corrosion weight gain of the coating samples was 70.1 mg/cm2 at 850 °C and 118.2 mg/cm2 at 950 °C. At these temperatures, sulfide formation on the surface increases, leading to a loose and porous surface. After 100 h of high-temperature corrosion at 850 °C, the primary oxidation product on the surface of the coating was tetragonal-ZrO2. At 950 °C, Y2O3, which mainly acts as a stabilizer in YSZ, reacted with Na2SO4, resulting in the continuous consumption of Y2O3. This reaction caused a substantial amount of tetragonal-ZrO2 to transform into monoclinic-ZrO2, altering the volume of the ceramic layer, which induced internal stress, crack propagation, and minor spallation. A continuous and dense internal thermally grown oxide (TGO) layer effectively impeded the diffusion of molten salt substances and oxygen, thereby significantly improving the thermal corrosion resistance of the thermal barrier coating.

Evaluation of wear resistance of CrN, CrAlN, and TiAlN coatings deposited by multi-arc ion plating on spinning die of Cr12MoV

Abstract This study successfully deposited CrN, CrAlN, and TiAlN coatings on the surface of Cr12MoV substrate using multi-arc ion plating (MAIP). The influence of phase composition and surface morphology on the hardness, adhesion strength, friction performance, and wear mechanisms of these coatings was investigated, with a comparative analysis of their wear resistance. Nanoindentation results revealed that the hardness (H) of CrN, CrAlN, and TiAlN coatings increased by 70.37%, 74.97%, and 75.64%, respectively, compared to the substrate. The hardness (H) and elastic modulus (E) were found to be positively correlated. CrAlN demonstrated superior resistance to deformation, reflected in its higher H/E and H 3 /E 2 radios compared to the CrN and TiAlN. Adhesion tests showed that CrAlN had the strongest adhesion strength to the substrate, with an adhesion force of 81.55 N, representing a 14.78% and 8.46% improvement over CrN and TiAlN, respectively. Friction and wear tests identified CrAlN as having the lowest friction coefficient (0.389), attributed to its high hardness and strong adhesion. The wear mechanisms of CrAlN observed were primarily mild abrasive wear, oxidative wear, and adhesive wear. In comparison, CrN and TiAlN coatings exhibited higher friction coefficients of 0.424 and 0.391, respectively, due to their lower hardness and adhesion, which led to more severe oxidative and abrasive wear. Additionally, the TiAlN coating showed signs of brittle failure in wear scars, likely due to the formation of Al2O3 oxides during wear.

High-throughput preparation and quick characterization of oxidation behaviors of complex Al–Cr compositional gradient coatings on a novel Co–Al–W–based superalloy prepared using multi-arc ion plating technology

The early oxidation behaviors of complex Al–Cr compositional gradient coatings on a novel Co–Al–W substrate prepared by multi-arc ion plating technology (MIPT) at 1000 °C for 20–60 min were rapidly characterized. The as-deposited coatings with compositions ranging from (55%–90%Al, 45%–10%Cr) exhibited the laminated structure α-Al + Al80Cr20+Al8Cr5+α-Cr. After annealing at 640 °C for 40 h, a two-layered coating composed of (Co(Al, Cr) + Al8Co18Cr4) and IRL formed, and the thickness of the coating increased from the 14–18 μm of the as-deposited state to 25–35 μm. During oxidation at 1000 °C for 20–60 min, a three-layer structure consisting of an outer α-Al2O3+α-Cr2O3+CoCr2O4 layer, a central unoxidized Al–Cr layer, and an inner μ-Co7(W0.55Cr0.45) 6+B2–CoAl layer formed on the substrate. The Al–Cr coatings with higher Cr content had a looser oxide layer due to the CoCr2O4 phase, which might degrade the intended protective effect of the Al–Cr coatings. Thus, the Al–Cr coatings with higher Al content were suitable for preventing oxidation behavior. This work proposes a high-throughput screening method for rapid characterization of the early oxidation mechanism of the complex Al–Cr compositional gradient coatings.

Effect of O2/Ar ratio on the microstructure and tribological properties of Y2O3 films by multi-arc ion plating

Multi-Arc Ion Plating (MAIP) technology was used to deposit yttrium oxide (Y2O3) ceramic thin films on Al2O3 ceramics and silicon wafers. The effects of varying the O-to-Ar gas flow ratio (Rc: 0.5, 1.0, 1.5, 2.0) and the annealing conditions on the phase composition, microstructure, mechanical properties, and tribological performance of the Y2O3 films were assessed. The films deposited at Rc values of 1.0 and 1.5 consisted of a single cubic phase structure. In contrast, films deposited at Rc values of 0.5 and 2.0 contained a small monoclinic phase and the cubic phase structure. The film deposited at an Rc value of 1.0 (oxygen flow rate of 200 sccm) exhibited a dense microstructure, the best mechanical properties (hardness of 14.2 ± 0.191 GPa), and the lowest friction coefficient (0.142 ± 0.003). Furthermore, the colour of the film changed from grey-black to white after annealing at 800 °C for 6 h. The oxygen vacancy of the thin film increased, with improving crystallinity, decreasing hardness and elastic modulus, and increasing grain size, friction coefficient and wear rate. The film exhibited the best tribological properties at 25 °C.

Effect of nitrogen pressure on the microstructure, conductivity, and corrosion resistance of ZrN-coated stainless steel as bipolar plate for proton exchange membrane fuel cell

Zirconium nitride (ZrN) coatings were deposited on the stainless steel using multi-arc ion plating under varying nitrogen partial pressures (PN) ranging from 0.5 to 3.5 Pa. The effect of phase composition, microstructure, and surface morphology on the corrosion resistance and conductivity of the ZrN-coated stainless steel in a simulated proton exchange membrane fuel cell (PEMFC) cathode environment was systematically explored. XRD and TEM revealed that the columnar-structured ZrN coating mainly comprised the fcc-ZrN phase. The Zr3N4 phase was discovered near the substrate during coatings prepared at low nitrogen partial pressures. Surface defects were reduced at nitrogen partial pressures exceeding 2.5 Pa. The ZrN coating exhibited enhanced corrosion resistance and conductivity (ZrN-3.5, Ecorr = 0.307 V, Icorr = 2.085 × 10−7 A/cm2, Rct = 1.125 × 105 Ω·cm2) compared to bare stainless steel in the simulated PEMFC cathode environment. The presence of surface defects influenced the corrosion resistance, while differences in conductivity were related to the phase composition and microstructure of the coating. Thus, the findings indicate that ZrN coatings prepared under optimal deposition conditions can have potential applications in PEMFC bipolar plates.

Corrosion studies of duplex surface-treated M420 stainless steel by plasma nitrocarburizing and WCrAlTiSiN multilayer coating

M420 stainless steel has good mechanical properties, but its corrosion resistance is poor, which limits its application in marine conditions. Single-technology processing has been unable to meet the development needs of modern industry. In this work, plasma nitrocarburizing (PNC) and CrN/CrTiAlSiN/WCrTiAlN multi-layer coating were carried out on M420 martensitic stainless steel by hollow cathode-assisted plasma treatment and multi-arc ion plating, respectively. The modified layers were characterized by X-ray diffraction, scanning electron microscopy, atomic force microscopy, and transmission electron microscopy. The results show that the nitrocarburized layer effectively improves the hardness gradient between the coating and the substrate. The presence of the composite strengthening layer enables the sample to obtain a thick and dense corrosion-resistant surface, effectively blocking the invasion of the corrosive medium. The corrosion rate of the PNC + C sample decreased by an order of magnitude. Combining hollow cathode-assisted rapid nitrocarburizing technology and multi-arc ion plating technology can significantly improve the mechanical properties and corrosion resistance of M420 stainless steel in a shorter time. The duplex surface-treated M420 stainless steel by plasma nitrocarburizing and WCrAlTiSiN multilayer coating exhibited excellent corrosion resistance compared to the nitrided and coated M420 stainless steel.

Corrosion resistance and conductivity of CrN, CrAlN, and CrTiN coatings applied to bipolar plates for proton exchange membrane fuel cells

In order to improve the corrosion resistance and conductivity of 316L stainless steel bipolar plates used for proton exchange membrane fuel cells, three Cr-containing nitride coatings were deposited on 316L stainless steel by multiarc ion plating. First, the microstructure, composition, and contact angle of the three coatings were systematically investigated. Then, electrochemical impedance spectroscopy, potentiodynamic polarization, potentiostatic polarization (PSP), and interfacial contact resistance (ICR) of the three coatings were also fully examined. The results revealed that CrN coating has the highest contact angle of 98.26°, indicating its superior hydrophobicity. Additionally, CrN coating performed the best corrosion resistance with the highest corrosion potential of 0.31 V, the lowest corrosion current density of 2.28 × 10−7 A cm−2, and the largest resistance. Furthermore, CrN coating showed the lowest current density during PSP tests and the smallest ICR value after corrosion. The superior corrosion resistance of CrN coating is mainly attributed to its decreased pore density caused by vacancylike defects and its uniform structure. This article provided evidence for the potential application of CrN coating to bipolar plates.

Current carrying tribological properties of multi arc ion plated titanium nitride doped silver coating

Sliding electrical contact materials play a crucial role in the transmission and conversion of electrical energy, but due to various factors such as force, electricity, and heat, the interface exhibits complex wear behavior. A single solid or liquid lubrication system can no longer meet the growing performance requirements of current carrying tribology. In this study, a TiN-Ag coating was prepared using multi arc ion plating technology, and a solid–liquid composite lubrication system was formed with ionic liquid and polyurea grease, respectively. Through current carrying friction and wear tests, their tribological properties, electrical contact resistance(ECR) values, and stability were tested, and compared with the results obtained during dry friction. The coating and worn surfaces were analyzed using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The results indicated that compared with dry friction, TiN-Ag coatings lubricated with ionic liquids and polyurea grease showed higher friction reduction, wear resistance, and conductivity, especially the synergistic effect between ionic liquids and coatings is prominent. The behavior of ionic liquids under voltage was analyzed, and it was found that ionic liquids formed a physical adsorption film composed of a mixture of anions and cations on the worn surface. The ordered layered structure improved the tribological performance of the system.

Critical processing parameters optimization and characterization of CrAlSiWN coating by industrial arc ion plating

CrAlSiWN coating has been deposited on SKH-51 steel by multi-arc ion plating technique. An orthogonal experimental approach is employed to optimize the processing parameters, including current, bias voltage, rotating stand speed, and duty cycle. The coating exhibits superior comprehensive properties under the following conditions: 150 An of current, −50 V to −200 V of bias voltage, 2 r/min of speed, and 80 % duty cycle. The microstructure, mechanical and tribological properties, thermal stability, and oxidation resistance have been investigated. The results indicate that the CrAlSiWN coating consists of an fcc-(Cr, Al) N solid solution. The hardness is approximately four times that of the substrate (3827 HV) and the adhesion strength between the coating and substrate reaches 89.20 N. Wear mechanisms primarily involve abrasive and oxidation wear with a friction coefficient of 0.478. Additionally, CrAlSiWN coating exhibits excellent thermodynamic stability until 1100 °C when annealed under vacuum conditions and a remarkable oxidation resistance with a low oxidation weight growth rate of 0.08 mg/mm2 at temperatures up to 1100 °C.

Effect of N2 partial pressure on ZrN coating orientation and tribocorrosion behavior and mechanism

The ZrN coatings were prepared using multi-arc ion plating (MAIP) under different N2 partial pressures ranging from 10 % to 80 %. A comprehensive analysis of the microstructure, electrochemical behavior, and tribocorrosion properties of these coatings showed a gradual deposition rate decrease with rising N2 partial pressure. Analysis using GIXRD revealed higher N2 pressure led to a shift in crystal orientation from (111) to (200), initially increasing corrosion resistance but later declining. At 70 % N2 pressure, the ZrN coating exhibited the lowest values of capacitance Cpo (8.89 μF cm−2) and double-layer capacitance Cdl (1.14 × 10−7 F cm−2), with the highest values for the two-time constants τ recorded as 0.274 s and 5.749 s. The tribocorrosion behavior correlated closely with the corrosion performance, with the ZrN-70 % coating demonstrating superior tribocorrosion resistance and a minimal wear rate of 4.25 × 10−5 mm3/Nm. While the ZrN-80 % coating exhibited the lowest wear rate of 2.67 × 10−5 mm3/Nm, but was more susceptible to friction and corrosion synergy, causing localized failure. The outcomes reveal crystal texture significantly affected on the electrochemical and tribocorrosion characteristics of the coatings, primarily attributed to the robust passivation tendency and stability of the passivation film associated with the (200) crystal orientation. The dominant wear mechanism identified involves the interplay of adhesive, abrasive, and corrosion-erosion wear processes. Based on these results, ZrN coatings prepared using MAIP are expected to emerge as candidate materials for critical friction components in marine equipment or other corrosion-erosion environments.

The effect of AlCrN, TiN and Ni-Cr-Nb coatings on the wear and corrosion performance of 45 # steel in 3.5 % sodium chloride solution

The press bar of the oil press is prone to corrosion and abrasion in the high-temperature and high-pressure environment, which reduces the quality of oil and the efficiency of agricultural production. In this paper, Ni-Cr-Nb, TiN and AlCrN coatings were prepared on the surface of press bar substrate by thermal spraying and multi-arc ion plating technology. The tests were analyzed by modern analytical methods such as HV-1000Z micro Vickers hardness tester, SEM, XRD and electrochemical corrosion. The results show that: Vickers hardness tester analysis shows that the surface hardness of AlCrN coating is 3.6 times higher than that of the base material, which is higher than that of several other coatings; SEM shows that the surfaces of the Ni-Cr-Nb, TiN and AlCrN coatings are smooth and even, the film structure is compact and uniform, and the thickness of the coating film is 5.67μm, 6.31 μm and 6.55 μm, respectively; XRD shows the elemental content of each coating, and the Al atoms in the AlCrN coating have good corrosion resistance; Electrochemical corrosion experiment shows that AlCrN coating has the biggest and most important advantages. It shows that AlCrN coating has the maximum potential and minimum corrosion current density, which indicates that its corrosion resistance is the best, followed by TiN coating, Ni-Cr-Nb layer of the corrosion resistance of the first two coatings, but better than the press bar substrate.

Microstructure evolution and failure mechanism of Cr-coated Zry-4 in air and steam at 1200 °C

The dense and uniform Cr coating is successfully applied to the Zry-4 (zircaloy-4) substrate using multi-arc ion plating as an accident-tolerant fuel cladding. The isothermal oxidation behavior of the Cr-coated Zry-4 is investigated in air and steam at 1200 °C. The mass gain, microstructure evolution and phase composition of the Cr-coated Zry-4 after different oxidation times are compared. The mass gain of Cr-coated Zry-4 in air is higher than in steam. In air, the dense Cr2O3 layer consisted of bulk Cr2O3, while protruding flake Cr2O3 is found on the surface of the Cr coating in steam. The degradation process and oxidation failure mechanism of the Cr-coated Zry-4 in air and steam at 1200 °C are analyzed.

Corrosion behavior of Al–O coating in oxygen-saturated lead-bismuth eutectic at 550 °C

The amorphous Al–O coating with a thickness of approximately 6 μm was prepared on 316 L stainless steel using multi-arc ion plating technology to investigate the corrosion resistance of the coating in static lead–bismuth eutectic at 550 °C. The corrosion time ranged from 100 to 1000 h. The samples were characterized using different instruments, and the results showed that the Al–O coating had poor wettability and could effectively protect the substrate material from lead–bismuth corrosion in a static lead–bismuth eutectic. However, during the long-term high-temperature corrosion process, the coating changes from an amorphous phase to a polycrystalline doped structure, resulting in pores on the coating. Further, elemental interdiffusion was identified between the substrate and coating, indicating risk of coating failure.

Mechanical, tribological, corrosion and tribocorrosion properties of ZrNxOy coatings on Ti–45Nb alloys by multi-arc ion plating

Mechanical, tribological, corrosion and tribocorrosion properties of ZrNxOy coatings on Ti–45Nb alloys by multi-arc ion plating

Structural evolution and self-destructive behavior of Mo/Ti transition layers during free-standing diamond-film preparation

Graphite-based metal transition-layer substrates hold great potential for preparing large-area diamond films and achieving crack-free release. In this study, a five-inch crack-free free-standing diamond film was prepared on a graphite substrate with a sacrificial Mo/Ti double-layer transition layer using direct-current arc plasma jet chemical vapor deposition (DC jet CVD). The interfacial bonding and diffusion behavior between the diamond and the transition layers were investigated. The effect of abundant metal particles and elemental diffusion between layers on film adhesion and stress release are discussed and analyzed. The surface of Ti layer prepared by the multi-arc ion-plating contains numerous metal particles that provide a template for the fine-crystalline Mo layer. Metal particles are encapsulated and embedded in the diamond and act as anchors that ensure the stability of the substrate–diamond bond during high-temperature deposition. After deposition, those metal particles act as weak points and play crucial stress-release roles. Mutual elemental diffusion occurs between the Ti, Mo, and diamond layers. Ti penetrates the Mo layer to form a continuous 140-nm-thick thin layer during the initial deposition period, facilitating diamond nucleation. Carbon from the plasma and diamond diffuses into the metal transition layer. Thermal stress generated between the diamond and the graphite substrate is released by destroying the metal transition layer with high thermal expansion coefficient and low elastic modulus during cooling from the deposition temperature. Cracks rapidly propagate along the interface between destroyable transition layers and graphite substrate, which results in the liftoff of a fully crack-free diamond film.

Effects of multilayer structure on the high-speed dry-cutting performance of AlCrBN/AlCrN multilayer coatings

To investigate the effects of different structures on the cutting performance of AlCrBN/AlCrN multilayer coatings, AlCrBN/AlCrN coatings with different multilayer structures (single layer, 10 bilayers, and 20 bilayers corresponding to T1 coating, T10 coating, and T20 coating) were synthesized using multi-arc ion plating technology. Grazing incidence X-ray diffraction (GIXRD) and transmission electron microscopy (TEM) results showed that the coatings were mainly composed of fcc-(Cr, Al) N phases located on the (111) and (200) crystal planes. All coatings exhibited a good indentation adhesion to the substrates. The hardness of the T10 coating (32.6 GPa) and T20 coating (31.2 GPa) was significantly higher than that of the T1 coating (28.0 GPa). Annealing experiments show that no phase composition evolution was revealed at 800 °C. High-speed milling tests imply that the milling life of the T10 coating (13 m) and the T20 coating (10 m) was increased by 62.5% and 25.0% compared to the T1 coating (8 m), respectively. In high-speed dry turning tests, the T10 coated tool also showed the longest lifetime (16 mins), an improvement of 23.1% over T1 or T20 coated tools (13 mins). SEM analyses of wear coated tools indicated that a multilayer structure enhanced their resistance to abrasion and adhesion wear, and led to better cutting performance, probably because of their excellent mechanical properties and thermal stability.

Effect of nitrogen/argon ratios on structures and properties of high-entropy (ZrTiNbV)N nitride films by multi-arc ion plating

The multi-arc ion plating technique has been used to prepare high-entropy (ZrTiNbV)N ceramic films. Meanwhile, the effects of different nitrogen/argon ratios of RN on film microstructures, mechanical properties, tribological properties and corrosion resistance are systematically investigated. The high-entropy (ZrTiNbV)N ceramic films with face-centered cubic structure are fabricated when the RN exceeded the critical value of RN = 1. Additionally, the films form dense structures and bond tightly to the substrate under all RN conditions. Compared with other films, the films deposited at RN = 3 have the best mechanical and tribological properties. The hardness up to 31.70 ± 1.67 GPa, and the wear rate is as low as (3.39 ± 0.18) × 10−6 mm3/N−1m−1. Moreover, the corrosion current density in 3.5 wt% NaCl solution is only 1.119 × 10−7A/cm2, showing excellent corrosion resistance.

Mechanical and Tribological Properties of CrWN/MoN Nano-Multilayer Coatings Deposited by Cathodic Arc Ion Plating

CrWN/MoN nano-multilayer coatings were deposited in pure N2 by multi-arc ion plating using CrW and Mo targets, with the cathode co-controlled by a permanent magnet combined with an electromagnet. The effects of the thickness modulation period on the microstructure and mechanical and tribological performance were systematically analyzed by grazing-incident X-ray diffraction (GIXRD), transmission electron microscopy (TEM), Nanoindentation, scanning electron microscope (SEM) and profilometry using a Talysurf profilometer. The local coherent interfaces and nanoscale modulation period were confirmed by TEM, while the coatings were confirmed to be composed of fcc-CrWN and hexagonal δ-MoN by GIXRD. With the increase in the modulation period, the hardness of the CrWN/MoN nano-multilayer coatings decreased, and the values of the H/E ratio and friction coefficient showed the same variation trend. At an 8.0 nm modulation period, the CrWN/MoN nano-multilayer coating showed the maximum hardness (30.2 GPa), the lowest H/E value (0.082) and an H3/E*2 value of 0.16. With the decrease in the modulation period, the average friction coefficient of the CrWN/MoN nano-multilayer coatings gradually decreased from 0.45 to 0.29, while the wear rate decreased from 4.2 × 10−7 mm3/Nm to 3.3 × 10−7 mm3/Nm.