DC pulsed plasma deposition of nanocomposite coatings for improved tribology of gray cast iron stamping dies

Agarwal, Kuldeep; Shivpuri, Rajiv; Vincent, J. L.; Roliński, E.; Sharp, G.

doi:10.1016/j.jmatprotec.2013.01.002

Cited by 19 publications

(7 citation statements)

References 12 publications

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“…Hydrogenated amorphous carbon (a-C:H) films are typically produced by plasma enhanced chemical vapor deposition (PECVD) using radio frequency plasma sources, yet this configuration has restrictions related to the production scalability due to lack of discharge stability with larger reactor chambers volumes [9,10]. It has been reported that a-C:H has been successfully produced in industrial scale with lower discharge frequencies, ranging between 1 and 500 kHz [10][11][12][13][14][15]. In addition, this reactor configuration is frequently used for nitriding soft substrates assuring mechanical support and anchoring, enabling deposition of DLC in such materials [14][15][16][17][18].…”

Section: Introductionmentioning

confidence: 99%

Effect of soft substrate topography on tribological behavior of multifunctional DLC coatings

Soprano

Salvaro

Giacomelli

et al. 2018

J Braz. Soc. Mech. Sci. Eng.

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In this study, the influence of soft substrate surface finishing (5 distinct conditions) on tribological properties of hydrogenated amorphous carbon (a-C:H) films is investigated. Low carbon steel substrates were plasma-nitrided and DLCcoated in a single PECVD batch. Topographical evolution was investigated through white light interferometry (WLI) and scanning electron microscopy (SEM). The substrate topography leads to a negligible impact on bonding structure and mechanical properties of a-C:H films, which were analyzed by Raman spectroscopy (RS) and nano-indentation. The nitriding and deposition process resulted in two groups of samples regarding the topographic features: (A) RoughS q coated & 0.17-0.23 lm; (B) SmoothS q coated & 0.08-0.11 lm. Tribological performance of multifunctional coatings under incremental normal load reciprocating dry sliding tests in ambient air revealed friction coefficients of 0.09 (Rough) and 0.05 (Smooth). Wear scars were analyzed by WLI, SEM and RS. The results suggest that rougher substrates inhibit tribolayer formation and stability, leading to higher friction coefficients.

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Section: Introductionmentioning

confidence: 99%

Effect of soft substrate topography on tribological behavior of multifunctional DLC coatings

Soprano

Salvaro

Giacomelli

et al. 2018

J Braz. Soc. Mech. Sci. Eng.

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“…Fraser and Jahedi investigated alumina coating to prevent adhesion and soldering on Al-11Si-3Cu die-casting [7], and Mendez proposed model of heat transfer of solid lubricant on hot dies [8]. Thermochemical treatments have shown potential in improving the wear, corrosion resistance and fatigue of cast iron die surfaces [9,10]. However, little work has been reported on the tribological behaviour of surface engineered cast irons sliding against aluminium alloys.…”

Section: Introductionmentioning

confidence: 99%

Development of low-friction and wear-resistant surfaces for low-cost Al hot stamping tools

Dong

Formosa

Fernandez

et al. 2015

MATEC Web of Conferences

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Abstract. In this study, advanced surfaces and coatings have been developed using plasma thermochemical treatment, PVD coating, electroless Ni-BN plating and duplex surface engineering to produce low-friction and wear-resistant surfaces for cast iron stamping tools. Their microstructural and nano-mechanical properties were systematically analysed and the tribological behaviour of these new surfaces and coatings were evaluated. The experimental results have shown that under dry sliding condition, the tribological behaviour of aluminium differed great from that of steel regardless of the counterpart material. Highly reactive aluminium had a strong tendency to solder with tool surfaces during dry sliding. However, the lubricity of gray cast irons can be significantly improved by Ni-BN and DLC coatings. The coefficient of friction reduced from about 0.5 for untreated cast irons to about 0.2 sliding against aluminium. Duplex treatment combining plasma nitrocarburising with lowfriction coatings showed superior durability than both DLC and Ni-BN coatings.

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“…Enabling the use of DLC multifunctional coatings on lowercost substrates while preserving the tribological and mechanical performance of the system is undoubtedly a current challenge in the industry and demands additional research. Gray cast irons (GCI) and nodular cast irons (NCI) arise as potential candidates to fulfill the demand due to their vast industrial applications such as large stamping tools (Corbella et al, 2004), automotive parts (Sánchez-López et al, 2003;Podgornik et al, 2008;Maurizi et al, 2014), household appliances industry (Agarwal et al, 2013), among others. Despite that, a small number of studies concerning GCI and NCI tribological behavior when used as a substrate for DLC coating was found in the literature (Andújar et al, 2003;Corbella et al, 2004;Podgornik et al, 2008).…”

Section: Substrate Surface Finishingmentioning

confidence: 99%

“…Due to the cruciality of this aspect, surface treatments were developed by different research groups to remove all near-surface graphite before the nitriding of similar materials (Karamiş and Yildizli, 2010;Zenker et al, 2013). Another critical issue is the relatively low hardness of cast iron metallic matrixes, which induced the necessity of the development of suitable mechanical support layers, being the nitriding of ferrous substrates a commonly used solution (Agarwal et al, 2013;Ebrahimi et al, 2015;Shioga et al, 2016;Giacomelli et al, 2017). However, as reported, the plasma nitriding of gray cast irons strongly affects its topography, generating wedge-like features (Rolinski et al, 2007(Rolinski et al, , 2009.…”

Section: Substrate Naturementioning

confidence: 99%

In situ Tribo-Fluorination for Oil-Less Hermetic Compressor Applications

et al. 2021

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In the present work, we overview the multidisciplinary development of a regular, lubricated, hermetic compressor which works in an on-off cycle, circular motion, single-speed, many tribological contacts, into an innovative, linear motion, variable displacement, single tribological contact, oil-less hermetic compressor presenting high versatility in terms of refrigerator design, sustainability and improved efficiency. The original approach encompassed the development of new surface engineering procedures applying purpose-oriented phases to soft substrates. Particular emphasis is given to the in situ fluorination of the tribolayer formed in the piston-cylinder tribopair. Although chlorinated halocarbons (CFC) are efficient refrigerants from a thermodynamic point of view, they do have serious environmental implications that have forced the refrigeration industry to switch to more environmentally friendly hydrofluorocarbon (HFC) based refrigerants. The first and most successful alternative to the CFCs was tetrafluorocarbon, particularly tetrafluoroethane (CF3CH2F), aka R134a refrigerant. The current trend to downsizing mechanical systems, smaller clearances, and increased speeds leading to greater energy efficiencies associated with miscibility issues imposing the use of costly, fully synthetic lubricants with the R134a refrigerant gas led to the introduction of a new hermetic compressor design, the Wisemotion®, the first, and until now, unique, oil-free hermetic compressor on the world market. In this context different types of multi-layers, their thickness, substrate material, processing routes, etc., have been studied and optimized. Si-rich hydrogenated DLC (a:C-H) presented enhanced tribological properties when tested under fluorine-rich atmospheres, and semi-industrial scale tests have been carried out to understand this point further. A homemade tribological emulator was developed allowing close-to-real tribopair, atmosphere, and imposed mechanical conditions used in an oil-free commercial hermetic compressor. The tests were carried under different stroke frequencies (5, 20, and 40 Hz) and atmospheres (R134a, ambient air, and argon). Results showed a strong influence of both atmosphere and stroke frequencies. The friction coefficients were significantly lower (~3.8X) for the refrigerant gas atmosphere, attributed to the fluorine and highly disordered graphitic structures rich tribolayers. Under the high frequency (40 Hz), the energy input seems to be a deterrent to the formation of stable tribolayers, and the DLC coating shatters on the first few sliding meters.

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DC pulsed plasma deposition of nanocomposite coatings for improved tribology of gray cast iron stamping dies

Cited by 19 publications

References 12 publications

Effect of soft substrate topography on tribological behavior of multifunctional DLC coatings

Effect of soft substrate topography on tribological behavior of multifunctional DLC coatings

Development of low-friction and wear-resistant surfaces for low-cost Al hot stamping tools

In situ Tribo-Fluorination for Oil-Less Hermetic Compressor Applications

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