Energy efficiency improvements in dry drilling with optimised diamond-like carbon coatings

Zolgharni, Massoud; Jones, Benjamin; Bulpett, R.; Anson, A. W.; Franks, J.

doi:10.1016/j.diamond.2007.11.012

Cited by 36 publications

(46 citation statements)

References 13 publications

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“…DLC (Diamond-Like Carbon) coating is high-lighted as a promising method to prolong the tool life in practice. As had been reported in Jones (2012) and Zolgharni, Jones, Bulpett, Anson, and Franks (2008), adhesion of aluminum alloys to cutting tools was significantly reduced by DLC coating. In case of bare tools, the wrought aluminum alloy was easy to glue into teeth of tools even at the beginning stage of machining.…”

Section: Introductionsupporting

confidence: 60%

Recycling of DLC-Coated Tools for Dry Machining of Aluminum Alloys via Oxygen Plasma Ashing

Aizawa¹,

Masaki²,

Morimoto³

et al. 2014

MER

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DLC coated tools have been widely utilized in the dry milling and cutting of aluminum alloy parts and components for automotive industries and cellular phone makers. Most of these tools are inevitably exchanged with new ones to preserve high quality of machined products. Then, the used DLC coating must be removed or ashed away before grinding and polishing. Complete removal of used DLC coating plays a key to make DLC-recoating onto the ashed surface of tools for their reuse. High density oxygen plasma ashing provides a solution to make perfect ashing of DLC coating together with metallic interlayers before recoating. In the present paper, this plasma system with quantitative diagnosis instrumentation is first stated to describe the effect of processing conditions on the ashing behavior. Two types of end-milling tools were prepared to prove that the whole DLC-coating should be completely removed with fast rate. This ashed tool substrate was ground and DLC-recoated to demonstrate that the reused tools have the same machinability in dry as the original virgin tools through dry milling experiments.

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Section: Introductionsupporting

confidence: 60%

Recycling of DLC-Coated Tools for Dry Machining of Aluminum Alloys via Oxygen Plasma Ashing

Aizawa¹,

Masaki²,

Morimoto³

et al. 2014

MER

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“…Substrates were sputter-cleaned in an argon plasma with flow rate of 30 sccm, pressure of 8×10 −2 torr and a bias voltage of 300 V. This reduces impurities on the substrates, through energetic argon ion bombardment. Following the deposition of interfacial layers to enhance the adhesion of the film to the substrate, the argon flow rate was adjusted to 20 sccm, acetylene gas at 60 sccm was introduced into the chamber and the bias voltage adjusted to 450 V for deposition of the final DLC film; producing a layer ∼4 µm in thickness, with similar structure and properties to the optimum film developed for dry drilling processes [10]. Control of both the epoxy and DLC components, as well as the interfacial structure, enables the development of the optimum wear resistance properties.…”

Section: Methodsmentioning

confidence: 99%

“…These drawbacks can be mitigated to a degree by tuning the coating deposition and hence film structure: PECVD is a flexible process allowing control over the composition of the DLC film, including the graphitic/diamond-like ratio, as well as the incorporation of hydrogen and other species. This can have a considerable effect on the levels of residual stress, as well as affecting the film properties such as hardness, elasticity, the final surface structure and chemistry, as well as the concentration of defects, and the ability of the film to bond to different materials [10,11]. Inevitably, there is a trade off, film flexibility and reduced stresses can be achieved, but often at the expense of coating hardness.…”

Section: Introductionmentioning

confidence: 99%

“…Previous research and development efforts have established that diamond-like carbon (DLC) coatings have the potential to minimise the friction and wear of various moveable devices [5][6][7][8][9][10]. DLC coatings possess many attractive properties such as high hardness, low friction and high chemical stability and have been successfully used in many different applications, for example in the automotive, medical and manufacturing sectors.…”

Section: Introductionmentioning

confidence: 99%

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Structure and Tribological Performance of Diamond-Like Carbon Based Coatings for Aerospace Component Processing

Podgoric

Jones

Bulpett

et al. 2009

e-J. Surf. Sci. Nanotechnol.

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This work examines diamond-like carbon (DLC) coatings deposited by plasma enhanced chemical vapour deposition (PECVD) as an environmentally friendly alternative to chromium plating in restoration of worn or damaged aircraft components. DLC coatings offer superior mechanical properties; however, high internal stresses and poor adhesion can prevent the deposition of thick films. This work examines a series of layered structures based on epoxy-resin interlayers with DLC applied as a surface film. Wear testing and examination with scanning electron microscopy and atomic force microscopy lead to the development of an optimum DLC/epoxy system with wear characteristics superior to those of chromium-plated steel. This new coating system has a great potential in restoring aircraft components in a more efficient and environmentally friendly manner.

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“…Tuning the balance of the constituents, phases and ordering allows the creation of an amorphous carbon material with properties that can range from polymer-like to diamond-like. This range of materials can therefore be tailored to match functional requirements, resulting in applications in many areas including aerospace [5] manufacturing [6] and medical devices [7][8][9][10].…”

Section: Introductionmentioning

confidence: 99%

Argon plasma treatment techniques on steel and effects on diamond-like carbon structure and delamination

Jones

Anguilano

Ojeda

2011

Diamond and Related Materials

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We demonstrate alteration in diamond-like carbon (DLC) film structure, chemistry and adhesion on steel, related to variation in the argon plasma pretreatment stage of plasma enhanced chemical vapour deposition. We relate these changes to the alteration in substrate structure, crystallinity and chemistry due to application of an argon plasma process with negative self bias up to 600 V.Adhesion of the DLC film to the substrate was assessed by examination of the spallated fraction of the film following controlled deformation. Films with no pretreatment step immediately delaminated. At 300 V pretreatment, the spallated fraction is 8.2%, reducing to 1.2% at 450 V and 0.02% at 600V. For bias voltages below 450V the adhesion enhancement is explained by a reduction in carbon contamination on the substrate surface, from 59at.% with no treatment to 26at.% at 450V, concurrently with a decrease in the surface roughness, R q , from 31.5nm to 18.9nm. With a pretreatment bias voltage of 600V a nanocrystalline, nanostructured surface is formed, related to removal of chromium and relaxation of stress; X-ray diffraction indicates this phase is incipient at 450V. In addition to improving film adhesion, the nanotexturing of the substrate prior to film deposition results in a DLC film that shows an increase in sp 3 /sp 2 ratio from 1.2 to 1.5, a reduction in surface roughness from 31nm to 21nm, and DLC nodular asperities with reduced diameter and increased uniformity of size and arrangement. These findings are consistent with the substrate alterations due to the plasma pretreatment resulting in limitation of surface diffusion in the growth process. This suggests that in addition to deposition phase processes, the parameters of the pretreatment process need to be considered when designing diamond-like carbon coatings.Prime Novelty: We elucidate the mechanisms behind the enhancement of diamond-like carbon film adhesion with increase in pretreatment bias voltage, and demonstrate the effect on the final film structure of alterations in the pretreatment process.

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Energy efficiency improvements in dry drilling with optimised diamond-like carbon coatings

Cited by 36 publications

References 13 publications

Recycling of DLC-Coated Tools for Dry Machining of Aluminum Alloys via Oxygen Plasma Ashing

Recycling of DLC-Coated Tools for Dry Machining of Aluminum Alloys via Oxygen Plasma Ashing

Structure and Tribological Performance of Diamond-Like Carbon Based Coatings for Aerospace Component Processing

Argon plasma treatment techniques on steel and effects on diamond-like carbon structure and delamination

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