State-of-the-Art Developments in Advanced Hard Ceramic Coatings Using PVD Techniques for High-Temperature Tribological Applications

Abstract

Hard and wear-resistant coatings created utilizing physical vapor deposition (PVD) techniques are extensively used in extreme tribological applications. The friction and wear behavior of coatings vary significantly with temperature, indicating that advanced coating concepts are essential for prolonged load-bearing applications. Many coating concepts have recently been explored in this area, including multicomponent, multilayer, gradient coatings; high entropy alloy (HEA) nitride; and functionally modified coatings. In this review, we highlighted the most significant findings from ongoing research to comprehend crucial coating properties and design aspects. To obtain enhanced tribological properties, the microstructure, composition, residual stress, hardness, and HT oxidation resistance are tuned through doping or addition of appropriate materials at an optimized level into the primary coatings. Such improvements are achieved by optimizing PVD process parameters such as input power, partial pressure, reactive gas flow rates, substrate bias, and temperature. The incorporation of ideal amounts of Si, Cr, Mo, W, Ag, and Cu into ternary and quaternary coatings, as well as unique multilayer designs, considerably increases the tribological performance of the coatings. Recent discoveries show that not only mechanical hardness and fracture toughness govern wear resistance, but also that oxidation at HT plays a significant role in the lubrication or wear failure of coatings. The tribo-induced metal oxides and/or Magnéli phases concentrated in the tribolayer are the key governing factors of friction and wear behavior at high temperatures. This review includes detailed insights into the advancements in wear resistance as well as various failure mechanisms associated with temperature changes.

Tribological behaviour of TiAlN and AlCrN coatings on stainless steel

“…Additionally, the introduction of Aluminium into the crystallographic structure of nitrides has proven to increase oxidation resistance and hardness. 1,7,8 There are several publications about the tribological behaviour of AlCrN and TiAlN coatings. [5][6][7][8][9][10][11][12][13][14][15] However, the behaviour of these coatings deposited on martensitic stainless steels has not been extensively studied.…”

“…1,7,8 There are several publications about the tribological behaviour of AlCrN and TiAlN coatings. [5][6][7][8][9][10][11][12][13][14][15] However, the behaviour of these coatings deposited on martensitic stainless steels has not been extensively studied. Since the tribological performance depends not only on the coating but also on the substrate microstructure and chemical composition, as well as the deposition method, it is important to consider the whole system: substrate-interphasecoating.…”

“…Additionally, the introduction of Aluminium into the crystallographic structure of nitrides has proven to increase oxidation resistance and hardness. 1,7,8…”

Analytical Model of Deformation of a Functionally Graded Ceramic Coating under Local Load

“…The traditional approach involves the use of a coating on the base material's surface to provide protection against environmental influences, contact or local loads; to provide the required aesthetic parameters of the product; etc. [1][2][3][4].…”

Electron-beam synthesis of ceramic- and boron-based coatings

“…One of the most promising directions in the development of modern mechanical engineering is the use of wearresistant parts with ceramic coatings [1,2] in friction units, which can maintain their operational performance under heavy duty conditions (high temperatures and aggressive environments), under which metal coatings lose their properties [3]. Much attention is being paid to studying the characteristics of dielectric, in particular ceramic, materials [4,5].…”