ICMCTF 2012! - CD-Lab Application Oriented Coating Development

* Sandia National Laboratories is a multi-program laboratory managed and
operated by Sandia Corporation, a wholly owned subsidiary of Lockheed
Martin Corporation, for the U.S. Department of Energy's National Nuclear
Security Administration under contract DE-AC04-94AL85000
11:40am E1-3-13 The Effect of Ag Content on Friction Behavior of
MoN-Ag and Mo2N-Ag Nanocomposite Coatings, K. Ezirmik
(ezirmik@atauni.edu.tr), Ataturk University, Turkey, O. Eryılmaz, Argonne
National Laboratory, US, K. Kazmanlı, Istanbul Technical University,
Turkey, A. Erdemir, Argonne National Laboratory, US, M. Ürgen, Istanbul
Technical University, Turkey
Mo2N-Ag and MoN-Ag nanocomposite films were deposited by using a
hybrid deposition system composed of cathodic arc and magnetron
sputtering. Molybdenum is evaporated by cathodic arc, and silver is
introduced into the structure through magnetron sputtering. Sputtering
power is used as a variable for changing the silver content of the films. The
crystal structure of the films was evaluated using a glancing angle X-ray
diffractometer with a thin film attachment. The cross-sectional film
morphology and elemental analyses were conducted using a Field emission
scanning electron microscope (FE-SEM) equipped with energy dispersive
spectroscopy (EDS) unit. The tribological properties of films were
investigated under atmospheric conditions against different counterface
materials, namely 440C and Al2O3. The morphology of coatings and wear
tracks of both side were examined using scanning electron microscopy
(SEM), light microscopy, and 3D optical profilometry. Wear debris and the
coatings were analyzed by micro-Raman system. The results revealed the
positive role of silver addition both on film and counterbody wear. Low
friction coefficients (0.28 and 0.31) were observed for MoN+8at. % Ag and
Mo2N+10at.% Ag coatings, respectively. Raman investigation showed that
silver -molybdate compounds were formed in the wear tracks. The decrease
in the friction coefficients was attributed the formation of silver - molybdate
phases at the surface during the friction test. Higher Ag content (>22 at. %)
caused deterioration of the mechanical properties and wear resistance of the
coatings.
Applications, Manufacturing, and Equipment
Room: Tiki Pavilion - Session G1-1
Innovations in Surface Coatings and Treatments
Moderator: R. Cremer, KCS Europe GmbH, Germany, L.
Bardos, Uppsala University, Sweden
8:00am G1-1-1 Mathematical modeling of metal dusting during initial
stages., F. Castillo-Aranguren (francast@itesm.mx), J. Oseguera-Peña,
ITESM-CEM, Mexico
This work presents a mathematical model which describes the initial stages
of a metal dusting process on iron. The model is related to a moving
boundary value problem and takes into account theoretical and experimental
information of the process. In this frame, the existence of a critical value for
the carbon activity and its relationship to cementite decomposition and coke
formation on iron are studied.
8:20am G1-1-2 A Dip soldering process for three dimensional
integration, M. Rao (mrrao@crimson.ua.edu), J.C. Lusth, S.L. Burkett,
The University of Alabama, US
A novel way of three dimensional (3D) chip stacking has been designed as a
way to improve heat dissipation across the layers. Chip stacking using
vertical interconnections to form microscale channels for coolant to
circulate through the gaps. Solder-based self assembled (SBSA) 3D
structures have been designed as posts on simulated through silicon vias
(TSVs) to prove the processing concept. The processing of SBSA structures
using a low temperature solder alloy via dip soldering method will be
described. Two types of soldering, face soldering and edge soldering, were
studied to fabricate SBSA structures. Face soldering refers to deposition of
solder on the complete metal face whereas edge soldering refers to selective
deposition of solder on only the edges of the metal face. Mechanical
grinding of the 3D structures shows that face soldered SBSA structures are
void free and robust enough to be used as a connection post for chip
stacking. Edge soldered SBSA structures collapsed when grinding was
performed. This suggests a hollow nature to the fabricated edge soldered 3D
structure. Face soldered SBSA structures provide a solder bump that serves
as a connection paths in the integration of dissimilar electronic
technologies. Conventional copper posts, developed in a previous project,
can be an effective approach to integrated circuit (IC) stacking. However,
the SBSA post provides more variety in size and shape with the potentialto
also serve as a reservior for solder to aid in chip bonding. The solder bumps
are heat resistant and uniform thicknesses are obtained across a large array
of SBSA structures.
8:40am G1-1-3 Coatings for Aerospace Applications, C. Leyens
(christoph.leyens@tu-dresden.de), Technische Universität Dresden,
Germany INVITED
In aero engines, coatings are facing severe attack under multiple loading
conditions. Sand erosion, e.g., can cause great damage to turbine hardware
in the compressor, while hot corrosion and oxidation are of concern in the
hotter parts of the engines. Today, coatings are widely applied to protect
high pressure turbine airfoils, however, their use in the compressor and the
low pressure turbine is scarce yet.
The paper will review recent developments in the field of erosion protection
of aerospace alloys such as titanium and nickel alloys indicating that
coatings can substantially improve the component lifetimes under erosion
attack. Moreover, examples of coatings for intermetallic titanium aluminide
alloys will be addressed. These alloys are the latest aerospace materials
brought into service by General Electric in their GEnx for stage 6 and 7 of
the low pressure turbine. Yet unprotected today, future application of
titanium aluminides at even hotter temperatures will require oxidation and
potentially heat protection. Therefore, considerable research efforts are
underway to develop coating systems including thermal barrier coatings
which will be highlighted in this paper as well.
9:20am G1-1-5 Solid particle erosion resistance of thick coating
deposited by new AIP (Arc Ion Plating) cathode., J. Munemasa
(munemasa.jun@kobelco.com), K. Yamamoto, H. Fujii, Kobe Steel Ltd.,
Japan, Y. Iwai, University of Fukui, Japan
Recent Iceland Volcanic action (known as Eyjafjallajokul volcano) posed a
serious threat to jet engine reliability over European sky. Any solid particles
sucked into jet engine system are likely to hit the compressor blade at high
velocity with various angles. Erosion of the compressor blade leads to
change of blade shape and consequence is loss of aero dynamical integrity
and engine efficiency. Erosion resistant coatings such as TiN, TiAlN
applied by PVD processes can be used to improve the life time of
compressor blade. Kobe Steel is developing a new AIP cathode (SFC)
which can reduce the residual stress of the coating substantially, make it
possible to deposit a thick coating.
In the present investigation solid particle erosion resistance of several
nitride coatings including TiAlN deposited by SFC with different
thicknesses has been evaluated by using the sand blast test equipment. The
sand blast tests have been done by using comparatively large size solid
particles as an erodent. To understand the effect of the film thickness to the
large particle erosion resistance, TiAlN films with several 10um thicknesses
have been tested by using ave.diameter 190um-silica sand as the erodent
with approximately 100m/s air velocity on the test surface and 90deg
impact angle. As a result, doubling the film thickness improved the sand
blast erosion resistance of the coating by more than 10 times.
9:40am G1-1-6 Combination of Hardness and Toughness of CVD
HARDIDE Coatings Provides Enhanced Protection against Wear and
Erosion., N. Zhuk (yzhuk@hardide.com), Hardide Plc, UK
Hardide is a new family of nano-structured CVD Tungsten
Carbide/Tungsten coatings used to increase the life of critical parts and
tools operating in abrasive, erosive and chemically aggressive
environments.
The Hardide coatings consist of Tungsten Carbide nano-particles dispersed
in metal Tungsten matrix. This structure gives a combination of ultrahardness
with excellent toughness, crack and impact resistance. From
extensive laboratory and field testing it was found that the combination of
sufficient hardness with enhanced toughness achieves the optimum
protection against both wear and erosion in most applications. The coating’s
ultra-hardness inhibits the micro-cutting mechanisms of wear and erosion,
while its toughness, ductility, residual compressive stresses and
homogeneous micro-structure prevent fatigue micro-cracking/chipping and
platelet mechanisms of erosion.
Hardide coatings are typically 50 microns thick – exceptionally thick
among hard CVD coatings – tough and ductile to withstand 3000 microstrain
deformations without damage; this deformation will crack or chip
most other thick hard coatings.
The company developed a low-temperature CVD technology to deposit the
coatings at around 500 o C. This enables the coating of a wide range of
materials: stainless steel, tool steels stable at 500 o C, Ni-, Cu-, and Co-based
alloys, Titanium. The coating has a strong metallurgical adhesion to these
substrates, with the bond strength typically exceeding 70 MPa.
The gas-phase CVD process enables the uniform coating of external and
internal surfaces and complex shapes, such as valves, pump cylinders ID
and extrusion dies.
57 Wednesday Morning, April 25, 2012