ICMCTF 2012! - CD-Lab Application Oriented Coating Development

AP-12 Wear characteristics of Zr-Al-Ni based PVD nanocomposite
thin films deposited on non-ferrous alloy substrates, J. Lawal, A.
Matthews, A. Leyland (a.leyland@sheffield.ac.uk), University of Sheffield,
UK
Non-ferrous engineering alloys (eg. titanium and aluminium alloys; nickel
alloys and austenitic stainless steels) are increasingly used in the aerospace,
automotive, chemical processing, and biomedical industries, owing to
combinations of desirable functional properties such as corrosion resistance,
high strength-to-weight ratio, biocompatibility, toughness and durability in
extreme environments. However, it is well known that such materials
exhibit poor tribological properties – especially under conditions of sliding
wear and/or abrasion.
Nanocomposite coatings comprising a hard nanocrystalline phase embedded
in an amorphous matrix have been found to exhibit improved tribological
properties over a range of varying conditions. This study investigates the
wear characteristic of Zr-Al-Ni nanocomposite films prepared by reactive
magnetron sputtering. The sliding and abrasive wear behaviour of different
coating-substrate systems was studied using reciprocating ball-on-plate
sliding and slurry microabrasion wear testing, respectively, in different
ambient environments. SEM, (with EDX) and XRD evaluations were
conducted to determine coating thickness/morphology and chemical/phase
composition. Hardness and elastic modulus were also determined by
instrumented micro- and nano-indentation measurements.
AP-13 The microstructure, mechanical properties and oxidation
resistance of CrAlSiN coatings, Y.C. Kuo, National Taiwan University of
Science and Technology, Taiwan, J.W. Lee (jefflee@mail.mcut.edu.tw), C.J.
Wang, Ming Chi University of Technology, Taiwan
The CrAlSiN thin films with various Si contents were deposited by a
magnetron sputtering system. In this study, effects of silicon contents on the
microstructure, mechanical properties and oxidation resistance of CrAlSiN
films were investigated. The crystalline structure of thin film was
determined by a glancing angle X-ray diffractometer (GA-XRD). The
surface and cross-sectional morphologies of thin films were examined by a
field emission scanning electron microscopy (FE-SEM). The hardness and
Young's modulus of thin film were evaluated by a nanoindenter. The
adhesion of coatings was determined by the scratch tester and Rockwell-C
hardness tester, respectively. For the oxidation resistance evaluation, the
CrAlSiN thin films were annealed at 700, 800, and 1000 o C for 100 hrs in
air, respectively. It was found that the microstructure and mechanical
properties of CrAlSiN thin films were affected by the silicon content. The
oxidation resistance of CrAlSiN coating was enhanced as the silicon content
increased. The mechanism for the oxidation resistance improvement of
coatings was also proposed in this work.
AP-14 Improvement of interface adhesion and thermal stability in
thermal barrier coatings through plasma heat treatment, S. Myoung, J.
Jang, K. Lee, Z. Lu, Y. Jung (jungyg@changwon.ac.kr), J. Lee, Changwon
National University, Republic of Korea, U. Paik, Hanyang University,
Republic of Korea
The thermal durability of thermal barrier coatings (TBCs) is closely related
to its adhesive strength and microstructure. Numerous factors have to be
considered in practical applications of TBCs, including the thermomechanical
properties. There is therefore a need to improve the adhesive
strength and thermal stability, which are essential to improving the
reliability and lifetime performance of the air-plasma sprayed (APS) TBC
system. Possible ways for enhancing the thermal durability are to control
the surface microstructure of bond coat and to bring a vertical type crack to
the top coat. Recently, TriplexPro TM -200 system has been launched to offer
an advanced TBC performance resulting from higher particle velocity,
lower particle oxidation, and higher coating density, compared with the
commercial APS system. Therefore, in this study, TBC samples were
prepared by the specialized coating system (TriplexPro TM -200) and the
microstructure of TBC was controlled by reheating the surface of both the
bond and top coats without powder feeding in same equipment. The
thickness of the bond and top coats was controlled as 200 and 1000 mm,
respectively, and Ni-based metallic material (AMDRY 962) and ZrO2–
8wt% Y2O3 (METCO 204 C-NS) were used as starting powders of the bond
and top coats, respectively. In order to investigate the improvement of
thermal durability the thermal fatigue tests were performed for the TBC
samples with and without surface modification, at a surface temperature of
1100°C with temperature difference of 150°C between the surface and
bottom of sample, with a dwell time of 1 h for 850 cycles, in a specially
designed apparatus: one side of the sample was exposed and the other side
air cooled. The TBC prepared by the surface modification of bond coat is
more efficient in improving adhesive strength than that without the surface
modification, and the thermal durability is enhanced by introducing the
vertical type cracks to the top coat. These evidences allow us to enhance the
thermal durability of TBC and to propose the efficient coating in improving
lifetime performance of TBC at high temperature environments. The
Thursday Afternoon Poster Sessions 96
relationship between the microstructural evolution and thermo-mechanical
characteristics of the TBCs with and without the surface modification and
vertical cracks is discussed.
AP-15 On Machining of Hardened AISI D2 Steel with Coated Tools,
W. Mattes, C. Viana (ceviana@catolicasc.org.br), Brazil
ON MACHINING OF HARDENED AISI D2 STEEL WITH COATED
TOOLS
Wilmar Mattes, mattes@catolicasc.org.br; Carlos Eduardo Viana,
ceviana@catolicasc.org.br
This paper describes an experimental investigation on machining of a
difficult-to cut material, AISI D2 steel of hardness 65 HRC with three tool
coatings (AlCr, TiAlN and TiAlN + AlCrN). It was found that the most
feasible feeds and speeds fall in the ranges 0.08–0.20 mm/rev and 80–120
m/min, respectively and that most of the tested coatings tools reached the
end of life mainly due to flank wear. The highest acceptable values of tool
life and volume of material removal were obtained at the lowest speed
tested (70 m/min), indicating that this speed is more suitable for machining
the selected tool/work material combination. While the highest feed used
resulted in the highest volume of material removal, lower feeds resulted in
higher tool life values. It was also found that the most appropriate feeds for
this type of hardened steel are 0.14 mm/rev for finishing operations and
0.20 mm/rev for roughing operations. The best results were obtained with
tools coated with TiAlN + AlCrN for the parameters of lower flank wear,
better surface quality and dimensional.
AP-16 Microstructure characterization of diffusion aluminide coatings
obtained by gas phase aluminizing on direct solidification Ni base
superalloys Rene 142 and Rene 108, B.W. Witala
(bartosz.witala@polsl.pl), L.S. Swadzba, Silesian University of
Technology, Poland, L.K. Komendera, AVIO Polska Sp. z o.o., Poland,
M.H. Hetmanczyk, B.M. Mendala, R. Swadzba, G.M. Moskal, Silesian
University of Technology, Poland
Aluminide diffusion coatings plays meaningful role in protection material to
high temperature oxidation and corrosion. In this paper result of
development and properties of high-temperature coating deposited on
superalloys such as direct solidification Ni base superalloys Rene 142 and
Rene 108 will be presented. Three different pack cementation and one out
of pack process were carried out. There will be shown influence of
technological parameters on microstructure, thickness and phase
composition of aluminide coatings. Aluminide coatings were investigated
by light microscopy (LM), scanning electron microscopy (SEM), electron
probe microanalysis (EPMA), glow discharge optical spectroscopy (GDOS)
and X-ray diffraction analysis (XRD).
AP-17 Degradation and thickness evaluation of thermal barrier
coatings using nondestructive 3D scanning method, G.M. Moskal, R.
Swadzba (rswadzba@gmail.com), L.S. Swadzba, M.H. Hetmanczyk, B.M.
Mendala, B.W. Witala, Silesian University of Technology, Poland
Thermal barrier coatings applied on turbine blades and vanes provide
reduction of temperature on these components, which in turn leads to
increasing their lifetimes. Producing TBCs of appropriate thickness and
uniform coating material distribution on the surface of a component is of
critical importance in meeting their intended performance and durability
requirements. This paper presents results of plasma sprayed (APS) thermal
barrier coatings investigation using 3D optical white-light scanning method.
The purpose of this investigation was non-destructive evaluation of
thickness and distribution of TBCs on jet engine turbine vanes, as well as
oxidation-induced degradation related to thermally grown oxide (TGO)
formation underneath the ceramic top coat. Obtained results provide
information concerning coating material distribution on the surface and in
cross sections of the turbine vanes. Methodological aspects and final results
are discussed and analyzed.
Hard Coatings and Vapor Deposition Technology
Room: Golden Ballroom - Session BP
Symposium B Poster Session
BP-1 Trends in elasticity of binary and ternary transition metal
aluminium nitrides, P. Wagner, Montanuniversität Leoben, Austria, M.
Friák, Max-Planck-Institut for Iron Research, Germany, P.H. Mayrhofer, D.
Holec (david.holec@unileoben.ac.at), Montanuniversität Leoben, Austria
Protective hard coatings make use of the outstanding mechanical and
thermal stability of early transition metal nitrides (TMN) and their alloys
with Al. Modern applications require sophisticated designs of the protective