Papers by Author: D. Chaliampalias

Abstract: In this research, the possibility of applying multilayer multielement super hard coatings by Cathodic Arc is investigated. More precisely the structure of the coating consisting of quaternary CrAlSiN and ternary AlSiN layers is examined by electron microscopy, X-ray diffraction and X-ray photoelectron microscopy analytical methods. The as-deposited samples were found to have distinguishable layers. The CrAlSiN layer is characterized by an extra sequence of repeated nanolayers. The AlSiN layer consisted of nanosized grains having a preferential orientation. Finally the surface layer was found to contain a solid solution of CrxAl1-xN, while Si3N4was identified only by XPS most probably due to its amorphous structure.

Abstract: The present study addresses the influence of the gradient microstructure of nanocrystalline TiAlSiN coatings on their tribological behaviour. Cathodic arc deposition was applied to elaborate such coatings, with a total thickness of 3.5 μm, onto stainless steel substrates. Their microstructure has been characterised via Transmission Electron Microscopy (TEM) and X-ray Photoelectron Spectroscopy (XPS) and has been reported in detail previously. Since the main application of TiN-based coatings is the enhancement of the anti-wear resistance of metallic substrates, this work is focused on the tribological performance of gradient TiAlSiN coatings under dry sliding conditions. For this purpose, tests were carried out in a ball-on-disc apparatus, using an alumina ball as counterbody. The influence of the sliding velocity on the evolution of the friction coefficient and the wear lifetime of the gradient coatings has been evaluated in comparison to those of TiN coatings of the same thickness, tested under the same experimental conditions. It was found that the gradient microstructure results in an increase of the coatings’ mean lifetime by an average factor of three.

Abstract: A study of the structural and mechanical properties of nanocrystalline TiAlSiN gradient coatings deposited by cathodic arc deposition techniques at 500 °C and post-annealed at 525 °C is presented. Analysis of the coatings, chemical composition and microstructure revealed that the coatings have a structure based on (Ti, Al)N nanocrystals with an average size of 10 nm embedded in an amorphous Si₃N₄ phase. The study of the mechanical properties showed that post-annealing causes improvement and increase of the coatings hardness. A maximum hardness of 48 GPa and elastic modulus of 560 GPa were measured. Also, excellent adhesion to the WC-Co substrate was observed in the post-annealed coatings.

Abstract: In this work the feasibility of depositing magnesium coatings, on copper substrates is investigated. The deposition was accomplished by pack cementation process and the experiments were undertaken at 500°C, 550°C and 600°C for different deposition times. The purpose of these experiments was also to investigate the effect of deposition temperature on the morphology and the structure of the as-formed coatings. The characterization was performed with a SEM microscopy and XRD analysis. It was revealed that the as formed coatings mainly contain two phases corresponding to CuMg₂ and MgCu₂. Furthermore, the coating thickness and morphology was significantly affected by temperature and time.

Abstract: Multilayered, Gradient Tialsin-Based Nanocomposite Coatings Have Been Developed and Investigated with Respect to their Applicability in the Machining Industry. the Main Coating Layer Was Composed of 5-8 Nm Tin and Aln Nanograins. the Coating Possessed Hardness as High as 40 GPA, which Allows it to Be Classified as Superhard. during Heating up to 900oC in Air in Steps of 100oC for 6 H at each Temperature, the Coating Showed Good Stability up to 700oC. Thermal Treatment over this Temperature Caused a Decrease in the Hardness to Values Characteristic for Tialn Multilayered Coatings, while the Adhesion to the Substrate Remained Steady.

Abstract: In the present work the phases of the zinc coatings deposited with hot-dip galvanizing, pack cementation and wire flame spraying are examined with Scanning Electron Microscopy and Transmission Electron Microscopy. The different phases which are observed are identified with the combined results of electron and X-Ray diffraction. From the results it is concluded that pack cementation coatings are consisted by two different layers while hot dip galvanized coatings are composed by the same phases and additionally two extra phases of the Fe-Zn phase diagram. Flame sprayed coatings are composed by pure zinc, in the form of thin lamellae, together with nanocrystaline zinc oxide which is formed from the oxidation of liquid metallic droplets during the spray procedure.

Abstract: In the herein work coatings containing NiCrBSi alloy were deposited on low carbon steel by flame spray technique. The microstructure and morphology of the coatings were examined by electron microscopy and X-ray diffraction analysis. The as sprayed coatings are extremely rough with characteristic lamellic formations and porosity while a nanometer oxide film was formed on the top of the coating. High temperature oxidation tests revealed the high resistance of these coatings when exposed in such environment. This is mostly attributed to the existence of the temperature resistant oxide scale on the surface of the coupons.

Abstract: Zinc hot-dip galvanizing is one of the most effective methods for the corrosion protection of ferrous substrates. However, the failure of zinc coatings is possible when exposed to harsh environments for rather long periods. The application of a thin diamond like carbon (DLC) film on the top of the zinc coating might be a promising method for promoting their corrosion resistance. In the present work, a DLC thin film was deposited on zinc galvanized coatings by Plasma Enhanced Chemical Vapor Deposition. The as-formed film was composed of nanostructured and amorphous areas. The electron diffraction patterns acquired from the nanograins correspond to carbon phases with d-spacing ranging from diamond to graphite. Additionally, after 18 days of exposure in a simulated marine atmosphere, the DLC coated samples were proven to be more resistant than the naked galvanized coatings indicating its potential to improve the corrosion resistance of galvanized ferrous materials.

Abstract: One of the most effective methods for the protection of ferrous substrates from corrosion is zinc hot-dip galvanizing. Although this method has many advantages, it is characterized by a very negative effect on the environment. In the present work Zn coatings were formed with thermal spraying, pack cementation and fluidized bed reactor, which are friendlier to the environment. Their microstructure was characterized with X-ray diffraction and scanning electron microscopy, while their corrosion performance was estimated with exposure in a salt spray chamber. From this investigation it was deduced that CVD coatings are composed by two layers referring to Γ-Fe11Zn40 and δ-FeZn10 phase of the Fe-Zn phase diagram. By contrast the thermal coatings are very porous and composed by pure Zn. However, the corrosion performance of all coatings is similar. This conclusion is very important because it verifies that hot-dip galvanizing could be replaced by the other coating methods.

Abstract: This work aims to investigate the feasibility of Zn-Al deposition on low alloy steels at temperatures from 400 up to 440oC by pack cementation process aiming to increase their corrosion resistance. A series of experiments were undertaken to investigate the effects of pack powder composition and the deposition temperature of the process. It was observed that the parameters of zinc content and temperature affect only the coating deposition speed, but not the phase composition of the as produced coating. Al forms an overlying layer that seals the zinc coating. In any case, the deposition of successive layers of Zn and Al is feasible with pack cementation. The corrosion performance of Zn-Al coatings formed with alternative methods is already studied and proved to be resistant in harsh environments. So the herein studied coatings are expected to be corrosion resistant. Furthermore as Al is much more resistive than Zn, these coatings are more effective than pure Zn ones.