Papers by Keyword: Coating

Abstract: The BTA (Boring and Trepanning Association) deep hole drilling process is commonly used to machine boreholes with a large drilling depth-to-diameter ratio (l/D) and outstanding workpiece quality. The asymmetric tool design leads to a nonzero radial component of the cutting force and the passive force, which are conducted to the borehole wall by so-called guide pads. These guide pads smooth the borehole wall by a forming process and improve the surface quality. Processes, that machine materials with a high adhesion tendency, such as high alloy stainless steel, suffer from poor surface quality in the borehole and the adhesion from the workpiece material on the guide pads. In this paper modified Diamond-Like-Carbon (DLC) coated guide pads for BTA deep hole drilling tools are investigated. The scope of the experiments was the reduction of the adhesion by reducing the friction coefficient of the guide pads, as well as the improvement of the quality of the borehole wall.

Abstract: In cold forging processes the high tribological and mechanical loads often lead to early tool failure. If the cause of failure is wear, an extension of tool life could be achieved by the application of PVD coatings. In industrial tools there is a great variety of load cases that causes wear. Therefore a lot of coatings with different properties are necessary, which need to be adjusted to the various applications. In order to adapt the coatings appropriately to the different processes, a sufficient characterization of the coatings is required. In this paper three new types of PVD coatings based on TiC, AlCrN and TiAlN and two reference PVD coatings based on TiN and TiAlCN are investigated. Since friction plays an important role for the tribological conditions between workpiece and tool, the friction factor m of the coatings is determined for different lubricants in the so called Double Cup Extrusion (DCE) test. A major influence of the lubricants and a minor influence of the coatings can be seen in the conducted tests. Furthermore wear behavior of the coatings is investigated with a so called combined Punching-Forward Extrusion (CPFE) test. In this test it is possible to test simultaneously coated dies and punches under realistic conditions. For the new coating (TiAlN), characterized by monolayer structure, there is wear debris visible in some regions of the die shoulder. The early occurrence of wear might be caused by the ductility of the coating or adherence problems. The other new coatings (TiC and AlCrN), which have a multilayer structure, are revealing excellent wear behavior. The high wear resistance of these two coatings can be explained with their high hardness in combination with a special layer composition.

Abstract: This paper describes the special demands placed on the grinding of arc-sprayed WC-Fe coatings on a conventional machining center. Basic process configuration, experimental results, measurement methods and an approach for a hybrid simulation system are presented.

Abstract: Over the last decades demands for optical systems and complex optical products made of glass increased steadily. Precision glass moulding has a great potential for the bulk production of complex lenses with high precision and low costs. To prevent sticking or reactions between hot glass and moulding, and to reduce abrasive wear of the die a protective coating is deposited on the tool. In this research two coating systems suitable for this application are compared by analysing their behaviour under an impact load. The PVD (Physical Vapor Deposition) coating PtIr with two different bond coatings Ni or Cr is analysed. During impact test number of impacts and loads are varied. Compared to industrially used coating system PtIr with a Ni interlayer the adhesion can be improved by using a Cr interlayer. The PtIr-based coating with Cr as bond coating shows an excellent endurance even at very high loads causing Hertzian stresses in the range of 10 14 GPa. An impact load of 600 N which corresponds to a contact pressure of app. 13.2 GPa generates almost no damage after 200,000 impacts.

Abstract: The effect of the developed chip length on the coated tool’s cutting performance was investigated. Milling experiments at various cutting speeds and chip lengths were performed, which resulted to different tool wear developments. To explain these results, a FEM simulation of the cutting process was conducted and the related chip geometries were predicted and compared to the corresponding experimental ones. Based on these results, the Coulomb friction coefficient between chip and tool rake was appropriately adjusted to achieve a sufficient correlation between experimental and computational data. By additional FEM calculations, the mechanical and thermal loads of the cutting edge were estimated and insight was provided concerning the effect of chip length on coated tool stresses and film fatigue fracture. The obtained results revealed that the chip length reduction improves the cutting performance of coated tools and a significant increase of the removed material volume and material removal rate as well can be achieved.

Abstract: The complexity of optical components increases steadily in recent years, while their dimension de-crease. This situation makes the production of state of the art optical components by grinding and polishing very difficult and expensive. However, the technology of precision glass molding can be used to replace these traditional manufacturing methods by a single step replicative process. To achieve economies of scale with precision glass molding, a long molding tool lifetime is necessary. This can only be realized by applying protective PVD coatings on the molding tool surfaces. Well known thin hard coatings like TiAlN or CrN, as well as noble metal coatings are possible candidates. However, practical testing of carious coating-glass combinations in precision glass molding machines is not feasible due to long process times that make such testing very expensive and time consuming. In this work, these coatings are compared with each other and in combination with various glass types by performing oxidation and contact angle tests. The results of these tests are compared to the results of practical tests, in order to determine to which extent such model tests can replace practical testing.

Abstract: Active screen plasma nitriding (ASPN) is an emerging surface engineering technology that offers many advantages over the conventional DC plasma nitriding (DCPN). In this research, plasma nitriding of H11 tool steel, using titanium active screen was investigated. Samples were plasma nitrided at 550oC, for 10 and 20 h with 3 different gas mixtures of H2/N2% = 3, 4, 5. The coating microstructure and phase analysis were investigated using Scanning Electron Microscopy (SEM) and X-ray Diffraction techniques. The dominant phase in the compound layer was TiN. With increasing processing time, the layer thickness was increased. According to SEM results, the sample surface was formed of nano sized and particulate titanium nitride particles. It was shown that with increasing H2% in gas mixtures, better surface quality, golden yellow color, was obtained. Also, the intensity of TiN peaks and layer thickness were increased significantly.

Abstract: Calcium phosphate biocoatings were fabricated on the surface of magnesium alloy by micro-arc oxidation (MAO) technique. The properties of biocoatings related with MAO technics parameters and the electrolyte constitute. The surface morphology, constitute and friction coefficient were studied by SEM XRD and fret test machine. The results indicated that the optimum electrolyte was CaCO3-Na3PO4 contained 20g/L phosphate ions and 1.5 Ca/P ratio, and the optimum technics parameters was 350V oxidation voltage for10min, 500HZ pulse frequency and 1:10 in duty cycle. The main phase constitutes of the porous biocoatings contained were Mg, MgO, Mg3(PO4)2 and CaNaPO4. The anode polarization potential of the coating was -1.36V and enhanced about 0.29V compared with that of magnesium alloy substrate, which indicated that the biocoatings had better corrosion resistant properties. The friction coefficient of the biocoatings was 0.23 and decreased 0.15 compared with that of magnesium alloy substrate, which indicated that the biocoatings had better wear resistant properties. The biocoatings could induce hydroxyapatite to form on its surface after soaked in body fluid, which showed that the composite coatings owned good bioactivity.

Abstract: Microarc oxidation (MAO) is a relatively convenient and effective technique to deposit ceramic coatings on the surfaces of Al, Ti, Mg and their alloys. This technique can introduce various desired elements into titania-based coatings and produce various functional coatings with a porous structure. Microarc oxidized (MAO) TiO2-based coatings on titanium alloy were formed in electrolytes containing aluminate and ZrO2 particles. The phase composition of the samples was analyzed by glance-angle X-ray diffraction and the surface morphologies of the samples were observed by a scanning electron microscopy (SEM). In addition, the element concentrations on the surfaces of the samples were measured by an energy dispersive X-ray spectrometer. The experiment results indicated that: MAO coatings, which are porous structures and exhibit good interfacial bonding to the substrate, may possess specific surface structures such as crystal phase, non-equilibrium solid and complex mixed-compounds since complex plasma physical and chemical reactions.

Abstract: Ca0.6Mg0.4Zr4(PO4)6 coating was used as environmental barrier coatings (EBC) to improve the alkali corrosion resistance of SiC ceramic at high temperature. A new sol-gel based process has been developed for preparing high quality and thick C0.6M0.4ZP coating on SiC ceramic with once deposition. The prepared C0.6M0.4ZP coating on SiC ceramic is homogeneous and dense, and shows a thickness of about 200 μm when sintered at 1400 °C for 3h. The effectiveness of C0.6M0.4ZP coating in improving the alkali corrosion resistance of SiC ceramic was evaluated based on the SEM microstructural analysis, mass change and flexural strength measurements after being subjected to alkali Na-salt attack at 1000 °C for 96 h. Significantly improved alkali corrosion resistance was confirmed for SiC ceramic using C0.6M0.4ZP coating as EBC.