Papers by Keyword: Surface Engineering

Abstract: The problem of punching tools resistance increasing is investigated. Methods for intermetallic coatings synthesis are investigated. Mathematical model of vacuum ion-plasma deposition process allowing predicting coatings composition basing on intermetallic system Ti-Al was developed. Experimental verification confirmed the adequacy of the computer model. The technology hardening punching tools with wear-resistant coatings deposition based on intermetallic Ti-Al system on pre-nitriding surface in vacuum was developed. Production tests of the hardened punching tools were carried out.

Abstract: The paper presents the results of tests on an “intermetallic layer TiAl / coating AlCrTiN" hybrid layer, which was obtained using a hybrid method combining magnetron Sputtering, diffusion, and arc evaporation in a single technological process. The hybrid layer obtained was subjected to studies on morphology and chemical composition using the TM3000 scanning electron microscope. Additionally, hardness and Young's modulus as a function of distance from the surface were measured using a nanohardness tester CSM. Based on the analysis of the results obtained, the authors suggest the mechanism of layer growth in the technological process. The composite layer was also subjected to wear resistance using the ball-cratering method and erosion resistance tests using the glass powder. The obtained results showed that the Ti-Al _{intermetallic} / AlCrTiN hybrid layer significantly increases resistance to abrasion as well as erosion wear resistance of the Ak12 alloy.

Abstract: The research on erosion resistance can be classified into two groups, i.e. standardized research, conducted with specific parameters of the test and dedicated to commercially available products, and experimental studies whose the aim is to investigate different mechanisms of erosion (e.g. micro-cutting, the formation of grooves, fatigue wear, and cracking and chipping of brittle materials) with different parameters of the process, i.e. the angle of impact of the particles, the speed and particle size, the particle temperature, and the temperature of the eroded material. Devices available on the market allow the implementation of erosion tests in accordance with the requirements of the standards. Experimental studies are carried out exclusively on laboratory equipment with incomparable characteristics. The Institute for Sustainable Technologies - National Research Institute in Radom designed and produced a universal testing device enabling investigations both in accordance with the requirements of the applicable standards: ASTM-G76, PN-76/C-81516, PN-EN ISO 16282, as well as experimental research. The device enables the execution of experiments in a wide range of parameters relevant to the processes of erosion, i.e. temperature (≤ 600 °C), the angle of the sample relative to the abrasive particles (25^o to 90^o), the speed of abrasive particles (10 to 130 m/s) and abrasive particles flow (2 to 10 g / min). In the paper, the authors described the construction of the device and the reported ranges of the erosive wear test parameters and presented examples of the results of tests for selected solid materials and selected coatings produced by PVD methods.

Abstract: Based on the analysis of the research directions in the field of coatings and layers with special operating properties, the production technologies of composite coatings, including the gradient, multi-layer, and multi-component coatings, should be distinct. The paper presents the results of material properties tests of a multi-layer coating Ti / TiN / TiAlN_gradient / (TiAlN/VN)_multinano obtained on hot working steel EN X32CrMoV3.3. The preparation of the multilayer coating was specially designed to increase the durability of forging dies in the brass forging process. The authors discuss the results of the microstructure tests for the obtained coatings (STEM+FIB) and present the hardness and Young's modulus as a function of the distance from the surface (nanoHardness Tester CSM) and the results of adhesion tests carried out using a scratch-test method. The obtained multilayer coatings were also subject to a tribological test using a tribometer tester by DUCOM. The authors indicate that the coatings based on vanadium nitride have very high hardness and Young's modulus (HV = 32–35 GPa, E = 420–450 GPa), a much lower coefficient of friction in combination with brass than steel, and a lower stability of these parameters at elevated temperatures. According to the authors, the coating represents an interesting material solution to increase the durability of forging dies in the process of brass forging.

Abstract: Advanced surface engineering technologies are the basis of the intense technological development in the world over the past several decades. The rapid development of surface engineering resulted in the appearance of many new top layer solutions, such as multi-layer coatings, nanostructured coatings, and hybrid layers, which prove to be very effective in their applications. The production of layers and coatings with complex microstructure and application requirements (related to coated materials, the geometry of the engineered elements, economic viability) create a need for advanced technological and organizational solutions.This article presents a technology of manufacturing a hybrid layer: “nitrided layer + (Cr/CrN) _multilayer,” intended to increase the durability of hot forging dies. Based on this example, those surface engineering fields are presented where simultaneous intensive development is necessary to ensure an efficient process of transferring innovative surface engineering solutions to the industry.

Abstract: This paper presents the results of an investigation using transmission electron microscopy concerning the structure of AlSi7Cu2 cast aluminium alloy after alloying and remelting with a high power diode laser (HPDL). In particular, the changes in the particle/precipitation type, size and shape were determined, concerning especially the SiC and TiC particles added to the initial material. The aim of this work was also to present the laser treatment technology which will be used for further alloying and remelting with ceramic powders – especially carbides and oxides. The innovatory arrangement of this investigation is based on the mixing of two different powders, which were fed simultaneously to the laser-treated aluminium surface. The overview focuses on the laser power required to achieve good layer hardness to prevent hot work tool steel from losing its work stability and to make the tool surface more resistant to action in external conditions.

Abstract: Nitriding is the most common surface engineering technique that is being used in Titanium alloys for improving their surface properties, viz hardness, wear resistance, etc. Ti6Al4V (Grade 5) Titanium Alloy is a super alloy that exhibits excellent mechanical strength; it is highly resistance to creep at very high temperatures which maintains good surface stability. It is resistant to corrosion and oxidation. The main objective of this review paper is to study the recent research works carried on Nitriding of Ti6Al4V alloy by using, viz gas Nitriding and laser Nitriding. This process is used in the surface hardening of machine parts such as aircraft engine parts, crank pins, valve seats, gears, bush, aero engine cylinders, aero crank shafts. Gas Nitriding is a diffusional technique in which the nitrogen atoms are diffused into the surface of the metal to obtain hard surface. By Laser Nitriding is a diffusional technique by which the surface properties of the titanium alloy is enhanced. Laser nitriding process comprises of various stages, viz, transport of heat, melting effect, diffusion and convection effect. By Nitriding technique the surface hardness of super alloys like Titanium Alloy Ti6Al4V Grade 5 can be increased by increasing the hardness on the surface there by its scope of application is widened. In this paper a literature survey is carried out and the recent research works on surface engineering of Ti6Al4V alloy using gas and laser Nitriding technique is summarized.

Abstract: Due to instrumentation and time constraints, it is infeasible to perform thorough research, especially experiments, for all the possible solutions, encompassing a full combination of materials with the expected mechanical and functional properties and the manufacturing technologies ensuring such properties. An objectivised selection of a material for research and its surface treatment technology is, therefore, essential in the planning phase of a materials science experiment. A methodology of computer-integrated prediction of development is dedicated to such task, enabling to perform an expert assessment and to present results thereof graphically using contextual matrices being a tool of a quantitative analysis that is very desirable in engineering circles. Considering the three groups of materials, i.e.: steels, casting magnesium alloys and casting aluminum alloys subjected to an expert assessment using a dendrological matrix being an inherent part of materials surface engineering development prediction methods, aluminum casting alloys has achieved the best position. It was further demonstrated that laser treatment is a technology of the highest potential and attractiveness in the context of applying aluminum casting alloys for surface treatment.

Abstract: The paper presents new, possible applications of artificial neural networks in the field of materials science and material engineering in relation to other artificial intelligence methods known and applied in this area. The most recent simulation experiments, the exemplary results of which are presented in this paper, point out that the scope of the existing applications of artificial neural networks can be extended to encompass new areas related to prediction of development of materials treatment and processing technologies. The goal of such research is to focus, intentionally, the areas of future research and investments on the most promising areas likely to yield the highest added value in the future together with mitigating a risk relating to such a process. The computational models created were used for creating multi-variant probabilistic scenarios of future events based on heuristic independent variables acquired in the process of multi-stage expert surveys. Dependencies were determined, in particular, between the probability of occurrence of alternative macro-scenarios of future events and the development of the relevant thematic areas of M1–M7 and P1–P7.

Abstract: The article presents the strategic positions of 140 critical materials surface engineering technologies. Critical technologies are such having the best development prospects and/or key significance in industry for the assumed time horizon. For the purpose of preparing forecasts and analyses, expert studies were carried out comprised of three stages with the e-Delphix method. The strategic positions of the technologies were expressed with numbers and entered into the matrix of strategies for technologies consisting of 16 fields.