Materials Science Forum Vol. 941

Abstract: Environmental surfaces have been widely recognized as an important source of hospital-associated transmissions. A number of silver-based antibacterial coatings have been reported in the literature. However, the success of any antibacterial strategy depends on the ability to control the kinetics of the silver ions released from the coating. The novel strategy proposed in this work is based on plasma surface engineering for a controlled-release of silver ions. Plasma-based nanocoatings, plasma oxidation processes and surface patterning of silver coatings were designed and optimized. Surface analyses such as XPS and AFM, as well as silver ion release over 168 h, was evaluated by MIP-AES. Results showed that surface plasma engineering successfully allow tuning the silver release and bioactivity in Ag-containing antibacterial coatings.

Abstract: To reduce maintenance and to increase the corrosion protection and lifetime of maritimestructures while complying with environmental standards, multilayer coatings are applied to protectsteel sections. A new generation of hybrid sol-gel and/or HiPIMS Ni-based thin films appear toconstitute an efficient pre-treatment before the anti-corrosion paint application. However, increasingthe number of coatings and associated interfaces may lead to coating failure due to stresses inducedby the different deposition processes. Therefore developing smart models to assess the stressdistribution along these multilayers appears of significant importance. The well-known Stoneyformula cannot be used for multilayers and owing to the large dimensions of the object to be protected.To assess an easily measurable curvature after deposition, thin steel sheets are used but do not respectany more the Stoney hypotheses. So we set up an analytical thermo-elasto-plastic model to evaluatethe stresses induced by depositions in each layer. This model is based on the various thermalexpansion coefficients of every coat. After extrapolation along the complete thickness, combiningsol-gel and PVD deposition smoothens the stress difference between steel and paint. The shearstresses at interface seems thus to be reduced. The evolution of the stress difference between layerswith the imposed deflection can predict the mechanical strength and the interface failure. In order toevaluate the quality of the model, in-situ four-point bending in SEM was performed to study of theadhesion between the various layers. The results deduced from the model are in good agreement withSEM images.

Abstract: The splat test is usually generated by low feed rate cold spraying of particles onto an as-polished substrate and it can be considered as a monolayer coating deposition. In this study, in order to investigate cold spray deposition mechanisms, Fe splats were sprayed onto the cold-sprayed single component 316L, Fe, and a composite 90Fe coatings. Results showed that although there is only 3.6 vol.% of 316L in the composite 90Fe coating, Fe splats exhibit a much better deposition behavior onto the 90Fe as compared with the single component Fe coating. To explain this observation, Fe splat samples were characterized using the scanning electron microscope (SEM), optical profilometry, splat adhesion tests, and splat nanoindentation. Finally, a preliminary explanation towards the Fe splat deposition behavior onto the composite coating was drawn.

Abstract: This study aims to investigate the microstructure and hardness of multi-layered Stellite-6/WC metal-matrix composites coatings on metallic substrates cladded by laser metal deposition (LMD) for improvement of wear and corrosion resistances. As coating materials, Stellite-6 and WC-12wt.%Co powders were selected. Powder mixtures having various mixing-ratios of Stellite-6 and WC-12wt.%Co were provided vertically on S45C substrates by controlling powder feeding rates of the two powder feeders, individually. Stellite-6/WC composites which consist of three layers with different compositions were cladded on the S45C substrates by laser melting. Cross-sectional microstructure observation was carried out by using an optical microscope (OM). Vickers microhardness tests were conducted to evaluate hardness of the cladding layers and substrates. The experimental results demonstrate that hard multi-layered Stellite-6/WC metal-matrix composites coatings were successfully cladded on the S45C substrates. Property gradients in the Stellite-6/WC composites could be made due to the position-dependent chemical composition and microstructure made by controlling powder feeding rates of an LMD system.

Abstract: The potential of a recently developed technique that uses a clean supercritical High Pressure Cryogenic Nitrogen Jet (HPCryoN2Jet) for surface ablation and cleaning is depicted. In contrast to existent coating-removal techniques (chemical stripping, hydro-blast, water jet cleaning...), as nitrogen is naturally recycled in the air, this process has a high potential for surface treatment without any chemical and physical effluents or sewage disposal. The treatment consists in impacting the surface with a high pressure (up to 3500 bar) cryogenic nitrogen jet (down to-160°C). The pressurized cryogenic nitrogen exits from a nozzle - having generally a 0.2 to 0.5 mm diameter outlet - to form the high velocity (supersonic) nitrogen jet. In this contribution, the ability of the process to remove polymeric (PA) coatings is evaluated on different types of metallic substrates (Cu, Al, E24, 316L stainless steel). The mechanisms of chip formation have been visualized using a high speed camera. Coating failure is shown experimentally to occur downstream of the jet and the influence of the substrate thermal properties on the stripping efficiency of the PA coating is highlighted.

Abstract: The use of coated hard metal is spread in all fields of mechanical working, both forming and machining. Different hard metals are used based on their mechanical characteristic that strongly depends on composition and grain size. Substrates such as HSS and WC – Co are typically coated with PVD thin layers in applications such as metalworking and cutting; thus lot of efforts are put in researching this specific field. Coating composition, and coating architecture are paramount topics in the subsject of surface anti – wear thin films. The focus of this study is to analyze the difference between two AlTiN coatings, a monolayer and a multilayer with gradient composition, from the point of view of microstructure and adhesion. Experimental cutting tests were done to characterize the behavior of the coating in face milling of AISI 660 heat resistant alloy: varying cutting speeds from 15 to 40 m/min it was finally assessed that a multilayer coating can give higher tool life with respect to a monolayer coating of the same composition.

Abstract: Industrial application of superhydrophobic surfaces is limited by the unsatisfactory mechanical properties of the material. Combining chemical etching and anodization terraced features containing aluminium oxide on different aluminium alloy surfaces were produced. After modified by fatty acid, the surfaces were superhydrophobic and they showed self-cleaning effect. The highest contact angle was obtained after forming hierarchical structures with a solution free of fluorine compounds; therefore, the process is considered eco-friendly. The alumina formed in the coating process promotes an improved corrosion resistance. The present study has three main objectives: to identify the molecules responsible for superhydrophobicity, the mechanism by which superhydrophobicity is produced, and consequently the influence of variables such as anodization time on the proposed processing method. We use time-of-flight secondary ion mass spectrometry (TOF-SIMS) and X-ray photoelectron spectroscopy (XPS) techniques to identify each compound involved in the final surface, by paying close attention to the analysis of the mechanism by which the chemical reaction proceeds. The morphology of the superhydrophobic surfaces was further observed by scanning electron microscope (SEM) and atomic force microscopy and was used to elucidate the effect of the anodization time in the properties of the superhydrophobic material.

Abstract: The adhesion performance of Cold Sprayed coatings depends on the quality of the substrate [1,2,4,8]. Before deposition, the surface of substrate must be prepared to a specific required quality, which promotes the anchoring of sprayed coating. Grit Blasting (Samson et al.) [1] is known as the conventional surface preparation before Cold Spraying. But such method causes issues: a) shallow roughness, which does not strengthen bonds between layer and substrate; b) embedment of particles in the substrate, which creates discontinuity of the material at the interface and causes cracks that degrade the layer. Recently, Laser [2] and Pulsed Water Jet (PWJ) [1] have been tested as substrate preparation methods. These methods have shown their ability to generate improved roughness without particle embedment. PWJ has particularly shown interest in Al substrate to generate crevices, which are anchors for the Cold Sprayed coatings. Nevertheless, Laser affects thermally the substrate and induces constraints that may disadvantage the coating quality. PWJ generates liquid effluents. Besides some substrates such as ferrous metals can react with oxygen of water leading to corrosion and coating adhesion weakness.

Abstract: Within the large scale fusion experimental device ITER, Ion Cyclotron Resonance Heating (ICRH) system is one of the three heating systems which will supply total heating power of 20 MW (40-55 MHz) up to one hour operation. Radio-Frequency (RF) contacts are integrated within the antennas for assembly and operation considerations, which will face extremely harsh service conditions, including neutron irradiation, heavy electrical loads (RF current reaches up to 2 kA with a linear current density of 4.8 kA/m), high thermal loads and also long-duration vacuum baking at 250°C before each experimental plasma campaign. CuCrZr and 316L steel have been shown to be proper base candidate materials for ITER RF contact louvers and conductors respectively. However, in order to limit the wear and the diffusion phenomena at the RF contact as well as to reduce the contact resistance, functional protective layers should be developed. The aim of this work is to investigate Au-Ni and Rh functional layers, electroplated on CuCrZr and 316L respectively. The efficiency of the Au-Ni/Rh coated pairs was evaluated through thermal ageing diffusion tests, using EDS cross-section mapping and XRD techniques. Wear and electrical contact performances of the Au-Ni/Rh original and thermally aged pairs have also been deeply studied on a dedicated tribometer operated at ITER relevant conditions.

Abstract: Ti6Al4V alloy is widely used for aeronautical components due to a special combination of high mechanical properties, low density and good corrosion resistance at high temperature. These components are usually damaged by particles impacts during their operating time. When the reliability of these components is compromised, they are replaced with the consequent cost of material and time. Spraying coatings on the damaged surface could reveal as an alternative process to repair these components, increasing their operating life. Traditionally, thermal spray processes are used to repair the aeronautical components. However, the coatings produced by these processes are characterized by high residual stresses, porosity and oxidation. The cold spray technique is revealed as a promising spraying alternative due to the characteristic low temperature of the process. Consequently, residual stresses, oxidation, crack formation, phase transformations and microstructural changes are minimized. In this work, a cold spray technique was used to generate Ti6Al4V coatings onto a bulk of the same material. Three different spraying conditions were studied: Ti6Al4V coatings sprayed at 800oC; Ti6Al4V coatings sprayed at 1100oC; and Ti6Al4V coatings sprayed at 1100oC with a subsequent heat treatment: The wear resistance of these coatings was investigated by solid particle erosion and micro-scratch tests. The wear behaviour was determined under several wear tests conditions. Additionally, instrumented indentation tests were carried out on the coatings to determine their mechanical response. The wear mechanisms of the coatings were identified and compared to their microstructure and mechanical properties.