ICMCTF 2023 Session G1-WeM: Advances in Application Driven Research: New Methods, Materials, and Equipment for PVD, CVD, and PECVD Processes

Multilayer TiN/TiAlxN coating deposited by arc-cathodic PVD method evaluated in this work. The adhesion of the single or multiplayer coating was studied and stress formation as the function of bias voltage during the deposition process in solid carbide. Industrial Arc-cathodic PVD with a balanced magnetron was used to coat end-mills carbide. The samples coated were tried in slotting operation in the CNC machine center using extreme cutting parameters.

The main goals of the mobility driven global energy system transformation are to increase the efficiency and environmental compatibility of conventional and renewable energy to reduce the global CO₂ footprint. More than 60% of all product innovations are based on the development of new and improved high-performance materials, which requires continuous optimization of associated production technologies and manufacturing processes. Here, the right coating solution produced by physical vapor deposition (PVD), chemical vapor deposition (CVD) and plasma-assisted CVD (PACVD) can increase productivity and ensure excellent product quality while minimizing production downtime and scrap rate in forming and molding tool applications.

Within the automotive sector, there is a prime example of continuous development of new materials in the use of press hardened steels (PHS), martensitic and multi-phase ultra-high strength steels (UHSS), dual phase advanced high strength steels (AHSS) and aluminum alloys in the automotive body-in-white. The associated forming applications cover a broad stress profile that results in complex demands on the forming tools, e.g. a high resistance to impact fatigue and crack formation under cyclic loading and a high resistance to abrasive and adhesive wear. One encouraging way of forming these materials is to reduce the frictional forces between the die and the workpiece to obtain an optimum material flow, and to reduce stresses on the die by extending the work-hardening of the workpiece material. The optimum friction state while minimizing costly and environmentally harmful lubricant usage can be set by incorporating the lubrication properties into the coating.

Plasma electrolytic oxidation (PEO) is a surface treatment technique employed to light metals to enhance their properties such as heat, wear, and corrosion resistance. The coating comprises of inner thin layer and a porous outer layer. The inner layer provides passive protection separating the substrate from the surrounding environment. However, the presence of the porous outer layer allows the propagation of aggressive ions toward the substrate initiating localized corrosion.

This study aims to functionalise PEO coating by incorporating corrosion inhibitors encapsulated into nanocontainers in a single-step process. The inhibitors will be released when detecting electrochemical activity associated with corrosion initiation, providing corrosion protection on demand. The incorporation of nanocontainers in a single step allows the homogenous distribution of the nanocontainers through the coating matrix, but the integrity of the nanocontainers might be compromised due to the high temperatures developed at microdischarge sites. To prevent this, the thermodynamic conditions of the plasma process will be optimised by establishing the soft spark regime at the earliest stage of the PEO process, which allows the non-reactive incorporation of nanocontainers.

The presence of nanocontainers in PEO coating was confirmed by scanning electron microscopy and the corrosion behaviour of PEO coating was assessed by electrochemical impedance spectroscopy.