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Wear Resistant Amorphous and Nanocomposite Coatings

Description: Glass forming materials (critical cooling rate <10{sup 4}K.s{sup -1}) are promising for their high corrosion and wear resistance. During rapid cooling, the materials form an amorphous structure that transforms to nanocrystalline during a process of devitrification. High hardness (HV 1690) can be achieved through a controlled crystallization. Thermal spray process has been used to apply coatings, which preserves the amorphous/nanocomposite structure due to a high cooling rate of the feedstock particles during the impact on a substrate. Wear properties have been studied with respect to process conditions and feedstock material properties. Application specific properties such as sliding wear resistance have been correlated with laboratory tests based on instrumented indentation and scratch tests.
Date: March 26, 2008
Creator: Racek, O.
Partner: UNT Libraries Government Documents Department

High Density Infrared (HDI) Transient Liquid Coatings for Improved Wear and Corrosion Resistance

Description: This report documents a collaborative effort between Oak Ridge National Laboratory (ORNL), Materials Resources International and an industry team of participants to develop, evaluate and understand how high density infrared heating technology could be used to improve infiltrated carbide wear coatings and/or to densify sprayed coatings. The research included HDI fusion evaluations of infiltrated carbide suspensions such (BrazeCoat® S), composite suspensions with tool steel powders, thermally sprayed Ni-Cr- B-Si (self fluxing alloy) and nickel powder layers. The applied work developed practical HDI / transient liquid coating (TLC) procedures on test plates that demonstrated the ability to fuse carbide coatings for industrial applications such as agricultural blades, construction and mining vehicles. Fundamental studies helped create process models that led to improved process understanding and control. The coating of agricultural blades was demonstrated and showed the HDI process to have the ability to fuse industrial scale components. Sliding and brasive wear tests showed that high degree of wear resistance could be achieved with the addition of tool steel powders to carbide particulate composites.
Date: July 5, 2007
Creator: Smith, Ronald W.
Partner: UNT Libraries Government Documents Department

Abrasive wear behavior of heat-treated ABC-silicon carbide

Description: Hot-pressed silicon carbide, containing aluminum, boron, and carbon additives (ABC-SiC), was subjected to three-body and two-body wear testing using diamond abrasives over a range of sizes. In general, the wear resistance of ABC-SiC, with suitable heat treatment, was superior to that of commercial SiC.
Date: June 17, 2002
Creator: Zhang, Xiao Feng; Lee, Gun Y.; Chen, Da; Ritchie, Robert O. & De Jonghe, Lutgard C.
Partner: UNT Libraries Government Documents Department

The hardness, adhesion, and wear resistance of coatings developed for cobalt-base alloys

Description: One potential approach for reducing the level of nuclear plant radiation exposure that results from activated cobalt wear debris is the use of a wear resistant coating. However, large differences in stiffness between a coating/substrate can result in high interfacial stresses that produce coating de-adhesion when a coated substrate is subjected to high stress wear contact. Scratch adhesion and indentation tests have been used to identify four promising coating processes [1,2]: (1) the use of a thin Cr-nitride coating with a hard and less-stiff interlayer, (2) the use of a thick, multilayered Cr-nitride coating with graded layers, (3) use of the duplex approach, or nitriding to harden the material subsurface followed by application of a multilayered Cr-nitride coating, and (4) application of nitriding alone. The processing, characterization, and adhesion of these coating systems are discussed. The wear resistance and performance has been evaluated using laboratory pin-on-disc, 4-ball, and high stress rolling contact tests. Based on the results of these tests, the best coating candidate from the high-stress rolling contact wear test was the thin duplex coating, which consists of ion nitriding followed deposition of a thin Cr-nitride coating, while the thin Cr-nitride coating exhibited the best results in the 4-ball wear test.
Date: May 1, 2000
Creator: Cockeram, B.V. & Wilson, W.L.
Partner: UNT Libraries Government Documents Department

Anodic Behavior of SAM2X5 Material Applied as Amorphous Coatings

Description: Iron-based amorphous alloys are desirable industrial materials since they are highly resistant to corrosion and possess enhanced hardness for wear resistance. The amorphous materials can be produced from the melt as powder and later spray deposited as coatings on large engineering structures. As a laboratory experiment, SAM2X5 powder was coated on electrochemical specimens of 304SS for testing. Results show that the coated specimens did not perform satisfactorily during the laboratory testing. This is because of partial devitrification during the deposition of the powder on the small specimen substrates.
Date: August 10, 2007
Creator: Hailey, P D; Farmer, J C; Day, S D & Rebak, R B
Partner: UNT Libraries Government Documents Department

Evaluation Of Saltstone Mixer Paddle Configuration For Improved Wear Resistance

Description: A soft metal with low wear resistance (6000 series aluminum), was used to minimize run time while maximizing wear rate. Two paddle configurations were tested, with the first four paddles after the augers replaced by the wear paddles. The first configuration was all flat paddles, with the first paddle not aligned with the augers and is consistent with present SPF mixer. The second configuration had helical paddles for the first three stages after the augers and a flat paddle at the fourth stage. The first helical paddle was aligned with the auger flight for the second configuration. The all flat paddle configuration wear rate was approximately double the wear rate of the helical paddles for the first two sets of paddles after the augers. For both configurations, there was little or no wear on the third and fourth paddle sets based on mass change, indicating that the fully wetted premix materials are much less abrasive than the un-wetted or partially wetted premix. Additionally, inspection of the wear surface of the paddles at higher magnification showed the flat paddles were worn much more than the helical and is consistent with the wear rates. Aligning the auger discharge flight with the first set of helical paddles was effective in reducing the wear rate as compared to the flat paddle configuration. Changing the paddle configuration from flat to helical resulted in a slight increase in rheological properties. Although, both tests produced grout-like material that is within the processing rage of the SPF, it should be noted that cement is not included in the premix and water was used rather than salt solution, which does affect the rheology of the fresh grout. The higher rheological properties from the helical wear test are most likely due to the reduced number of shearing paddles in the ...
Date: September 27, 2012
Creator: Reigel, M. M.; Fowley, M. D. & Pickenheim, B. R.
Partner: UNT Libraries Government Documents Department

Study of PVD AlCrN Coating for Reducing Carbide Cutting Tool Deterioration in the Machining of Titanium Alloys

Description: This article studies a thin nanocomposite film made out of AlCrN (aluminum-chromium-nitrite) to show experimental work in the deposition process and its characterization.
Date: March 5, 2013
Creator: Cadena, Natalia L.; Cue-Sampedro, Rodrigo; Siller, Héctor R.; Arizmendi-Morquecho, Ana M.; Rivera-Solorio, Carlos I. & Di-Nardo, Santiago
Partner: UNT College of Engineering

Reactive multilayer synthesis of hard ceramic foils and films

Description: Disclosed is method for synthesizing hard ceramic materials such as carbides, borides and aluminides, particularly in the form of coatings provided on another material so as to improve the wear and abrasion performance of machine tools, for example. Method involves the sputter deposition of alternating layers of reactive metals with layers of carbon, boron, or aluminum and the subsequent reaction of the multilayered structure to produce a dense crystalline ceramic. The material can be coated on a substrate or formed as a foil which can be coiled as a tape for later use.
Date: December 31, 1993
Creator: Makowiecki, D.M. & Holt, J.B.
Partner: UNT Libraries Government Documents Department

Tribopolymerization as an anti-wear mechanism. Quarterly progress report, July--September 1996

Description: During this quarterly period, the author has made progress in a number of areas. He has continued to evaluate potential candidates for high load/high speed antiwear action using the approach of generating tribopolymers capable of withstanding high temperatures. Results are promising for ceramics as well as steel. The construction of a new instrument for high temperature studies of both liquid and vapor phase lubrication is almost complete. This will permit studies up to 350 C bulk temperature and considerably higher surface temperatures in controlled vapor-phase and liquid-phase studies. Selected monomers and monomer combinations found to be effective in hexadecane as a carrier fluid have also been tested in other fluids, including synthetic ester lubricant carriers. Additional studies using FTIRM for surface analysis of wear tracks have been made and are continuing. Further industrial contacts have been made to arrange for field testing of selected compounds as antiwear additives. The applications include the lubrication of 2-stroke and 4-stroke engines, machining and cutting, and fuel injector wear, particularly in gas (e.g., natural gas) engines.
Date: October 9, 1996
Creator: Furey, M.J.
Partner: UNT Libraries Government Documents Department

Potentially useful polyolester lubricant additives an overview of antioxidants, antiwear and antiseize compounds

Description: Reliable service lubrication of compressors with polyolesters that do not contain additives is the optimal goal for hermetic compressor use. Chlorine derived from CFC and HCFC refrigerants is reported to have effective antiwear properties and negates the widespread use of additives in mineral oil lubricated systems. The use of antioxidants for mineral oil and polyolesters have been reported; antioxidant additive activity seems essential for polyolesters.- Antiwear and antiseize additives seem to be a short term goal for use with polyolesters. High silicone aluminum to steel wear seems to be a primary target for additive use. The interaction of specific heteroatom organic compounds with highly polar surface active synthetic polyolester lubricants is complex. Results of an extensive literature search describe results from a service base determined at ambient conditions. Known lubricant additives used in the hermetic compressor industry, the. mode of action of several types of additives and some lubricant additive chemistry that demonstrates selective thermal stability in conjunction with the chemical structure are examined.
Date: November 1, 1996
Creator: Cavestri, R.C.
Partner: UNT Libraries Government Documents Department

Ceramic component manufacturing process development. Final report

Description: Ceramic materials are well suited for applications where temperature, wear, and corrosion resistance are necessary. The toughness and wear resistance properties that make ceramics desirable, also make fabrication of parts difficult. The objective of this CRADA was to increase the grinding efficiency on Ceradyne Incorporated silicon nitride. This was to be accomplished through optimization of grinding wheel life and increasing silicon nitride material removal rates. Experiments were conducted to determine the relationship between grinding parameters, wheel wear, and material removal rates. Due to excessive, unexplained variation in the experimental results, a consistent relationship between the selected grinding parameters and wheel wear could not be established. Maximum material removal rates were limited by spindle and table drive power. Additional experiments were conducted to evaluate high speed grinding. When compared to conventional grinding speeds, the material removal rates using high speed grinding (13,000 SFM) increased by a factor of five to ten with no degradation of fracture strength.
Date: September 30, 1996
Creator: Robinson, S.
Partner: UNT Libraries Government Documents Department

Influence of environmental parameters on the frictional behavior of DLC coatings

Description: In a previous studies it was shown that diamond like carbon (DLC) films possess low friction coefficient (f) and excellent wear resistance. The reduction in f was found to be consistent with a ``wear induced graphitization`` mechanism of the DLC structure. A recent study showed that operational parameters (sliding velocity and loading level) influence the tribological behavior of DLC film through control of the kinetics of the graphitization process. The objective of the present study was to investigate the influence of environmental parameters (humidity and temperature) on the tribological behavior of DLC film and provide further support to the wear induced graphitization mechanism. Ion beam deposition was utilized to deposit DLC on a SiC substrate. Pin-on-disc experiments were conducted by varying humidity (0%, 40% and 100%) and temperature ({minus}10 C and 25 C). As-deposited DLC and wear debris was characterized by transmission electron microscopy. It was found that lower humidity increases the graphitization rate more than likely due to the reduction in the effect by the water molecules. A decreased graphitization rate was observed at lower temperature and higher humidity and can be attributed to suppression of temperature rise at hot spots. The present findings are consistent with and further verify the wear induced graphitization mechanism.
Date: May 1, 1997
Creator: Liu, Y.; Erdemir, A. & Meletis, E.I.
Partner: UNT Libraries Government Documents Department

Lightweight materials for automotive applications/topic 2: Wear resistant aluminum alloy

Description: The replacement of cast iron by aluminum alloys in automotive engine blocks and heads represents a significant weight reduction in automobiles. The primary hurdle to the widespread use of aluminum alloy engine blocks in the North American automobile industry was high cost. The lack of wear resistance in most aluminum alloys added to manufacturing cost, since expensive procedures such as the incorporation of cast iron liners or special coatings were needed to achieve the required wear properties. The project targeted the development of a wear resistant aluminum alloy, as well as tools and the knowledge-base required to design the casting process, to allow it to be cast economically into engine blocks without the use of a cast iron liner or special coating, thereby providing benefits to both the material and manufacturing aspects of the process. The project combined the alloy development, wear and microstructural characterization, and casting modeling capabilities of the laboratory with the partners extensive alloy and casting process development and manufacturing experience to develop a suitable wear resistant aluminum alloy and casting process.
Date: January 31, 1997
Creator: Viswanathan, S.
Partner: UNT Libraries Government Documents Department

A filtered cathodic arc deposition apparatus and method

Description: A filtered cathodic arc deposition method and apparatus are described for the production of highly dense, wear resistant coatings which are free from macro particles. The filtered cathodic arc deposition apparatus includes a cross shaped vacuum chamber which houses a cathode target having an evaporable surface comprised of the coating material, means for generating a stream of plasma, means for generating a transverse magnetic field, and a macro particle deflector. The transverse magnetic field bends the generated stream of plasma in the direction of a substrate. Macro particles are effectively filtered from the stream of plasma by traveling, unaffected by the transverse magnetic field, along the initial path of the plasma stream to a macro particle deflector. The macro particle deflector has a preformed surface which deflects macro particles away from the substrate.
Date: December 1, 1997
Creator: Krauss, Alan R.
Partner: UNT Libraries Government Documents Department

Wear and friction behavior of Zr implanted D3 steel

Description: Multicharged, pure, high current and pulsed ion beams of Zr have been extracted from a metal vapor vacuum arc (MEVVA) source and implanted into AISI D3 (C: 2-2,35%, Mn: 0,60%, Si: 0,60%, Cr: 11-13,50%, Ni: 0,30%, W: 1%, V: 1%) tool steel samples at the 3,6.1016, 5.1016 and 1.1017 ions/cm2 doses. The wear resistance and friction coefficient have been estimated using pin-on-disc wear tests. Implantation of Zr decreased the wear loss and friction coefficient. RBS, AES and SEM Microprobe analyses were used as a guide for explanation of implantation's effects.
Date: August 23, 2001
Creator: Akbas, N.; Saklakoglu, I.E.; Monteiro, O.R. & Brown, I.G.
Partner: UNT Libraries Government Documents Department

Synthesis of diamondlike carbon films with superlow friction and wear properties

Description: In this study, the authors introduce a new diamondlike carbon (DLC) film providing a friction coefficient of 0.001 and wear rates of 10{sup {minus}9} to 10{sup {minus}10} mm{sup 3}/N.m in inert-gas environments (e.g., dry nitrogen and argon). The film was grown on steel and sapphire substrates in a plasma enhanced chemical vapor deposition system that uses using a hydrogen-rich plasma. Employing a combination of surface and structure analytical techniques, they explored the structural chemistry of the resultant DLC films and correlated these findings with the friction and wear mechanisms of the films. The results of tribological tests under a 10-N load (creating initial peak Hertz pressures of 1 and 2.2 GPa on steel and sapphire test pairs, respectively) and at 0.2 to 0.5 m/s sliding velocities indicated that a close correlation exists between the friction and wear coefficients of DLC films and the source gas chemistry. Specifically, films grown in source gases with higher hydrogen-to-carbon ratios had the lowest fiction coefficients and the highest wear resistance. The lowest friction coefficient (0.001) was achieved with a film on sapphire substrates produced in a gas discharge plasma consisting of 25% methane and 75% hydrogen.
Date: January 19, 2000
Creator: Erdemir, A.; Eryilmaz, O. L. & Fenske, G.
Partner: UNT Libraries Government Documents Department

Effect of W coating on microengine performance

Description: Two major problems associated with Si-based MEMS (MicroElectroMechanical Systems) devices are stiction and wear. Surface modifications are needed to reduce both adhesion and friction in micromechanical structures to solve these problems. In this paper, the authors present a CVD (Chemical Vapor Deposition) process that selectively coats MEMS devices with tungsten and significantly enhances device durability. Tungsten CVD is used in the integrated-circuit industry, which makes this approach manufacturable. This selective deposition process results in a very conformal coating and can potentially address both stiction and wear problems confronting MEMS processing. The selective deposition of tungsten is accomplished through the silicon reduction of WF{sub 6}. The self-limiting nature of the process ensures consistent process control. The tungsten is deposited after the removal of the sacrificial oxides to minimize stress and process integration problems. The tungsten coating adheres well and is hard and conducting, which enhances performance for numerous devices. Furthermore, since the deposited tungsten infiltrates under adhered silicon parts and the volume of W deposited is less than the amount of Si consumed, it appears to be possible to release adhered parts that are contacted over small areas such as dimples. The wear resistance of tungsten coated parts has been shown to be significantly improved by microengine test structures.
Date: March 1, 2000
Creator: MANI,SEETHAMBAL S.; FLEMING,JAMES G.; WALRAVEN,JEREMY A.; SNIEGOWSKI,JEFFRY J.; DE BOER,MAARTEN P.; IRWIN,LLOYD W. et al.
Partner: UNT Libraries Government Documents Department

Four great challenges confronting our understanding and modeling of sliding friction

Description: This paper addresses four challenges whose solutions may together enable significant progress in the predication and control of friction for energy conservation. Posed as questions these are: (1) how can materials with greatly different properties and compositions produce similar kinetic friction coefficients when tested under comparable conditions; (2) how is it possible that the kinetic friction coefficient for the same materials pair can differ greatly when it is slid in different tribosystems; (3) how can frictional phenomena at different size scales be reconciled; and (4) how can the effects of the machine, the materials (including lubricants) and the environment be successfully incorporated into quantitative and predictive friction models? Examples related to these four challenges are provided, as are possible approaches for attacking them in future research efforts.
Date: August 1, 1997
Creator: Blau, P.J.
Partner: UNT Libraries Government Documents Department

Friction and wear performance of diamondlike carbon films grown in various source gas plasmas

Description: In this study, the authors investigated the effects of various source gases (methane, ethane, ethylene, and acetylene) on the friction and wear performance of diamondlike carbon (DLC) films prepared in a plasma enhanced chemical vapor deposition (PECVD) system. Films were deposited on AISI H13 steel substrates and tested in a pin-on-disk machine against DLC-coated M50 balls in dry nitrogen. They found a close correlation between friction coefficient and source gas composition. Specifically, films grown in source gases with higher hydrogen-to-carbon ratios exhibited lower friction coefficients and higher wear resistance than films grown in source gases with lower hydrogen-to-carbon (H/C) ratios. The lowest friction coefficient (0.014) was achieved with a film derived from methane with an WC ratio of 4, whereas the coefficient of films derived from acetylene (H/C = 1) was of 0.15. Similar correlations were observed for wear rates. Specifically, films derived from gases with lower H/C values were worn out and the substrate material was exposed, whereas films from methane and ethane remained intact and wore at rates that were nearly two orders of magnitude lower than films obtained from acetylene.
Date: January 18, 2000
Creator: Erdemir, A.; Nilufer, I. B.; Eryilmaz, O. L.; Beschliesser, M. & Fenske, G. R.
Partner: UNT Libraries Government Documents Department

Friction and wear properties of smooth diamond films grown in fullerene-argon plasmas

Description: In this study, we describe the growth mechanism and the ultralow friction and wear properties of smooth (20-50 nm rms) diamond films grown in a microwave plasma consisting of Ar and fullerene (the carbon source). The sliding friction coefficients of these films against Si{sub 3}N{sub 4} balls are 0.04 and 0.1 in dry N{sub 2} and air, which are comparable to that of natural diamond sliding against the same pin material, but is lower by factors of 5 to 10 than that afforded by rough diamond films grown in conventional H{sub 2}-CH{sub 4} plasmas. Furthermore, the smooth diamond films produced in this work afforded wear rates to Si{sub 3}N{sub 4} balls that were two to three orders of magnitude lower than those of H{sub 2}-CH{sub 4} grown films. Mechanistically, the ultralow friction and wear properties of the fullerene-derived diamond films correlate well with their initially smooth surface finish and their ability to polish even further during sliding. The wear tracks reach an ultrasmooth (3-6 nm rms) surface finish that results in very little abrasion and ploughing. The nanocrystalline microstructure and exceptionally pure sp{sup 3} bonding in these smooth diamond films were verified by numerous surface and structure analytical methods, including x-ray diffraction, high-resolution AF-S, EELS, NEXAFS, SEM, and TEM. An AFM instrument was used to characterize the topography of the films and rubbing surfaces.
Date: August 1, 1995
Creator: Erdemir, A.; Fenske, G.R.; Bindal, C.; Zuiker, C.; Krauss, A.R. & Gruen, D.M.
Partner: UNT Libraries Government Documents Department

Carbon, nitrogen, and oxygen ion implantation of stainless steel

Description: Ion implantation experiments of C, N, and O into stainless steel have been performed, with beam-line and plasma source ion implantation methods. Acceleration voltages were varied between 27 and 50 kV, with pulsed ion current densities between 1 and 10 mA/cm{sup 2}. Implanted doses ranged from 0.5 to 3 {times} 10{sup 18}cm{sup -2}, while workpiece temperatures were maintained between 25 and 800 C. Implant concentration profiles, microstructure, and surface mechanical properties of the implanted materials are reported.
Date: December 31, 1995
Creator: Rej, D.J.; Gavrilov, N.V. & Emlin, D.
Partner: UNT Libraries Government Documents Department

Performance of Ultra Hard Carbon Wear Coatings on Microgears Fabricated by Liga

Description: Stiction and friction are of concern for the reliable, long-term application of Ni-alloy micromachines. We have found that the application of a 30-70 nm hard carbon coating produces a significant reduction in the friction coefficient and wear rate of electroformed Ni substrates in reciprocating sliding contact under simulated MEMS operating conditions. To evaluate the performance of coated components, a series of 70-pm-thick microgears ranging in diameter from 0.2 to 2.2 mm were fabricated from electroformed Ni via standard LIGA processes and fixtured on posts in preparation for the coating procedure. A pulsed vacuum- arc deposition process was used to deposit a carbon coating on the gears with the plasma incident at a shallow angle to the gears' top surface. A sample bias of -2 keV was used in order to produce a coating with relatively low stress and good adhesion while maintaining high hardness. This coating process is known to be somewhat comformal to the component surfaces. The coating uniformity, particularly in the high-aspect-ratio areas between the gear teeth, was evaluated with micro-Raman spectroscopy. It is shown that the coating can be applied uniformly on the top gear surface. Between the gear teeth the coating was the same thickness as on top of the gear down to a point 50 ~m below the top surface. Below that point (i.e. between 50 and 70 Lm), the coating thickness is somewhat thinner, but is still present. These results demonstrate that it is possible to a deposit hard carbon coating on microgears to reduce friction and wear in micromachines.
Date: December 18, 1998
Creator: Ager III, J.W.; Brown, I.G.; Christenson, T.R.; Dugger, M.T.; Follstaedt, D.M.; Knapp, J.A. et al.
Partner: UNT Libraries Government Documents Department

Surface alloying of silicon into aluminum substrate.

Description: Aluminum alloys that are easily castable tend to have lower silicon content and hence lower wear resistance. The use of laser surface alloying to improve the surface wear resistance of 319 and 320 aluminum alloys was examined. A silicon layer was painted onto the surface to be treated. A high power pulsed Nd:YAG laser with fiberoptic beam delivery was used to carry out the laser surface treatment to enhance the silicon content. Process parameters were varied to minimize the surface roughness from overlap of the laser beam treatment. The surface-alloyed layer was characterized and the silicon content was determined.
Date: October 28, 1998
Creator: Xu, Z.
Partner: UNT Libraries Government Documents Department

IMPROVEMENT OF WEAR COMPONENT'S PERFORMANCE BY UTILIZING ADVANCED MATERIALS AND NEW MANUFACTURING TECHNOLOGIES: CASTCON PROCESS FOR MINING APPLICATIONS

Description: During this reporting period, the debinding and off-gassing furnace was switched from a vacuum furnace to a conventional kiln to solve the HIP can expansion problem during high temperature off-gassing, which caused disc distortion. Two 6.5 inch discs were produced. Both looked acceptable and one was machined. It was found that the disc hub section was little bit thin and micro cracks were seen along the disc radial directions.
Date: March 22, 2004
Creator: Huang, Xiaodi & Gertsch, Richard
Partner: UNT Libraries Government Documents Department