There is increasing scientific and commercial interest in the development of nanostructured coatings, particularly those based on low-miscibility ‘ceramic–ceramic’ or ‘ceramic–metal’ crystalline/amorphous nanocomposite phase mixtures deposited by plasma-assisted PVD or CVD. In laboratory mechanical testing, extreme values of hardness (which may be in excess of 70 GPa) are often found for such films, similar to those claimed for intrinsically hard materials such as c-BN and diamond. High hardness is, however, often accompanied by an associated high elastic modulus, which although desirable in principle for cutting tool materials and/or coatings, may in practice limit coating durability, on low-strength, low-modulus substrates (e.g. low-alloy steels and the light alloys) and in many wear applications other than metal cutting. In this paper, we discuss the benefits of using the ratio of hardness to elastic modulus ( H / E ) as an indicator of coating durability since this parameter essentially describes the elastic strain to failure capability (and resilience ) of a candidate material. Furthermore, we consider the likely need for tribological coatings to accommodate some degree of substrate deformation; in this respect film toughness , i.e. ‘engineering toughness’ in the sense of an ability to absorb deformation energy (both elastic and plastic) needs to be considered. The concept of predominantly metallic films with a nanograined and/or glassy microstructure (containing little or no high-modulus ceramic constituents) is introduced, through which we point to the importance of retaining ‘sufficient’ coating hardness, whilst reducing coating elastic moduli to more closely match those of candidate substrate materials. With regard to the implications of H / E for practical tribological coating applications, we propose that closer matching of the coating/substrate interfacial elastic properties and thus an improved ability for the coating to accommodate substrate strain, where necessary, is often a more important factor in wear resistance than is extremely high hardness.

Design criteria for wear-resistant nanostructured and glassy-metal coatings

Since the early stages of thermal spray, it has been recognized that the powder composition, size distribution, shape, mass density, mechanical resistance, components distribution for composite particles play a key role in coating microstructure and thermo mechanical properties. The principal characteristics of particles are strongly linked to the manufacturing process. Coatings also depend on the process used to spray particles and spray parameters. Many papers have been devoted to the relationships existing between coating properties and structures at different scales and manufacturing processes. In many conventional spray conditions resulting in micrometric structures, among the different parameters, good powder flow ability, and dense particles are important features. Thermal plasma treatment, especially by RF plasma, of particles, prepared by different manufacturing processes, allows achieving such properties and it is now developed at an industrial scale. Advantages and drawbacks of this process will be discussed. Another point, which will be approached, is the self-propagating high-temperature synthesis, depending very strongly upon the starting composite particle manufacturing. However, as everybody knows, “small is beautiful” and nano- or finely structured coatings are now extensively studied with spraying of: (i) very complex alloys containing multiple elements which exhibit a glass forming capability when cooled-down, their under-cooling temperature being below the glass transition temperature; (ii) conventional micrometer-sized particles (in the 30-90 μm range) made of agglomerated nanometer-sized particles; (iii) sub-micrometer- or nanometer-sized particles via a suspension in which also, instead of particles, stable sol of nanometer-sized particles can be introduced; and (iv) spray solutions of final material precursor. These different processes using plasma, HVOF or sometimes flame and also cold-gas spray will be discussed together with the production of nanometer-sized particles via the chemical reaction method or by a special type of milling: the cryogenic milling process often referred to as “cryomilling.”

https://link.springer.com/content/pdf/10.1007%2Fs11666-009-9435-x.pdf

From Powders to Thermally Sprayed Coatings

coatings with a composition of Fe(48)Cr(15)Mo(14)C(15)B(6)Y(2) were prepared by means of high velocity oxygen fuel (HVOF) thermal spraying under different conditions. Microstructural studies show that the coatings present dense layered structure and low porosity with a fraction of nanocrystals precipitated. The porosity and fraction of the coatings decrease as the kerosene and oxygen flow increase within the parameter range examined. Corrosion behavior of the amorphous coatings was investigated by electrochemical measurement. The results show that the coatings are spontaneously passivated with wide passive region and low passive current density in 3.5% NaCl. 1 N HCl and 1 N H(2)SO(4) solutions. and exhibit an excellent ability to resist localized corrosion. However, the corrosion resistance of the coatings decreases in 1 N NaOH solution with lower transpassive potential and passive region. In addition, the optimal spraying parameter improves the corrosion resistance of the amorphous coatings obviously due to the proper proportion of porosity and amorphous fraction. (C) 2009 Elsevier B.V. All rights reserved.

Formation and corrosion behavior of Fe-based amorphous metallic coatings by HVOF thermal spraying

Wear behavior of HVOF-sprayed Fe-based amorphous coatings

Pitting initiation in Fe-based amorphous coatings

In this article, amorphous and nanocomposite thermally deposited steel coatings have been formed by using both plasma and high-velocity oxy-fuel (HVOF) spraying techniques. This was accomplished by developing a specialized iron-based composition with a low critical cooling rate (≈104 K/s) for metallic glass formation, processing the alloy by inert gas atomization to form micron-sized amorphous spherical powders, and then spraying the classified powder to form coatings. A primarily amorphous structure was formed in the as-sprayed coatings, independent of coating thickness. After a heat treatment above the crystallization temperature (568 °C), the structure of the coatings self-assembled (i.e., devitrified) into a multiphase nanocomposite microstructure with 75 to 125 nm grains containing a distribution of 20 nm second-phase grain-boundary precipitates. Vickers microhardness testing revealed that the amorphous coatings were very hard (10.2 to 10.7 GPa), with further increases in hardness after devitrification (11.4 to 12.8 GPa). The wear characteristics of the amorphous and nanocomposite coatings were determined using both two-body pin-on-disk and three-body rubber wheel wet-slurry sand tests. The results indicate that the amorphous and nanocomposite steel coatings are candidates for a wide variety of wear-resistant applications.

D. J. Branagan

Papers

Wear-resistant amorphous and nanocomposite steel coatings