ICMCTF2016 Session G5: Application-Driven Cooperations between Industry and Basic Research Institutions

Monday, April 25, 2016 10:00 AM in Room California

Monday Morning

Time Period MoM Sessions | Abstract Timeline | Topic G Sessions | Time Periods | Topics | ICMCTF2016 Schedule

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10:00 AM G5-1 Multisectorial Aspects of Surface Engineering - Win-Win Scenario for the University-Industry Partnership
Ludvik Martinu (Polytechnique Montreal, Canada)

Further progress in surface engineering is strongly stimulated by a simultaneous action of two forces: a) the “pulling force” represented by the economic, technological and societal needs including sustainable development; and b) the “pushing force” related to the curiosity-driven nanotechnology combining new design concepts of materials and devices, fabrication processes and innovative characterization tools, where the only limitation appears to be our imagination.

This presentation will describe different aspects of cooperation between our university laboratory that has developed a close collaboration with industry, while bringing together a consortium of OEM (original equipment manufacturer) partners representing different sectors. Using the setting of university-industry partnership programs in Canada, we will discuss tangible benefits for both industry and academia when developing a research program in which multiple outcomes are at stake, namely the marketable product or technology, new knowledge, and training of highly qualified personnel. We will provide specific examples of the synergies between research activities on the development of novel nanostructured coating systems related to different multibillion-dollar sectors including optics, aerospace and outer space, manufacturing, and energy generation, distribution and saving.

10:40 AM G5-3 Al-Cr-Ti-O Coatings Synthesized by Cathodic Arc
Marcus Hans, Denis Music, Yen-Ting Chen, Damian Holzapfel (RWTH Aachen University, Germany); Daniel Primetzhofer (Uppsala University, Sweden); Denis Kurapov, Jürgen Ramm, Mirjam Arndt (Oerlikon Balzers, Oerlikon Surface Solutions AG, Liechtenstein); Helmut Rudigier (Oerlikon Balzers, Oerlikon Surface Solutions AG, Switzerland); Jochen Schneider (RWTH Aachen University, Germany)

Within the last decade Al-Cr based oxides have attracted large interest in academic research as well as industrial coating development due to phase formation of chemically inert and wear resistant α-(Al,Cr)2O3 at deposition temperatures < 600°C. We present our recent findings regarding the effect of Ti incorporation in Al-Cr-Ti-O on the structure and mechanical properties. (Al0.67Cr0.33-xTix)2O3-z coatings (0 ≤ x < 0.18) were synthesized with a combinatorial approach by reactive cathodic arc deposition in an Oerlikon Balzers Ingenia P3e™ deposition system. Chemical composition analysis by Time-of-flight elastic recoil detection suggests the substitution of Cr by Ti, while the Al concentration remains constant. The homogeneous distribution of Al, Cr, Ti and O was examined by 3D atom probe tomography. Crystal structure investigations were carried out by X-ray diffraction and experimental evidence for α-Al2O3 phase formation is given in case of x < 0.05. Mechanical properties were measured by nanoindentation of polished coatings, deposited onto cemented carbide substrates. Coatings with x < 0.15 exhibit elastic modulus and hardness values of 297 ± 21 GPa and 21 ± 2 GPa, respectively, while a reduction to 236 ± 19 GPa and 13 ± 2 GPa is obtained for 0.15 < x < 0.18. The present study on the relationship between chemical composition, crystal structure and mechanical properties of Al-Cr-Ti-O contributes to the design of protective Al-Cr based oxide coatings.

11:00 AM G5-4 Analysis of CrN/AlN/Al2O3 and Two Industrially Used Coatings Deposited on Die Casting Cores after Application in an Aluminum Die Casting Machine
Kirsten Bobzin, Tobias Brögelmann (Surface Engineering Institute - RWTH Aachen University, Germany); Ulrich Hartmann (Martinrea Honsel Germany GmbH, Germany); Nathan Kruppe (Surface Engineering Institute - RWTH Aachen University, Germany)

Aluminum die casting is one of the most important production processes in the die casting industry. Damage mechanisms, such as abrasive and adhesive wear, corrosion due to metallic melt as well as heat-shock cracks by thermo-cyclical load, have significant influence on tool life and product quality. Aluminum die casting cores are exposed to a thermo-cyclical load, high pressures and a high flow velocity of the melt. Multilayer coatings like CrN/AlN/Al2O3 based on transition metal nitrides such as CrN and AlN and oxide toplayers such as Al2O3 deposited via physical vapor deposition (PVD), offer high potential to be used as protective coatings due to their high hardness and chemical inertness. The present work deals with the investigation of a CrN/AlN/Al2O3 coating deposited by using pulsed cathodic arc evaporation and two industrially used hard coatings on AISI H11 (1.2343) hot work steel after application in tribological rotating immersion tests and furthermore in industrial scale aluminum die casting machines. Therefore, the uncoated die casting cores were pretreated by a plasma nitriding and pressure blasting process in order achieve a specific stress state at the surface. These cores were coated with CrN/AlN/Al2O3 and two industrially used hard coatings. In order to investigate the temperature stability of the Al2O3 toplayer, the coating was annealed at TF = 680 °C for tF = 2 h and analyzed by means of X-ray diffraction (XRD), scanning electron microscopy (SEM) and transmission electron microscopy (TEM). For the purpose of analyzing the corrosion resistance of the coatings against aluminum die casting melt A333.1 (EN AC-46000), tribological rotating immersion tests at TI = 680 °C for tI1 = 2 h and tI2 = 6 h were conducted. The tested samples were then analyzed by means of SEM and energy dispersive X-ray spectroscopy (EDS). In order to investigate the behavior of the three different coatings under realistic conditions, coated cores were tested in an industrial scale aluminum die casting machine. After 5,884 shots the coated cores were analyzed nondestructively by means of large chamber SEM and micrographs of the cores by means of SEM and EDS. It has been demonstrated that the pretreatment process led to an excellent resistance to heat-shock cracks in the die casting cores. Analyses of the thermal stability by means of TEM showed that the Al2O3 toplayer of the CrN/AlN/Al2O3 coating was deposited in an amorphous state and transformed into partially crystalline γ-Al2O3. Nevertheless, the results of the core analyses after 5,884 die casting shots indicate a good performance of CrN/AlN/Al2O3, also in comparison to industrially used coatings.

11:20 AM G5-5 Advanced Hard Coatings for Cutting Tools: Knowledge-based Design Approaches to Meet Industrial Needs and Requirements
Christian Mitterer (Montanuniversität Leoben, Austria); Christoph Czettl (CERATIZIT Austria GmbH, Austria)

Today’s cutting applications pose extreme requirements on the mechanical, chemical and thermal stability of coated cutting tools, which are often fulfilled by applying hard coatings to cemented carbide cutting inserts. Despite the tremendous progress achieved during the past decades, there is still a serious lack of the required basic coating information needed for knowledge-based development. Furthermore, also a detailed insight in coating degradation and failure mechanisms occurring during application is often missing. Breakthroughs in development and design of novel coating materials thus require intensive contributions from basic research, enabling access to sophisticated methods and facilities to provide the necessary information about coating microstructure and properties, and industry, defining needs and requirements and providing access to applications. Within this presentation, an example for a successful industry/university collaboration is given. There, advanced characterization techniques like site-specific preparation of coating cross-sections by focused ion beam milling, electron backscatter diffraction and synchrotron X-ray nanodiffraction enable to obtain the necessary depth-resolved information on coating microstructure and mechanical properties. With the feedback from application tests, the established fundamental understanding of microstructure/property/performance relations provides the basis for a knowledge-based design of advanced coating materials.

Time Period MoM Sessions | Abstract Timeline | Topic G Sessions | Time Periods | Topics | ICMCTF2016 Schedule