Nanocoatings for High-Efficiency Industrial and Tooling Systems
- Eaton Corporation
This industry-driven project was the result of a successful response by Eaton Corporation to a DOE/ITP Program industry call. It consisted of three phases in which ORNL participated. In addition to Eaton Corporation and ORNL (CRADA), the project team included Ames Laboratory, who developed the underlying concept for aluminum-magnesium-boron based nanocomposite coatings [1], and Greenleaf, a small tooling manufacturer in western Pennsylvania. This report focuses on the portion of this work that was conducted by ORNL in a CRADA with Eaton Corporation. A comprehensive final report for the entire effort, which ended in September 2010, has been prepared by Eaton Corporation. Phase I, “Proof of Concept” ran for one year (September 1, 2006 to September 30, 2007) during which the applicability of AlMgB14 single-phase and nanocomposite coatings on hydraulic material coupons and components as well as on tool inserts was demonstrated.. The coating processes used either plasma laser deposition (PLD) or physical vapor deposition (PVD). During Phase I, ORNL conducted laboratory-scale pin-on-disk and reciprocating pin-on-flat tests of coatings produced by PLD and PVD. Non-coated M2 tool steel was used as a baseline for comparison, and the material for the sliding counterface was Type 52100 bearing steel since it simulated the pump materials. Initial tests were run mainly in a commercial hydraulic fluid named Mobil DTE-24, but some tests were later run in a water-glycol mixture as well. A tribosystem analysis was conducted to define the operating conditions of pump components and to help develop simulative tests in Phase II. Phase II, “Coating Process Scale-up” was intended to use scaled-up process to generate prototype parts. This involved both PLD practices at Ames Lab, and a PVD scale-up study at Eaton using its production capable equipment. There was also a limited scale-up study at Greenleaf for the tooling application. ORNL continued to conduct friction and wear tests on process variants and developed tests to better simulate the applications of interest. ORNL also employed existing lubrication models to better understand hydraulic pump frictional behavior and test results. Phase III, “Functional Testing” focused on finalizing the strategy for commercialization of AlMgB14 coatings for both hydraulic and tooling systems. ORNL continued to provide tribology testing and analysis support for hydraulic pump applications. It included both laboratory-scale coupon testing and the analysis of friction and wear data from full component-level tests performed at Eaton Corp. Laboratory-scale tribology test methods are used to characterize the behavior of nanocomposite coatings prior to running them in full-sized hydraulic pumps. This task also includes developing tribosystems analyses, both to provide a better understanding of the performance of coated surfaces in alternate hydraulic fluids, and to help design useful laboratory protocols. Analysis also includes modeling the lubrication conditions and identifying the physical processes by which wear and friction of the contact interface changes over time. This final report summarizes ORNL’s portion of the nanocomposite coatings development effort and presents both generated data and the analyses that were used in the course of this effort.
- Research Organization:
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Sponsoring Organization:
- USDOE Office of Industrial Technology Program (EE-2F)
- DOE Contract Number:
- DE-AC05-00OR22725
- OSTI ID:
- 1005178
- Report Number(s):
- NFE-07-00620; ORNL/TM-2011/25; TRN: US201106%%77
- Country of Publication:
- United States
- Language:
- English
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Nanocoatings for High-Efficiency Industrial Hydraulic and Tooling Systems
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Related Subjects
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
ALUMINIUM
BORON
COATINGS
COMMERCIALIZATION
COMPOSITE MATERIALS
DEPOSITION
FRICTION
HYDRAULIC FLUIDS
HYDRAULICS
LUBRICATION
MAGNESIUM
MANUFACTURERS
MATERIALS
MIXTURES
PHYSICAL VAPOR DEPOSITION
PUMPS
STEELS
SURFACE COATING
TESTING
TRIBOLOGY