Multiphase Nano-Composite Coatings for Achieving Energy Optimization

Technical Report · Mon Mar 26 00:00:00 EDT 2012

DOI:https://doi.org/10.2172/1036989· OSTI ID:1036989

Nainaparampil, Jose

UES Inc. and ANL teamed in this work to develop novel coating systems for the protection of surfaces from thermal degradation mainly in two applications; Machining and Die casting. These coatings were specifically designed for the purpose by incorporating required material phases and the overall architecture, which led to reduce the energy usage and increase efficiency of the operations. Following the UES/ANL's feasibility work, the coatings were developed utilizing High power impulse magnetron sputtering (HiPMS) and Large area filtered arc deposition (LAFAD) techniques. Toughness, hardness and oxidation resistance: contrasting qualities have been mixed in the right proportion to attain the suitable material characteristic for the cause. Hafnium diboride (HfB2) based materials provided such a system and its properties were tamed to attain the right combination of toughness and hardness by working on the microstructure and architecture of coatings. An effective interfacing material (graded concentrations of topcoat) was also achieved in this work to provide the required adhesion between the substrate and the coating. Combination of an appropriate bond coat and a functional top coat provided the present thermal degradation resistant coating for cutting tools and die-casting applications. Laboratory level performance tests and industrial level application tests by partner companies (Beta Site Testing) were used for the development of these coatings.

• Research Organization: UES, Inc., 4401 Dayton-Xenia Rd, Dayton OH 45432
• Sponsoring Organization: USDOE EE Office of Industrial Technologies (EE-2F)
• DOE Contract Number: EE0003489
• OSTI ID: 1036989
• Report Number(s): DOE/EE003489-1; UES P921; TRN: US201211%%329
• Country of Publication: United States
• Language: English

Related Subjects

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
36 MATERIALS SCIENCE
42 ENGINEERING
99 GENERAL AND MISCELLANEOUS//MATHEMATICS, COMPUTING, AND INFORMATION SCIENCE
ADHESION
ARCHITECTURE
CASTING
COATINGS
CUTTING TOOLS
DEPOSITION
EFFICIENCY
FUNCTIONALS
HAFNIUM
HARDNESS
MACHINING
MAGNETRONS
MICROSTRUCTURE
OPTIMIZATION
OXIDATION
SPUTTERING
SUBSTRATES
TESTING
THERMAL DEGRADATION
Thermal degradation
tool coatings
die-casting
accelerated tool evaluation