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Title: Nanocoating for High-efficiency Industrial Hydraulic and Tooling Systems

Abstract

Characterization of the AlMgB14-based coatings revealed their semi-crystalline nature; as a single phase, AlMgB 14 appears amorphous. Combining this material with TiB2 through comminution of very fine-scale powders (~100 nm), produces a bulk solid that exceeds the hardness of its respective constituent phases. Through physical vapor deposition processing, the resulting nanocomposite coating combines the wear resistance characteristic of hard materials (e.g. the AlMgB 14) with a regenerating lubricant. Within the top layers (10-20 nm) of the nanocomposite coating, the same TiB2 phase used to enhance the strength and provide ductility to the otherwise brittle AlMgB 14 material reacts with available oxygen to form boron oxide. As the atoms of TiB 2 continue to react, layers of boric acid begin to form at the surface. This affords an exceptionally low coefficient of friction (as low as 0.02) to the coating. Physical vapor deposition processing parameters were evaluated and optimized during the project to minimize the difficulties common to transitioning a laboratory-scale process or technology to a salable product. Coating process times and temperatures, process gas flows and ramp rates, and a number of other adjustable parameters were optimized based on the results of testing and coating characterization. The overriding goal ofmore » all of these efforts was a repeatable coating process that yields the benefits observed in the laboratory, independent of the intended product or market.« less

Authors:
 [1]
+ Show Author Affiliations
  1. Ames Lab., Ames, IA (United States)
Publication Date:
Research Org.:
Ames Laboratory (AMES), Ames, IA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1233433
Report Number(s):
CRADA-2007-01
DOE Contract Number:
AC02-07CH11358
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE

Citation Formats

Cook, Bruce. Nanocoating for High-efficiency Industrial Hydraulic and Tooling Systems. United States: N. p., 2011. Web. doi:10.2172/1233433.
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Cook, Bruce. Nanocoating for High-efficiency Industrial Hydraulic and Tooling Systems. United States. doi:10.2172/1233433.
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Cook, Bruce. Wed . "Nanocoating for High-efficiency Industrial Hydraulic and Tooling Systems". United States. doi:10.2172/1233433. https://www.osti.gov/servlets/purl/1233433.
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@article{osti_1233433,
title = {Nanocoating for High-efficiency Industrial Hydraulic and Tooling Systems},
author = {Cook, Bruce},
abstractNote = {Characterization of the AlMgB14-based coatings revealed their semi-crystalline nature; as a single phase, AlMgB14 appears amorphous. Combining this material with TiB2 through comminution of very fine-scale powders (~100 nm), produces a bulk solid that exceeds the hardness of its respective constituent phases. Through physical vapor deposition processing, the resulting nanocomposite coating combines the wear resistance characteristic of hard materials (e.g. the AlMgB14) with a regenerating lubricant. Within the top layers (10-20 nm) of the nanocomposite coating, the same TiB2 phase used to enhance the strength and provide ductility to the otherwise brittle AlMgB14 material reacts with available oxygen to form boron oxide. As the atoms of TiB2 continue to react, layers of boric acid begin to form at the surface. This affords an exceptionally low coefficient of friction (as low as 0.02) to the coating. Physical vapor deposition processing parameters were evaluated and optimized during the project to minimize the difficulties common to transitioning a laboratory-scale process or technology to a salable product. Coating process times and temperatures, process gas flows and ramp rates, and a number of other adjustable parameters were optimized based on the results of testing and coating characterization. The overriding goal of all of these efforts was a repeatable coating process that yields the benefits observed in the laboratory, independent of the intended product or market.},
doi = {10.2172/1233433},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Wed Jun 22 00:00:00 EDT 2011},
month = {Wed Jun 22 00:00:00 EDT 2011}
}
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DOI:  10.2172/1233433
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  • Industrial manufacturing in the U.S. accounts for roughly one third of the 98 quadrillion Btu total energy consumption. Motor system losses amount to 1.3 quadrillion Btu, which represents the largest proportional loss of any end-use category, while pumps alone represent over 574 trillion BTU (TBTU) of energy loss each year. The efficiency of machines with moving components is a function of the amount of energy lost to heat because of friction between contacting surfaces. The friction between these interfaces also contributes to downtime and the loss of productivity through component wear and subsequent repair. The production of new replacement partsmore » requires additional energy. Among efforts to reduce energy losses, wear-resistant, low-friction coatings on rotating and sliding components offer a promising approach that is fully compatible with existing equipment and processes. In addition to lubrication, one of the most desirable solutions is to apply a protective coating or surface treatment to rotating or sliding components to reduce their friction coefficients, thereby leading to reduced wear. Historically, a number of materials such as diamond-like carbon (DLC), titanium nitride (TiN), titanium aluminum nitride (TiAlN), and tungsten carbide (WC) have been examined as tribological coatings. The primary objective of this project was the development of a variety of thin film nanocoatings, derived from the AlMgB14 system, with a focus on reducing wear and friction in both industrial hydraulics and cutting tool applications. Proof-of-concept studies leading up to this project had shown that the constituent phases, AlMgB14 and TiB2, were capable of producing low-friction coatings by pulsed laser deposition. These coatings combine high hardness with a low friction coefficient, and were shown to substantially reduce wear in laboratory tribology tests. Selection of the two applications was based largely on the concept of improved mechanical interface efficiencies for energy conservation. In mobile hydraulic systems, efficiency gains through low friction would translate into improved fuel economy and fewer greenhouse gas emissions. Stationary hydraulic systems, accordingly, would consume less electrical power. Reduced tooling wear in machining operations would translate to greater operating yields, while lowering the energy consumed during processing. The AlMgB14 nanocoatings technology progressed beyond baseline laboratory tests into measurable energy savings and enhancements to product durability. Three key hydraulic markets were identified over the course of the project that will benefit from implementation: industrial vane pumps, orbiting valve-in-star hydraulic motors, and variable displacement piston pumps. In the vane pump application, the overall product efficiency was improved by as much as 11%. Similar results were observed with the hydraulic motors tested, where efficiency gains of over 10% were noted. For variable displacement piston pumps, overall efficiency was improved by 5%. For cutting tools, the most significant gains in productivity (and, accordingly, the efficiency of the machining process as a whole) were associated with the roughing and finishing of titanium components for aerospace systems. Use of the AlMgB14 nanocoating in customer field tests has shown that the coated tools were able to withstand machining rates as high as 500sfm (limited only by the substrate material), with relatively low flank wear when compared to other industrial offerings. AlMgB14 coated tools exhibited a 60% improvement over similarly applied TiAlN thin films. Furthermore, AlMgB14-based coatings in these particular tests lasted twice as long than their TiAlN counterparts at the 500sfm feed rates. Full implementation of the technology into the industrial hydraulic and cutting tool markets equates to a worldwide energy savings of 46 trillion BTU/year by 2030. U.S.-based GHG emissions associated with the markets identified would fall accordingly, dropping by as much as 50,000 tonnes annually.« less

  • ; ;
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  • ; ;

  • This factsheet describes a research project whose goal is to develop degradation-resistant nano-coatings of AlMgB14 and AlMgB14– (titanium diboride) TiB2 that result in improved surface hardness and reduced friction for industrial hydraulic and tooling systems.

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    Pulse-combustion systems, in commercial/industrial (C/I) boiler applications, offer the potential benefits of increased efficiency and reliability. Aerovalved pulse-combustion (P/C) systems have no moving parts, pump their own combustion air, and generate an overall pressure rise through the burner system. These features should lead to more compact boilers requiring less maintenance. Aerovalved P/C technology has been developed in this program to permit P/C modules to operate on low pressure natural gas. Two modules were successfully coupled to operate in opposed phase. A laboratory demonstration boiler with 6 P/C modules was designed, fabricated, and tested with various module combinations. Results indicated thatmore » a more fundamental understanding of pulse combustion burners is required before practical commercial/industrial systems can be developed.« less