ULTRACOATINGS: Enabling Energy and Power Solutions in High Contact Stress Environments through Next-Generation Nanocoatings
- Eaton Corp.
This industry-driven project was the result of a successful response by Eaton Corporation to a DOE/ITP Program, Grand Challenge, industry call. It consisted of a one-year effort in which ORNL participated in the area of friction and wear testing. In addition to Eaton Corporation and ORNL (CRADA), the project team included: Ames Laboratory, who developed the underlying concept for titanium- zirconium-boron (TZB) based nanocomposite coatings; Borg-Warner Morse TEC, an automotive engine timing chain manufacturer in Ithaca, New York, with its own proprietary hard coating; and Pratt & Whitney Rocketdyne, Inc., a dry-solids pump manufacturer in San Fernando Valley, California. This report focuses only on the portion of 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 for DOE by the team. The term 'ultracoatings' derives from the ambitious technical target for the new generation of nanocoatings. As applications, Eaton was specifically considering a fuel pump and a gear application in which the product of the contact pressure and slip velocity during operation of mating surfaces, commonly called the 'PV value', was equal to or greater than 70,000 MPa-m/s. This ambitious target challenges the developers of coatings to produce material capable of strong bonding to the substrate, as well as high wear resistance and the ability to maintain sliding friction at low, energy-saving levels. The partners in this effort were responsible for the selection and preparation of such candidate ultracoatings, and ORNL used established tribology testing capabilities to help screen these candidates for performance. 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. Initial contact stress and speed calculations showed that laboratory tests with available geometries, applied forces, and speeds at ORNL could not reach 70,000 MPa-m/s for the project target, so test conditions were modified to enable screening of the new coating compositions under conditions used in a prior nano-coatings development project with Eaton Corporation and Ames Laboratory. Eaton Innovation Center was able to conduct screening tests at higher loads and speeds, thus providing complementary information on coating durability and friction reduction. Those results are presented in the full team's final report which is in preparation at this writing. Tests of two types were performed at ORNL during the course of this work: (1) simulations of timing chain wear and friction under reciprocating conditions, and (2) pin-on-disk screening tests for bearings undergoing unidirectional sliding. The four materials supplied for evaluation in a timing chain link simulation were hardened type 440B stainless steel, nitrided type 440B stainless steel, vanadium carbide (VC)-coated type 52100 bearing steel, and (ZrTi)B-coated type 52100 bearing steel. Reciprocating wear tests revealed that the VC coating was by far the most wear resistant. In friction, the nitrided stainless steel did slightly better than the other materials.
- Research Organization:
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Sponsoring Organization:
- USDOE EE Office of Industrial Technologies (EE-2F)
- DOE Contract Number:
- DE-AC05-00OR22725
- OSTI ID:
- 1027860
- Report Number(s):
- NFE-11-03544; TRN: US201123%%525
- Country of Publication:
- United States
- Language:
- English
Similar Records
Nanocoatings for High-Efficiency Industrial and Tooling Systems
Life Improvement of Pot Hardware in Continuous Hot Dipping Processes Final Report
Related Subjects
36 MATERIALS SCIENCE
AMES LABORATORY
BEARINGS
BONDING
COATINGS
ENGINES
FRICTION
MANUFACTURERS
MATING
SCREENS
SLIDING FRICTION
SLIP VELOCITY
STAINLESS STEELS
TARGETS
TESTING
TITANIUM
TRIBOLOGY
VANADIUM CARBIDES
VELOCITY
WEAR RESISTANCE
coatings
lubricants