Advanced Functional and Structural Thin Films and Coatings: Coating Technologies and Surface Structuring for Tools I
Sponsored by: TMS Functional Materials Division, TMS: Thin Films and Interfaces Committee
Program Organizers: Adele Carrado, University of Strasbourg; Ramana Chintalapalle, University of Texas at El Paso; Gerald Ferblantier, University of Strasbourg - IUT LP / ICube Laboratory - CNRS; Nancy Michael, University of Texas at Arlington; Karine Mougin, Cnrs, Is2m; Heinz Palkowski, Clausthal University of Technology; Nuggehalli Ravindra, New Jersey Institute of Technology; Vikas Tomar, Purdue University

Tuesday 2:00 PM
March 16, 2021
Room: RM 19
Location: TMS2021 Virtual

Session Chair: Karine Mougin, IS2M UHA; Heinz Palkowski, IMET


2:00 PM  Invited
Investigations on the Process Stability of Dry Deep Drawing with Volatile Lubricants Injected through Laser-drilled Microholes: Gerd Reichardt1; Manuel Henn2; Kim Riedmüller1; Rudolf Weber2; Thomas Graf2; Mathias Liewald1; Daniel Hemming3; Georg Umlauf4; Paul Reichle3; Jakob Barz4; Günter E.M. Tovar3; 1Institute for Metal Forming Technology; 2Institut für Strahlwerkzeuge; 3Institute of Interfacial Process Engineering and Plasma Technology; 4Fraunhofer Institute for Interfacial Engineering and Biotechnology
     To prevent damage to components and tools during deep drawing processes, the use of lubricants is recommended. Depending on the demands of given processes and materials, different types of lubricants such as mineral oils, synthetic oils, emulsions or waxes are generally used. However, these lubricants often contain substances that are harmful to human health and environment. Additionally, they must be applied before forming operations and washed off afterwards to enable subsequent processes.A novel tribological system using volatile lubricants such as CO2 or N2 has been developed and tested to counteract these disadvantages. The operating principle of this tribological system is based on the injection of volatile media into the friction zone under high pressure to ensure the separation of tool and sheet metal surface. This contribution presents the latest findings on the laser drilling of microholes and on process stability of the dry deep drawing process under endurance conditions.

2:30 PM  
Laboratory-on-a Crystal for Multifunctional, Multiscale Testing of Thin Films: Ilia Ivanov1; 1Center for Nanophase Materials Sciences, Oak Ridge National Laboratory
     Application of new experimental platform, Lab-on-a-crystal to measure optical, electrical, gravimetric, and viscoelastic properties of the same thin film under dynamic environment. The Lab-on-a-crystal enables high-throughput multifunctional materials characterization on a continuous scale, from meso scale down to nanoscale on the same h film. The system uses specially modified AT cut quartz crystal microbalance, QCM, and additional to enable electrical (impedance, resistance), optical, gravimetric, viscoelastic measurements simultaneously under controlled environment (light, gas, vapor atmosphere). We will show how machine learning tools can be used to correlate different functional properties of a thin film during exposure to environment during exposure to environment. Acknowledgement This research was conducted at the Center for Nanophase Materials Sciences, which is a DOE Office of Science User Facility.Machine Learning-Enabled Correlation and Modeling of Multimodal Response of Thin Film to Environment on Macro and Nanoscale Using "Lab-on-a-Crystal" Adv. Funct. Mater. (2020) DOI: 10.1002/adfm.201908010

2:50 PM  Keynote
Nanomanipulation and Nanolithography Experiments on Mono- and Multilayer MoS2 Surfaces: Enrico Gnecco1; Alper Özogul1; Felix Cassin1; Roberto Guerra2; Andrey Turchanin1; Franciszek Krok3; 1Friedrich Schiller University Jena; 2University of Milan; 3Jagiellonian University Krakow
    We report the results of rather unconventional nanotribological investigations on MoS2. In a first series of measurements we have manipulated Au islands along different directions of MoS2 single crystal surfaces and mono- and bi-layers on SiO2. The zigzag orientation turns out as a preferential direction of motion, in full agreement with molecular dynamics investigations of the manipulation process. As a result, the Au islands tend to form long nanostripes, whose compaction is prevented by the substrate roughness and/or charging effects. In the second part of the talk we will discuss the exfoliation of MoS2 layers obtained by scraping the aforementioned surfaces with a diamond nanotip. Interesting directionality effects are also seen in this case. Some hints on the energetics of the exfoliation process are obtained from a comparison of the friction force signals recorded while scraping and the morphology of the exfoliated structures.

3:30 PM  
Development of a Laboratory Test to Identify Permanent PVD Coatings to Minimize Lubricant Use during Forging: Kester Clarke; Trevor Kehe1; Spencer Randell1; Stephen Midson1; 1Colorado School of Mines
    A goal of the forging industry is to minimize the amount of conventional lubricants used during forging. To evaluate the impact of substrate conditions of the level of friction developed during forging, a laboratory test, called the ring compression test, has been identified and validated that provides a quantitative measurement of the impact of a range of substrate conditions on the level of friction between a forged aluminum workpiece and an H13 steel forging die. Several forging conditions have been examined at both room and elevated temperatures (100°C and 200°C), including lubricated and un-lubricated, un-coated, nitrided, and a number of PVD coatings. Results from the study will be presented, showing that in the unlubricated condition, the lowest friction factors were obtained with two PVD nanocomposite, thin-film coatings containing lubricious particles such as graphite and/or molybdenum disulfide.

3:50 PM  
Molten Aluminum Test for the Identification of PVD Coating Candidates for Lube-free Aluminum Die Casting: Nelson Campos Neto1; Andras Korenyi-Both1; Stephen Midson1; Michael Kaufman1; 1Colorado School of Mines
    In the aluminum high-pressure die casting process (HPDC) liquid-based lubricants are sprayed onto die surfaces prior to each shot to act as a parting agent, control die surface temperatures, and prevent aluminum soldering. Unfortunately, lubricants also cause several problems, such as reducing casting quality, increasing production costs, and the production of effluents that must be discarded. PVD coatings are often applied to die surfaces to minimize soldering and to enhance tooling life. The concept of a HPDC process free of liquid-based lubricants is new, but very promising, as demonstrated by recent research that achieved a ~85% reduction in conventional lubrication spray in a die casting trial through the deposition of an AlCrN PVD coating onto an entire H13 steel die. In this work, several PVD coatings have been evaluated using a laboratory-based molten aluminum test in an attempt to identify the best candidates for moving HPDC to a lube-free process.