Advanced Coatings for Wear and Corrosion Protection: Session II
Program Organizers: Evelina Vogli, Flame Spray Inc.; Virendra Singh, SLB
Monday 2:00 PM
October 10, 2022
Room: 334
Location: David L. Lawrence Convention Center
Session Chair: Evelina Vogli, LM Group Holdings Inc.; Virendra Singh, Schlumberger
2:00 PM
Friction and Anti-galling Properties of Diamond-like Carbon Coating on Oil Field Parts: Virendra Singh1; Alireza Zolfaghari1; Manuel Marya1; 1Schlumberger
Coating and surface treatments against wear, galling, and corrosion are critical to prolonging the life of the oil field parts. The conventional coatings (plating and carbide) and surface treatment (nitriding, carburizing and boronizing) processes are lacking the combination of properties such as low friction, wear, and anti-galling. The diamond-like carbon (DLC) coatings can provide low friction and high hardness for wear resistance applications. In this investigation, different DLCs, varying in thickness, composition, and hardness, have been applied on stainless (13 Cr) steel and Ni-alloys (718 and 925). They have been tested under high contact stresses and multi-make/break torque conditions with the goal to simulate the oil field stress and galling conditions. This study also discusses tribological properties (wear rate and friction) in dry conditions, galling threshold, and failure mechanism of a different flavor of DLCs in correlation with the mechanical properties.
2:20 PM
PVD Coated Ceramics and Cubic-boron Nitride (cBN) for Metalcutting-Benefits and Challenges: Abhijit Roy1; Debangshu Banerjee1; Brittany Macshane1; Joern Kohlscheen1; Christian Bareiss1; 1Kennametal Inc.
The global market for alumina, SiC, Si3N4/Sialon, and cubic-boron nitride (cBN) based metalcutting tools exceed $1B. They are used in high speed roughing and semi-finishing of heat resistant superalloys, cast iron, and high hardness steel, with minimal tool wear due to the better mechanical, tribological, and chemical stability of these ceramics at elevated temperatures. Despite the higher cutting performance, applications of these ceramics and cBN are limited due to their lower toughness, chemical reaction with work piece at high cutting temperatures, and inability to make complex chipbreaker designs. Therefore, there is a need to develop chemical and abrasion resistant hard coatings to improve tool life.This talk will examine development of various PVD and CVD coating techniques on ceramics and cBN based cutting tools and their physicochemical properties such as adhesion, microstructure, hardness, and toughness. The influence of coating design and deposition parameters on tool performance will also be discussed.
2:40 PM
Development of Novel Wear and Impact Resistant Titanium-Boron Nitride Coatings for Lunar Structural Components: Abhijith Sukumaran1; Cheng Zhang1; Arvind Agarwal1; 1Florida International University
Lightweight alloys of Aluminum (Al) and Titanium (Ti) are the major components of space systems because of their high strength to weight ratio. However, their poor tribological response in the presence of lunar regolith results in premature failures. Boron Nitride(BN) reinforced titanium coatings were produced by plasma spray method at low and high-volume percentage concentration of BN to counter this undesirable result, after powder preparation by cryo-milling. The microhardness results showed that coating hardness was 3 times that of conventional Ti6Al4V (335HV) substrate in the case of low vol.% hBN (1134 HV) concentration and, 1.5 times in the case of high vol.% hBN coating (516 HV). Tribological characterization by ball on disk tests revealed a 50% reduction in friction coefficient and absence of wear scars on the titanium coatings compared to conventional material. Coatings will be subjected to simulated lunar conditions in a custom-made erosion test rig in the future work.
3:00 PM
Features of Increase Wearproofness Became Influence of Polymethylmethacrylat at a Contact: Volodymyr Tsyganov1; Vadim Shalomeev1; Sergei Sheyko2; 1Zaporizhzhia Polytechnic National University; 2Zaporizhzhia National University
Influence of products destruction of high-molecular connections in composition a lubricating-cooling liquid on the change of mechanical properties of metals in the zone of contact tribounits is shown. The relationship between the structural state of superficial layer and wearproofness is marked. Difficult mechanochemical character of interaction рolymethylmethacrylat with a metal depending on the kinds of dynamic loading in tribounits is considered. Perspective of application additives рolymethylmethacrylat is shown in composition a lubricating-cooling liquid on the example of increase efficiency of treatment metals cutting.Keywords: wearproof surface, superficial layer, nanostructural state, tribocoupling, destruction polymer
3:20 PM Break
3:40 PM
Improved Coating Performance of REACH Compliant Trivalent Chromium Plating Process for Functional Applications: Andrew Moran1; Rajeswaran Radhakrishnan1; Tim Hall1; EJ Taylor1; George Bokisa2; Mark Feathers3; Stanko Brankovic4; Kamyar Ahmadi4; 1Faraday Technology Inc.; 2Coventya International; 3U.S. Army Aviation and Missile Command; 4University of Houston
Faraday will discuss recent research work on the development of functional REACH compliant trivalent chromium plating process to replace hard hexavalent chromium plating. Hexavalent chromium plating has been used for many years to provide hard, durable coatings with excellent wear and corrosion resistance properties. However, hexavalent chromium baths have come under increasing scrutiny due to the toxic nature of the bath, effects on the environment, and workers’ health. Faraday has demonstrated that the chrome coatings prepared using the FARADAYIC® Process have similar functional properties to the coatings produced with a hexavalent chromium bath. In this talk, Faraday will present results from its development programs and discuss the similarities between chrome deposits from the REACH compliant and hexavalent chemistries. Specifically, Faraday will discuss the effect of processing conditions on microstructure, in-situ stress development, wear resistance, and performance as well as evaluating its potential for a hexavalent chromium free plating shop.
4:00 PM
Novel Surface Treatment for Electrolytic Deposition of Chromium onto Zirconium: Benjamin Aronson1; Patrick Fourspring2; Justin Reiss1; Lucas Erich1; Michael Ammendola1; Ryan Romesberg1; Jason Clobes2; Brendan Ensor2; Leslie Stubna2; Douglas Wolfe1; 1Pennsylvania State University; 2Naval Nuclear Laboratory
Chromium coatings are a subject of growing interest for nuclear power, as they provide additional protection against corrosion for zirconium alloy components, without significantly compromising their thermal efficiency. Electrolytic deposition is commonly used to apply chromium coatings, but the persistent oxidation behavior of zirconium leads to heterogeneous nucleation of the coating structure. The resulting island growth causes crevices and pinholes in the coating surface, creating pathways for corrosive electrolytes. This study explores a novel surface treatment to be used before deposition. The process simultaneously removes the passive oxide layer of the zirconium substrate, and deposits a thin bonding layer in its place. This allows for uniform growth of chromium on the substrate surface, improving the corrosion protection and adhesion of the coating. Following the surface treatment, potentiodynamic corrosion testing showed that the novel coating process exhibited greater corrosion resistance than both the traditional zirconium alloy, and the untreated chromium coating.
4:20 PM
High-performance Coatings with Exposure to High Temperatures Obtained under SHS Conditions: Borys Sereda1; Dmytro Sereda1; Dmytro Kiforuk1; Anton Prolomov1; Igor Beolzor1; Darya Mukovska1; 1Dneprovsky State Technical University
Offered promising methods of high-performance coatings with exposure to high temperatures obtained under SHS(self-propagating high-temperature synthesis) conditions. To increase the corrosion resistance it is necessary to saturate the surface layer with elements that will form passive skin. The mechanism of coating degradation as a result of friction, wear and corrosion or other dynamic loads, the relationship between the composition, processing methods, and microstructural features are considered. To improve resistance at high temperatures, it is necessary to saturate the surface layer with elements that form an oxide film layer, having the following composition - Cr2O3, Al2O3, TiO2, SiO2, which protect the metal from destruction. The high hardness of the resulting alloy coating and the ability to withstand an oxidizing atmosphere at high temperatures of 900-1100 °C allows them to be used in metallurgy, mechanical engineering and aircraft building. Tests in an oxidizing atmosphere showed a weight loss of 34-65 mg/m2.