The coatings in manufacturing engineering : selected, peer reviewed papers from the 8th International Conference on THE coatings in Manufacturing Engineering, Erlangen-Germany, April 14-15, 2010

226 Pages·2010·63.88 MB·English

by  Friedrich-Wilhelm Bach

The Coatings in
Manufacturing
Engineering
The Coatings in
Manufacturing Engineering
Selected, peer reviewed papers from the
8th International Conference on
THE Coatings in Manufacturing Engineering, Erlangen-Germany,
April 14-15, 2010
Edited by
F.-W. Bach, K.-D. Bouzakis, B. Denkena,
M. Merklein, H.-K. Toenshoff

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Volume 438 of
Key Engineering Materials
ISSN 1013-9826
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THE Coatings Sponsors
International Scientific Committee
Prof. F.-W. Bach, Germany
Prof. K.-D. Bouzakis, Greece
Prof. B. Denkena, Germany
Prof. M. Geiger, Germany
Prof. M. Merklein, Germany
Prof. H. K. Tönshoff, Germany

International Programme Committee
Dr. M. Arentoft, Denmark Dr. C. Hinsel, Germany
Prof. N. Bay, Denmark Prof. B. Karpuschewski, Germany
Prof. D. Biermann, Germany Prof. F. Klocke, Germany
Prof. K. Bobzin, Germany Prof. R. Kolleck, Austria
Prof. G. Bräuer, Germany Prof. H. Meerkamm, Germany
Prof. E. Brinksmeier, Germany Prof. F. Miani, Italy
Prof. S. Bruschi, Italy Prof. F. Micari, Italy
Prof. G. Byrne, Ireland Prof. R. Singer, Germany
Prof. U. Engel, Germany Prof. S. Skolianos, Greece
Prof. M. Faulstich, Germany Prof. W. Tillmann, Germany
Prof. K. Fehr, Germany Prof. E. Uhlmann, Germany
Prof. P. Groche, Germany Dr. C. Ziebert, Germany
Prof. F. Vollertsen, Germany
Foreword
Coating technology has made great progress during the last years.
The properties of surface layers determine the function and the
quality of entire components. Thus it is essential to establish scien-
tific knowledge about the development and functionality of the
topmost layers. The beneficial effect of coating technology can be
observed in a multitude of manufacturing fields to solve problems
like wear, corrosion, friction conditions, electrical function etc. Fur-

thermore decorations or haptics are scope of this technology appli-
Prof. Marion Merklein
cation as well.
Coating provides the potential to combine different material properties and to improve the
functionality of a multitude of products. Knowledge of surface mechanisms and coating tech-
nologies play a key role in competition. Similar components can be improved considerably by
applying surface technologies at relatively low costs. Thus, efforts in developing new tech-
niques of surface optimisation are indispensable.
THE Coatings Conference represents a forum for academics of different research institutions
as well as industry to discuss latest research results concerning coating technology within
production engineering. The series was initiated by Prof. Bouzakis, Laboratory for Machine
Tools and Manufacturing Engineering, University of Thessaloniki, Prof. Thönshoff, Institute
for Production Engineering and Machine Tools, University of Hannover, and Prof. Geiger,
Chair of Manufacturing Technology, University of Erlangen-Nuremberg. The founding insti-
tutions have taking turns in hosting the conference. The 8th conference is organised by Prof.
Bach, Institute of Materials Science, University of Hannover, Prof. Bouzakis, Laboratory for
Machine Tools and Manufacturing Engineering, University of Thessaloniki , Prof. Denkena,
Institute for Production Engineering and Machine Tools, University of Hannover, and myself,
Chair of Manufacturing Technology, University of Erlangen-Nuremberg.
It is a great pleasure and honour for the Chair of Manufacturing Technology of the University
of Erlangen-Nuremberg to host the International Conference THE Coatings in Manufacturing
Engineering for the 2nd time in April 2010. The conference will focus on the presentation and
exchange of innovative research activities related to coating technology in 28 international
contributions presented in the upcoming two days. In addition the scientific and social events
of the conference will foster personal and professional contacts to establish profitable collabo-
rations.
The organisation of a conference is always creating numerous tasks and jobs that have to be
taken care of. The organisation group in Erlangen wants to thank the members of the Pro-
gramme Committee, a group consisting of 25 internationally well renowned colleagues, for
taking over the reviewing of the papers. I personally want to thank also two of my co-
workers, Dipl.-Ing. Stephan Weidel and Dipl.-Ing. Simon Opel, for their commitment in the
preparation of the conference, the proceedings and all belongings of this scientific event.
In this sense I look forward to offer a platform for discussion, giving all participants the
chance to get novel approaches and ideas in the field of coating technology. I hope the confer-
ence will be a successful experience for all participants.
Erlangen, January 27, 2010

Prof. Dr.-Ing. Marion Merklein
Table of Contents
Sponsors
Committee
Preface
TOOLS SESSION
Keynote
Cutting Edge Preparation by Means of Abrasive Brushing
B. Denkena, L. de Leon, E. Bassett and M. Rehe 1
Comparison of Nitride and Noble Metal Coatings for Precision Glass Molding Tools
F. Klocke, O. Dambon and K. Georgiadis 9
Pre PVD-Coating Processes and their Effect on Substrate Residual Stress in Carbide
Cutting Tools
B. Denkena and B. Breidenstein 17
Qualification of Coatings to Predict Wear Behavior of Micro Blasted Cutting Tools
F. Klocke, C. Gorgels, A. Stuckenberg and E. Bouzakis 23
Diamond Cutting of FeN-Layers on Steel Substrates for Optical Mould Making
E. Brinksmeier, R. Gläbe and J. Osmer 31
Coating Development for Gear Cutting Tools
J. Kohlscheen, H.J. Knoche, M. Hipke and A. Lümkemann 35
Nanostructured Bionic PVD-Coatings for Forming Tools
W. Tillmann, E. Vogli, J. Herper and M. Haase 41
Chip Length Effect on the Wear of Coated Cemented Carbide Inserts in Milling
K.D. Bouzakis, S. Gerardis, G. Katirtzoglou, S. Makrimallakis, G. Skordaris and K. Efstathiou 49
PROPERTIES SESSION
Keynote
Impact Behaviour of PtIr-Based Coatings with Different Interlayers for Glass Lens
Moulding
K. Bobzin, F. Klocke, N. Bagcivan, M. Ewering, K. Georgiadis and T. Münstermann 57
Diamond Machinable Sol-Gel Silica Based Hybrid Coatings for High Precision Optical
Molds
A. Mehner, J.A. Dong, T. Hoja, T. Prenzel, Y. Mutlugünes, E. Brinksmeier, D. Lucca and F.
Klaiber 65
Physico-Chemical Aspects of Surface Activation during Fluxless Brazing in Shielding-Gas
Furnaces
F.W. Bach, K. Möhwald and U. Holländer 73
Characterization of Heat Transfer Coefficients of Tool Materials and Tool Coatings for Hot
Stamping of Boron-Manganese Steels
M. Wieland and M. Merklein 81
Determination of Mechanical and Corrosion Properties of Boride Coating on P91 Steel
H. Omar, N. Michailidis, S. Skolianos, A. Mavropoulos, S. Tsipas and N. Maragoudakis 89
Interlaboratory Comparison of Friction Conditions in Hot Stamping Operations
F. Borsetto, A. Ghiotti, S. Bruschi, T. Stoehr, J. Lechler and M. Merklein 97
TEST / SIMULATION SESSION
Keynote
b The Coatings in Manufacturing Engineering
New Methods for Characterizing Coating Properties at Ambient and Elevated
Temperatures
K.D. Bouzakis, M. Batsiolas, G. Malliaris, M. Pappa, E. Bouzakis and G. Skordaris 107
Grinding of Arc-Sprayed Tungsten Carbide Coatings on Machining Centers - Process
Configuration and Simulation
D. Biermann, T. Mohn, H. Blum and H. Kleemann 115
Non-Contact Geometry Inspection of Workpieces with Optically Non-Cooperative Surfaces
F.W. Bach, K. Möhwald, M. Nicolaus, E. Reithmeier, M. Kästner and O. Abo-Namous 123
Determination of the Effective Film Mechanical Properties in the Impact Test Imprint of
Coated Specimens
K.D. Bouzakis, G. Skordaris, E. Bouzakis and E. Lili 131
COATINGS SESSION
Keynote
Suspension Plasma Spraying of Triboactive Coatings for High Temperature Applications
M. Erne, D. Kolar, K. Möhwald and F.W. Bach 139
Surface Zone Modification by Atmospheric Plasma-Nitriding (APN) with the Aid of the
Transmitted Plasma-Arc
T. Hassel, C. Birr and F.W. Bach 147
Influence of Malonic Acid on the Corrosion and SCC Behaviour of Anodic Coated 1050 Al-
Alloys
P. Spathis, E. Papastergiadis, G. Stalidis and G. Papanastasiou 155
Self-Supporting Nanocrystalline Diamond Foils – A New Concept for Crystalline Diamond
on any Technical Surface
M.A. Lodes, S.M. Rosiwal and R.F. Singer 163
TRIBOLOGY SESSION
Keynote
Simulation of Dynamic Lubricant Effects in Sheet Metal Forming Processes
M. Ludwig, C. Müller and P. Groche 171
Tribological Characterization of PVD-Coatings
T. Schrader, U. Engel and M. Merklein 179
Evaluation of PVD Coated Tools’ Life in Milling Ti6Al4V, Based on Impact Tests at
Ambient and Elevated Temperatures
N. Michailidis, K.D. Bouzakis, F. Klocke, M. Witty, E. Lili, S. Gerardis and M. Pappa 187
Modified DLC-Coated Guide Pads for BTA Deep Hole Drilling Tools
D. Biermann, N. Kessler, T. Upmeier and T. Stucky 195
Performance of γ-Al O -Based Coatings and Environmentally Friendly Lubricants in
2 3
Cutting Operations of Difficult-to-Machine Materials
F. Klocke, S.E. Cordes and K. Gerschwiler 203
Influence of Substrate Nitriding on Adhesion, Friction and Wear Resistance of DLC
(Diamond-Like Carbon)-Coatings
W. Tillmann, E. Vogli, F. Hoffmann and P. Kemdem 211