Tribology and Characterization of Surface Coatings

330 Pages·2022·47.452 MB·English

by  Sarfraj Ahmed, Vinayak S. Dakre

Tribology and Characterization
of Surface Coatings
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Martin Scrivener ([email protected])
Phillip Carmical ([email protected])
Tribology and Characterization
of Surface Coatings
Edited by
Sarfraj Ahmed
National Institute of Technology, Raipur, India
and
Vinayak S. Dakre
Department of Mechanical Engineering, G H Raisoni University, Amravati, India
This edition first published 2022 by John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, USA
and Scrivener Publishing LLC, 100 Cummings Center, Suite 541J, Beverly, MA 01915, USA
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Library of Congress Cataloging-in-Publication Data
ISBN 978-1-119-81878-6
Cover image: Pixabay.Com
Cover design by Russell Richardson
Set in size of 11pt and Minion Pro by Manila Typesetting Company, Makati, Philippines
Printed in the USA
10 9 8 7 6 5 4 3 2 1
Contents
Preface xiii
1 Overview of Coating Deposition Techniques 1
Neeraj Mehta
1.1 Introduction 2
1.2 Thin-Film Characteristics 4
1.3 Techniques Based on Physical Deposition Processes 5
1.3.1 Evaporation 6
1.3.1.1 Mean-Free Path: A Significant Parameter
for High-Quality Evaporation 8
1.3.2 Sputtering 9
1.3.2.1 Characteristics of Sputtering 12
1.3.2.2 Types of Magnetron Sputtering Technique 14
1.3.3 Other Techniques Based on Physical
Deposition Processes 15
1.4 Techniques Based on Chemical Deposition Processes 18
1.4.1 Chemical Vapor Deposition (CVD) 18
1.4.1.1 Atmospheric Pressure Chemical
Vapor Deposition (APCVD) 19
1.4.1.2 Low-Pressure Chemical Vapor
Deposition (LPCVD) 20
1.4.1.3 Metal Organic Chemical Vapor
Deposition (MOCVD) 21
1.4.1.4 Plasma Enhanced Chemical Vapor
Deposition (PECVD) 23
1.4.1.5 Laser Chemical Vapor Deposition (LCVD) 23
1.4.2 Atomic Layer Deposition (ALD) 25
1.4.2.1 ALD Versus CVD Deposition Technique 27
1.4.3 Other Techniques Based on Chemical
Deposition Processes 27
v
vi Contents
1.5 Present Status and Future Scope 29
1.6 Conclusion 30
References 30
2 Tribological Investigation of Developed Nanocomposite
Mos -Tio -Zro Coating Material 33
2 2 2
Avinash V. Borgaonkar, Deepak Rai and Ismail Syed
2.1 Introduction 34
2.2 Materials and Methods 37
2.3 Experimental Details 40
2.4 Results and Discussions 41
2.5 Conclusions 45
References 45
3 Methods of Microstructural Characterization of Coatings 49
A. M. Kamalan Kirubaharan, D. Dinesh Kumar,
K. Gobi Saravanan and Subhenjit Hazra
3.1 Introduction 49
3.2 X-Ray Diffraction 52
3.2.1 Coating Texture 54
3.2.2 Residual Stress Measurement 55
3.3 Atomic Force Microscopy 56
3.4 Scanning Electron Microscopy 57
3.5 Energy Dispersive X-Ray Spectroscopy 59
3.6 Transmission Electron Microscopy 60
3.7 X-Ray Photoelectron Spectroscopy 62
3.8 Electron Probe Microanalysis 63
3.9 Secondary Ion Mass Spectroscopy 64
3.10 Raman Spectroscopy 65
3.11 Conclusion 66
References 67
4 Wear Mechanisms and Methods of Wear Testing 71
Ahmed Abdelbary
4.1 Introduction 72
4.2 Mechanisms of Wear 72
4.2.1 Adhesion 72
4.2.2 Abrasion 74
4.2.3 Surface Fatigue 78
4.2.4 Corrosion 79
4.2.5 Erosion 80
4.2.6 Fretting 82
Contents vii
4.2.7 Impact 83
4.2.8 Thermal 84
4.3 Methods of Wear Testing 84
4.3.1 Sliding Wear Test 86
4.3.2 Rolling Wear Test 88
4.3.3 Scratch Wear Test 89
4.3.4 Abrasion Wear Test 90
4.3.5 Erosion Wear Test 92
4.3.6 Impact Wear Test 93
References 94
5 Mechanical Behavior of Thermal Spray Coatings 99
Jayant Gopal Thakare
5.1 Introduction 99
5.2 Elastic Modulus and Fracture Toughness 101
5.2.1 Effect of Microstructure on Fracture Toughness 108
5.3 Evaluation of Residual Stress 109
5.4 Conclusion 111
References 111
6 Tribological Properties of Carbon-Based Coatings 115
D. Dinesh Kumar, P. Kuppusami, Gobi Saravanan Kaliaraj,
Siva Sankar Sana and A.M. Kamalan Kirubaharan
6.1 Introduction 116
6.1.1 Classification of Carbon-Based Coatings 116
6.1.1.1 DLC Coatings 117
6.1.1.2 Diamond Coatings 119
6.2 Deposition of Carbon-Based Coatings 120
6.2.1 Physical Vapor Deposition Techniques 121
6.2.2 Chemical Vapor Deposition Techniques 122
6.3 Tribo-Mechanical Characteristics of Carbon-Based
Coatings 123
6.3.1 H-Free a-C or DLC Coatings 124
6.3.2 Hydrogenated a-C (H-DLC) Coatings 125
6.3.3 ta-C Coatings 126
6.3.4 Diamond Coatings: MCD, NCD, and UNCD 127
6.3.5 Metal-Doped Carbon-Based Coatings 129
6.4 Factors Influencing Tribological Properties
of Carbon-Based Coatings 130
6.5 Conclusions 132
References 133
viii Contents
7 Performance Evaluation of Journal Bearing Under
Thin-Film Lubrication 139
Sandeep Soni
7.1 Introduction 140
7.2 Governing Equations 141
7.2.1 Hydrodynamic Lubrication Modeling 141
7.2.2 Thin-Film Lubrication Modeling 143
7.3 Solution Strategy 144
7.4 Performance Characteristics 144
7.4.1 Load Carrying Capacity and Attitude Angle 145
7.4.2 Frictional Characteristics 145
7.4.3 Oil Flow Rate 146
7.4.4 Frictional Torque and Energy Loss 146
7.5 Results and Discussion 147
7.6 Conclusions 156
Nomenclature 157
Dimensionless Parameters 157
References 158
8 Bioactive Coatings for Biomedical Applications 159
Gobi Saravanan Kaliaraj, D. Dinesh Kumar
and A.M. Kamalan Kirubaharan
8.1 Introduction 160
8.2 Surface Coating 161
8.3 Polyether Ether Ketone 163
8.4 Nitride Composites Coating 164
8.5 Binary Transition Metal Nitride Coatings 166
8.6 Hydroxyapatite-Based Coating 169
8.7 Bioactive Glass Coatings 171
8.8 Composite Coatings 172
8.9 Conclusions 174
References 174
9 Study of Tribological Behavior and Wear Mechanism
of Nanocomposite Coatings 181
Lailesh Kumar, Pankaj Shrivastava, Deepankar Panda,
Arka Ghosh and Syed Nasimul Alam
9.1 Introduction 182
9.1.1 Techniques Employed for Depositing Nanocoatings 187
9.1.1.1 Electrodeposition Coating 188