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Thin-Film Surface Engineering - NFPA

Thin-Film Surface Engineering Frank Kustas, PhD Senior Research Scientist IV, AMP Lab Assistant Director, Surface Engineering Research Center South Dakota School of Mines and Tech (SDSM&T) Chief Technology Officer NanoCoatings, Inc. Rapid City SD 4/3/2017 1 2 SDSM&T AMP Lab Surface Processing Range Physical Vapor Deposition - CVD Very Dense, Smooth Surface High Hardness and Toughness Low Friction Virtually Any Material Net Shape / No Final Finishing Thin-Film : nm tens of m ( in.) Thicker: m ( in.) hundred m ( in.) Thick- film / Repair hundreds of m tens of mm (> in.) Hybrid AP-CVD / Nanospray Non-Vacuum Process Oxide / Nanoparticle Layers Superhydrophobic / Icephobic Plasma Electrolytic Oxidation Immersion; Non-Line-of-Sight Crystalline Oxides; High Hardness No Through-Thickness Porosity Green Electrolytes Cold Spray No Melting of Powder Low Heat Input Into

Thin-Film Surface Engineering Frank Kustas, PhD Senior Research Scientist IV, AMP Lab Assistant Director, Surface Engineering Research Center

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Transcription of Thin-Film Surface Engineering - NFPA

1 Thin-Film Surface Engineering Frank Kustas, PhD Senior Research Scientist IV, AMP Lab Assistant Director, Surface Engineering Research Center South Dakota School of Mines and Tech (SDSM&T) Chief Technology Officer NanoCoatings, Inc. Rapid City SD 4/3/2017 1 2 SDSM&T AMP Lab Surface Processing Range Physical Vapor Deposition - CVD Very Dense, Smooth Surface High Hardness and Toughness Low Friction Virtually Any Material Net Shape / No Final Finishing Thin-Film : nm tens of m ( in.) Thicker: m ( in.) hundred m ( in.) Thick- film / Repair hundreds of m tens of mm (> in.) Hybrid AP-CVD / Nanospray Non-Vacuum Process Oxide / Nanoparticle Layers Superhydrophobic / Icephobic Plasma Electrolytic Oxidation Immersion; Non-Line-of-Sight Crystalline Oxides.

2 High Hardness No Through-Thickness Porosity Green Electrolytes Cold Spray No Melting of Powder Low Heat Input Into Substrate Very High Adhesion No Limit on Thickness Deposit Virtually Any Metal Deposition on Metallic and Non-Metallic surfaces Atmospheric CVD of silica Nanoparticle spray Laser Powder Deposition Fuse Metal/Ceramic Powder to Metal surfaces Low Heat Input into Substrate Superior Adhesion, Abrasion and Corrosion Resistance 4/3/2017 2 SDSM&T Surface Engineering Research Center (SERC) What is it ? A new 3-Year SD Board of Regents (SDBOR) R&D collaboration grant to foster developments in Surface Engineering (SE) - Global market in SE > $100B annually; impacts all industrial sectors - 3 SD institutions (SD Mines (Lead), South Dakota State, Univ.)

3 Of SD) Goals: new multi-institution research collaborations to increase R&D grant awards and spur economic development (start-ups, jobs) in SD training for undergraduate and graduate students in SE our research capacity in SE Approach: resource development (new faculty, new course content) of new research instrumentation strong and sustainable collaborative research partnerships 4/3/2017 3 SERC Collaborations Incorporate established faculty/research staff with complementary expertise in: 1) SE technology, 2) advanced matls/manuf., 3) advanced materials characterization 4/3/2017 4 Application Driven: 1) Biomedical 2) Energy 3) Environment Define Industry Needs / Pain Solution(s) Cold Spray Technology Research Partners Equipment VRC Gen III Cold Spray System 1000 psi & 850 C Robotic or Hand-held capable 400 sq.

4 Ft. spray booth 6-axis motion system 3-axis motion system Powder processing equipment Tecnar cold spray velocimeter Metallographic Evaluation Wear & Corrosion Testing Mechanical Testing Research Efforts 20 m CP Ti Al 2024 Process Development Materials Characterization Equipment Development Modeling Repair Applications Commercialization & Transition Contact Information: Christian Widener, PhD AMP, SDSM&T @ (605) 394-6924 Dye Penetrant Test Showing Benefits of Process Control 10-3-16 Contact Information: Joshua Hammel AML, SDSM&T @ 605-394-5245 ASTM G65(B) 3-15mm3 Volume Loss Abrasion resistance is process dependent and can be tailored Abrasion characteristics on the order of common hard facing alloys with less added weight and lower COF when lubricated 0 20 40 60 80 100 120 140 Average Adjusted Volume Loss (mm3) ASTM G65B Abrasion Data AR400 Astralloy Mangabraze Stoody 101HC NT-60 NTCr-70SP BAM 10-3-16 4/3/2017 8 1.

5 Enhanced Physical Vapor Deposition (PVD) & Chemical Vapor Deposition (CVD) 2. High Voltage Anodize: Plasma Electrolytic Oxidation (PEO) 3. Atmospheric Plasma CVD (AP-CVD) & Ultrasonic Spray of Nanoparticles thin film Coating Technologies PVD CVD Processing Ar ion (+) bombardment of metal-target (-) ejects atoms that deposit on substrate. Thin-Film (<50 m ( in.), but recently up to 400 m thick Attributes: film porosity, excellent adhesion, high hardness and toughness virtually any material; metals, ceramics, polymers nanostructured coatings, multilayers, alloys, in-situ final-finishing required source for Ar+ plasma generation; increases ion-bombardment by 5-10X 6.)

6 Addition of CVD precursor PVD Process; Courtesy SwRI W-filament 4/3/2017 9 Coatings Fabricated by T-PVD Method 4/3/2017 10 BAM: Al-Mg-B14 with and w/o TiB2 addition (3rd hardest material) TiN / SiCN nanostructured coatings (high hardness and toughness) TiC / amorphous carbon (a-C) (low-friction, fretting-resistance) CrN (excellent salt-spray corrosion resistance), TiN WS2 (higher-temp. low-friction solid-lubricant) Energetic Metal-Multilayer Materials Quasicrystalline Alloys, High-Entropy Alloys/Compounds App. App. Example Industry Case Study-1 4/3/2017 11 Paint-spray system pump-shaft wear/failure SS shafts coated with nitride coatings (CrN, TiN) using arc-deposition process.

7 During use, pump leakage/failure. Large scratches observed on shaft surfaces . Optical image of failed shaft SEM image of failed shaft Example Industry Case Study-1 4/3/2017 12 Arc-deposited coatings exhibit large particles which dislodged and acted as abrasive-particles damaging the hard coating. SEM top-view image SEM cross-section image showing embedded particles Mechanical Property Comparisons 4/3/2017 13 Hardness and modulus measured by nanoindenter at SDSM&T T-PVD BAM coatings offer higher Figures of Merit (FOM) H/E and H3 / E2 than arc-deposited coatings. Coating Hardness (H), GPa Modulus (E), GPa H/E(2) H3 / E2 (2) CrN (CAT-ARC) (1) TiN (CAT-ARC) (1) BAM (NTC-F, ARC) BAM; T-PVD #A27 (#A46) BAM; T-PVD #A30 BAM & Ti ML #A48 (~50%Ti) / 23nm BAM; 131nm BAM 16 ( , ) 210 (217, 196) BAM & Ti ML #A58 (#A57); / 26 280 BAM T-PVD; #A28 NCI CrN (avg.)

8 Of 4) T-PVD NCI TiN-SiCN (5% Si) Notes: (1): Commercial product; (2) H/E = relative deformation (or strain) capability H3 / E2 = relative resistance to plastic deformation SEM Images of BAM Coating Cross-Sections 4/3/2017 14 NTC-F Arc-deposited BAM coating SDSMT/NCI T-PVD BAM coating Debris from silicon wafer Coating NTC-F T-PVD Ra, nm ( in) ( ) ( ) SD, nm ( in) ( ) ( ) BAM #A29 vs. 4620 Steel; Light Mineral Oil Test Conditions: 1) A29: constant-load (~59 ksi) vs. bare 4620 steel ring. No coating failure for A29 BAM vs. bare 4620 steel ring. Similar performance under PAO-Grease Lub.

9 4/3/2017 15 Wear factor: mm3/Nm Duration, SecondsCoefficient of FrictionPure BAM Coating #A46, Dry Sliding-Friction Test Conditions: 1) 17 RPM (3 cm/s sliding rate); 2) Stepped load test 3) 5-min. test durations; 4) RT laboratory air, 5) unlubricated, 6) vs. non-coated 4620 steel ring. No failure of coating observed 4/3/2017 16 Pure BAM Coating #A46, Wear Scar; No Failure Leading Edge Fe-oxide (~Fe2O3); O: a/o, Fe: a/o. Wear-Scar in BAM Coating 4/3/2017 17 Example DoD Case Study-2 4/3/2017 18 Sliding and fretting-wear applications such as propulsion-system components (brgs., gears), lubricant-free weapon parts, air-foil brgs.

10 V-22 Osprey, other rotorcraft Proprotor Al Transfer/Debris on M50 Steel Bearing Flange Shaker-table Test simulation Low Friction/Wear TiC / C-Gr PVD Coatings for Fretting-Wear Appl. 4/3/2017 19 :00:001:12:002:24:00 Time; hr:min:secCOF#75, Ti/C(ramp)ML, TiC(ramp)&Gr, #73, Ti/C(step) ML, TiC(ramp)&Gr#75: Smaller wear scar dia.,but same sliding speed; P: Noted:Ti bond layer, P= mt, Bias: -70V#56 Graded TiC & Gr (3-hr Test) Wear Factor: mm3/Nm HRC60 Steel Ball vs. TiC & Gr Graded Coatings on M50 Steel Showing COF Reduction With Time; GPa (187 Ksi) Initial Stress, Unlubricated, RT Air Good Fretting-Wear Resistance of TiC / C-Gr PVD Coatings 4/3/2017 20 Simulated fretting-wear test with bending bar and mechanically-bolted washers (slip at washer-bar interfaces).