PVD-Technology (Components)
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Completed Projects
Analysis of transfer layer formation in initially lubricated coated drive chains.
Short description:
Chains are a common machine element in drive and conveying technology. Current efforts to increase energy efficiency and sustainability are intended to exploit the still open potential. To increase sustainability, the aim is to increase the service life while reducing the use of lubricant. The service life is determined by the chain’s elongation, which is caused by wear between the chain pin and bush in the chain joint. The use of a triboactive (Cr,Al,X)N coatings (X = Mo, Cu) is intended to reduce wear in the chain joint despite one-time initial lubrication at the start of operation. The triboactive coating interacts with the lubricating grease and forms a reaction layer which is transferred to the counter surface inside of the chain bush and thus protects it from wear. Furthermore, a large part of the frictional losses, which significantly influence the energy efficiency of the entire chain, occurs in the contact zone between pin and bush. The reaction and transfer layer formed is intended to also have friction-reducing properties and to increase the energy efficiency of the drive chain. For this purpose, the solid lubricant MoS2 is formed in interaction between the coating and lubricant.
| Funding: | German Research Foundation (DFG) |
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| Project number: | BO1979/81-1 |
| Duration: | May 1, 2021 to October 31, 2023 |
Durability of friction-reducing Diamond-like Carbon (DLC) coatings for gears
Short description:
The demands on technical systems in terms of energy efficiency and climate protection are constantly increasing, especially in the field of mobility and plant engineering. To fully exploit the friction- and wear-reducing potential of DLC-coated gears in industrial applications, it is necessary to increase the durability and make DLC coatings usable for industrial applications. Only the integrated consideration of all influencing variables that are decisive for the durability of coated gears is considered to be target-oriented: Substrate materials, surface pre-treatment and heat treatment, coating parameters and gear geometry. The industrially established surface pre-treatment for gears is grinding. However, this surface quality leads to insufficient adhesion of the DLC coatings. Therefore, crosswise ground as well as vibratory ground and polished surfaces are investigated in the project. The adaptation of the heat treatment is closely linked to the selection of alternative substrate materials such as the quenched and tempered steel 42CrMo4 or the nitrided steel 15CrMoV5-9. The higher tempering temperatures allow higher temperatures in the PVD process in addition to nitriding. The adjustment of individual coating parameters is carried out in the overall context of the systematic consideration of these influencing variables. The tribological analysis of the coated samples is carried out at IOT and the Gear Research Centre (FZG) at the Technical University of Munich .
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Arbeitsgemeinschaft industrieller Forschungsgemeinschaften (AiF) Forschungsvereinigung Antriebstechnik e.V. (FVA) |
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| Project number: | IGF 21103 N/FVA 585 III |
| Duration: | July 1, 2020 to June 30, 2023 |
Investigation of high speed PVD technology concerning the deposition of α-Al-O+X and Al-Ti-O+X coatings for die casting of high melting steel alloys II
Short description:
The project BO 1979/42-1 showed that the deposition of thick, oxide based hard coatings is possible by high speed physical vapour deposition (HS-PVD) technology, due to high coating thickness, smax = 88 µm. In addition to processes for the deposition of amorphous and crystalline (Al,Cr)2O3 and Al-Ti-O coatings, a process concerning the deposition of industrially relevant α-like (Al,Cr)2O3 was developed. Especially, the achieved structure of the deposited α-like (Al,Cr)2O3 coating with high aluminum content and substrate temperatures of TS = 570 °C still represents a great challenge for conventional PVD technologies today. The overall objective of the project BO1979/42-3 is the detailed investigation and adaption of the α-like (Al,Cr)2O3 and Ti-Al-O coatings, which were deposited for the first time by HS-PVD technology in BO1979/42-1. Therefore, processes concerning the deposition of α-(Al,Cr)2O3 and Al2TiO5 coatings with high aluminum contents will be defined. Moreover, the influence of interlayer thickness and chemical composition on compound adhesion is investigated, in order to increase adhesion between substrate and oxide hard coating. The application-oriented development of the coatings is possible by the results of thermocyclic annealing tests in ambient air, isothermal annealing tests in vacuum and ambient air as well as immersion tests in steel melt.
| Funding: | German Research Foundation (DFG) |
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| Project number: | BO1979/42-3 |
| Duration: | June 1, 2021 to November 30, 2023 |
TRISTAN – Development of self-lubricating (Cr,Al)N+X:S coatings via pulsed Arc-PVD technology for dry running power train components
Short description:
Energy-efficient mobility is necessary in order to avoid restrictions on mobility in the future and to protect the environment. Thereby, increasing the efficiency of powertrains by reducing friction is of great importance. Lubricants, which are conventionally used today in order to reduce friction, often bear economic and ecological disadvantages. Dry running of tribological components could be a solution for dispensing the use of conventional lubricants. However, this requires the adaptation of the surface properties as a result of the changed stress collective in tribological contact. Therefore, Cr-based nitride hard coatings with self-lubricating properties, as a result of doping with Mo or W and S, are developed in the project TRISTAN. The aim of the project is the reduction of friction and wear in dry running powertrain components, such as joints or bearings. Of central importance will be how Mo, W and S are incorporated in the coating and which contact conditions are necessary in order to form MoS2 and WS2 in tribological contact. The coatings are deposited by means of industrially relevant arc evaporation (Arc-PVD), which is being further developed with regard to pulsed power supplies. At the end of the project the transfer of the developed coatings into the application is planned, which enables the application-related testing of the coatings. Corresponding results can be used for the iterative coating development.
| Funding: | Arbeitsgemeinschaft industrieller Forschungsvereinigungen (AiF) |
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| Project number: | AiF 20431 N |
| Duration: | September 1, 2019 to August 31, 2022 |
Dry Lubrication of Spur Gears - Tribological Analysis and Constructive Design
Short description:
The overall aim of this joint research project of the Gear Research Centre (FZG, TU Munich) and Surface Engineering Institute (IOT, RWTH Aachen University) within the DFG priority programme 2074 “Fluid-free lubrication systems at high mechanical loads” is the design of a fluid-free lubricated spur gear that reliably withstands the high mechanical loads. In cooperation with the FZG, three subgoals will be pursued in the first funding period. First, there will be fundamental research into the architecture of triboactive hard coatings (Cr,Al)N+X:S. Furthermore, the knowledge of provisioning processes of metal sulphide and graphite solid lubricants as well as the formation of transfer layers in fluid-free lubrication systems under tribological stress will be extended. In addition, the potential of spur gears for fluid-free applications is constructively supplemented by non-involute variants. During the entire duration of the project, tribological simulations of the temperature and material stress distribution are carried out, which contribute to the understanding of the mechanisms of action. Poster BO 1979/66-1
| Funding: | German Research Foundation (DFG) |
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| Project number: | BO 1979/66-1 |
| Duration: | January 1, 2019 to December 31, 2021 |
Network for the development and qualification of efficiency-maintaining protective coatings against erosion and corrosion of turbine blades in steam/gas turbines and compressors - Coat4Turbine.NRW
Short description:
The aim of the collaborative research project is the development of erosion and corrosion protective coatings, which result in the preservation of efficiency-optimized contours and the increase of the service life of rotating steam turbine and compressor blades. The consortium consists of MAN Energy Solution SE, Surface Engineering Institute (IOT) of RWTH Aachen University, Thermico GmbH & Co KG and University of Applied Sciences Gelsenkirchen. The aim of the Physical Vapour Deposition (PVD) subproject is the development of new coating concepts based on (Ti,Al,Si)N and (Cr,Al,Si)N by means of the High-Speed PVD (HS-PVD) technology. These coatings are tested under application-relevant erosive and corrosive conditions and applied on real components like compressor blades. The use of these protective coatings is expected to result in permanently high efficiency, increased life cycle efficiency and CO2 savings. Poster EFRE-0801003
| Funding: | European Regional Development Fund (ERDF) |
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| Project number: | EFRE-0801003 |
| Duration: | March 23, 2018 to March 22, 2021 |
Thermo-Elastohydrodynamics of Coated Polymer Gears
Short description:
The main objective of this research project is to analyze the thermo-elastohydrodynamic lubrication (TEHL) of thermoplastics and the potentials of coatings in these TEHL contacts in order to improve their tribological performance. For this purpose, coatings on thermoplastic polymers for tribologically stressed surfaces with sufficient adhesion between polymer and coating are developed. The practical investigations will be supported by validated tribosimulations in order to increase the understanding of the physical mechanisms in uncoated and coated thermoplastic TEHL contacts. In the future, the results will enable the application of coatings on thermoplastic gears and thus contribute to an increase in performance. Poster BO 1979/57-1
| Funding: | German Research Foundation (DFG) |
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| Project number: | BO 1979/57-1 |
| Duration: | August 1, 2018 to July 31, 2020 |
CHEOPS3 – Minimum quantity lubricated systems
Short description:
Within the compound project CHEOPS3 partners from research facilities and industrial partners build a consortium, which focuses on dry lubrication and minimum quantity lubrication. The field of addressed applications includes automobile and motorcycle gearboxes, timing chains, drive chains, and conveyor chains and pumping applications. The aim at IOT within CHEOPS3 is the development of triboactive (Cr,Al)N+X coatings (X = Mo, W, Cu) by means of arc physical vapour deposition (arc PVD) for friction and wear reduction. Therefore, at IOT the coating system (Cr,Al)N will be modified with Molybdenum, Tungsten and Copper regarding the demands of minimum quantity lubrication. Coating development is conducted in close collaboration with the project partners. At IOT an industrial coating unit is used to ensure fast transfer of the developed coatings into industrial production. Poster 03ET1286F
| Funding: | Federal Ministry for Economic Affairs and Energy (BMWi) |
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| Project number: | 03ET1286F |
| Duration: | October 1, 2015 to June 30, 2019 |
Physical-chemical interactions between diamond-like carbon (DLC) coatings, lubricants and additives
Short description:
The aim of the research project is the physical-chemical analysis of DLC coatings for the identification of tribochemically formed reaction layers. This improves the understanding of tribochemical mechanisms in tribological contact based on the interactions between amorphous carbon coatings a-C:H:Zr (ZrCg), lubricants and additives.The tribological tests are conducted under practice-oriented conditions in the twin-disc test-rig and in the gear efficiency test-rig. Poster BO 1979/46-1
| Funding: | German Research Foundation (DFG) |
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| Project number: | BO 1979/46-1 |
| Duration: | December 1, 2016 to May 31, 2019 |
Investigation of high speed PVD technology concerning the deposition of α-Al-O+X and Al-Ti-O+X coatings for die casting of high melting steel alloys
Short description:
Within the project “Triboactive HPPMS CrAlN+X PVD coatings” investigations focused on the modification of the nitride hard coating (Cr,Al)N with triboactive elements X (X = Mo, W) and on tribological analyses to evaluate, if tribochemical interactions between lubricant additives and the tricoactive coatings can lead to friction and wear reducing tribochemical reaction layers. The research project followed the approach of developing the nitride hard coating (Cr,Al)N which is well known for its wear resistance in many fields of application towards the use as friction reducing coating for machine elements as alternative to diamond-like carbon (DLC). Friction and wear analyses of the triboactive coatings (Cr,Al,Mo)N and (Cr,Al,W)N were conducted by means of pin on disc (PoD) tribometer. Furthermore, the interactions between the coatings and Sulphur, Sulphur-Phosphorous and Molybdenum dithiocarbamate doped mineral oil was evaluated. Especially, the addition of Mo in the coatings in combination with high Hertzian contact pressure pH and high temperatures, can lead to significant friction reduction. Analyses by means Raman spectroscopy revealed the in situ formation of MoS2 and WS2. The project showed the high potential of (Cr,Al,Mo)N and (Cr,Al,W)N coatings for tribological applications. Poster BO 1979/42-1
| Funding: | German Research Foundation (DFG) |
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| Project number: | BO 1979/42-1 |
| Duration: | January 1, 2016 to June 30, 2018 |
High Speed-PVD XAlON oxidation protective coatings for gamma TiAl alloys (HS-Oxi)
Short description:
The aim of the research project was to develop and produce thick, oxidation-resistant coatings by means of the High Speed-PVD (HS-PVD) technology for gamma-TiAl alloys. In the project coating concepts were developed based on XAlON, XAl (X = Cr, Si) and SiAlY. It has been shown that the HS-PVD technology is suitable for producing oxidation protective coatings with a dense microstructure at high deposition rates. Among them, the SiAlY coating system reveals the highest potential in terms of oxidation protection for γ-TiAl. The lowest mass increase and the highest diffusion barrier effect were achieved by this coating system in isothermal annealing test up to t = 1,000 h and thermocyclic annealing test up to N = 1,000 cycles. Poster BO 1979/40-1
| Funding: | German Research Foundation (DFG) |
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| Project number: | BO 1979/40-1 |
| Duration: | June 1, 2015 to January 31, 2018 |
Friction reduction due to diamond-like carbon (DLC) coatings in fully lubricated elastohydrodynamic contacts
Short description:
The aim of the research project was to analyze the influence of Diamond-like Carbon (DLC) coatings on the frictional behavior in elastohydrodynamic (EHD) contacts. Thereby, a better understanding of the causes of the friction-reducing effect of DLC coatings in EHD contacts could be achieved. The analysis of the frictional behavior in the EHD contact showed a reduction of the friction coefficient μ by up to 43 % by using the DLC coatings on gears in comparison to the uncoated tribological contact. The significantly lower thermal conductivity λ of the DLC coatings compared to steel leads to a thermal insulation effect in the lubrication film. The friction reduction can be attributed to the lower effective lubricant viscosity in the tribological contact due to the higher contact temperatures. Poster 585II/18490 N
| Funding: | Arbeitsgemeinschaft industrieller Forschungsgemeinschaften (AiF) |
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| Project number: | IGF 18490 N/FVA 585 II |
| Duration: | December 1, 2014 to July 31, 2017 |
Triboactive HPPMS CrAlN+X PVD coatings
Short description:
Within the project “Triboactive HPPMS CrAlN+X PVD coatings” investigations focused on the modification of the nitride hard coating (Cr,Al)N with triboactive elements X (X = Mo, W) and on tribological analyses to evaluate, if tribochemical interactions between lubricant additives and the tricoactive coatings can lead to friction and wear reducing tribochemical reaction layers. The research project followed the approach of developing the nitride hard coating (Cr,Al)N which is well known for its wear resistance in many fields of application towards the use as friction reducing coating for machine elements as alternative to diamond-like carbon (DLC). Friction and wear analyses of the triboactive coatings (Cr,Al,Mo)N and (Cr,Al,W)N were conducted by means of pin on disc (PoD) tribometer. Furthermore, the interactions between the coatings and Sulphur, Sulphur-Phosphorous and Molybdenum dithiocarbamate doped mineral oil was evaluated. Especially, the addition of Mo in the coatings in combination with high Hertzian contact pressure pH and high temperatures, can lead to significant friction reduction. Analyses by means Raman spectroscopy revealed the in situ formation of MoS2 and WS2. The project showed the high potential of (Cr,Al,Mo)N and (Cr,Al,W)N coatings for tribological applications. Poster BO 1979/36-1
| Funding: | German Research Foundation (DFG) |
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| Project number: | BO 1979/36-1 |
| Duration: | August 1, 2014 to June 30, 2017 |
Manufacturing and characterization of multilayer EB-PVD thermal barrier coatings based on rare earth oxides
Short description:
The aim of the research project was the development of double and quadruple multilayer thermal barrier coatings (WDS) by means of electron beam physical vapor deposition (EB-PVD) to increase turbine inlet temperature of aircraft engines. Research was carried out on multilayer WDS consisting of yttria-stabilized zirconia (YSZ) and gadolinium zirconate (Gd2Zr2O7) or lanthanum zirconate (La2Zr2O7). The analysis of microstructural and thermal properties, their correlation as well as the isothermal and thermocyclic annealing of the coatings provided important insights into the potential concerning thermal insulation and high temperature behavior of multilayer WDS. The project showed no major influence of multilayer architecture on thermal conductivity λ by means of the comparison of monolayer and multilayer systems. The conducted research indicated that multilayer TBC exhibit higher porosity Φ compared to 7YSZ monolayer. However, no strong correlation between porosity Φ and thermal conductivity λ was determined. Furthermore, no improvement of the thermal cycling behavior due to quadruple multilayer architecture was achieved. However, double layer structure showed improved thermal cycling behavior compared to monolayer TBC. Poster BO 1979/24-2
| Funding: | German Research Foundation (DFG) |
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| Project number: | BO 1979/24-2 |
| Duration: | July 1, 2015 to June 30, 2016 |