Completed Projects of PVD-Tools
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Investigations of temperature active, friction reducing coatings for turning titanium alloys
Short description:
Aim of the research project is to gain knowledge on the cause-effect relationships that can lead to a reduction of the tool load in the machining processes of the difficult to machine alloy TiAl6V4 by use of self-lubricating CrAlMoN coatings. The self-lubricating effect is based on temperature-induced formation of easily shearable molybdenum oxides on the coating surface during the cutting process. The deposition of the CrAlMoN coatings with varied element content are carried out in a hybrid direct current Magnetron Sputtering (dcMS) / High Power Pulse Magnetron Sputtering (HPPMS) coating process using an industrial coating unit. In subsequent analyses the influences of the temperature-active element molybdenum on coating and composite properties are determined. The oxidation and diffusion behavior as well as the friction behavior are investigated in model tests. Furthermore, the tools are used in machining tests and subsequently subjected to a detailed damage analysis. In addition, a novel temperature measurement setup is used to analyze the cutting temperature during the turning process. The machining tests are planned on the one hand with CrAlMoN-coated tools. On the other hand, reference tests with uncoated and CrAlVN-coated tools are planned in order to clarify open questions regarding the present cutting temperature.
| Funding: | German Research Foundation (DFG) |
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| Project number: | BO 1979/69-2 |
| Duration: | March 1, 2022 to February 28, 2023 |
Experimental and simulative investigations on the fatigue behavior of compounds, consisted of Cr-based nitride hard coatings on steel substrate under cyclic impact loads and bending stresses
Short description:
The PVD (Physical Vapor Deposition) coated tools are subjected to cyclic impact as well as superimposed bending loads in tribological applications, such as full forward extrusion. The main objective of the research project is therefore the experimental and simulative investigation of the fatigue behavior of material composites consisting of CrAlN hard coatings and the HS6-5-2C (1.3343) steel substrate under cyclic impact as well as under bending loads. A fundamental contribution is made to the description of failure mechanisms as a function of the layer properties layer thickness, morphology, chemical composition and elastic-plastic properties as well as the depth-dependent properties indentation hardness, indentation modulus and residual stresses. Poster BO 1979/71-1
| Funding: | German Research Foundation (DFG) |
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| Project number: | BO 1979/71-1 |
| Duration: | July 1, 2020 to December 31, 2022 |
High Power Pulsed Magnetron Sputtering (HPPMS) coating deposition and process understanding
Short description:
Project A1 is a subproject of the Transregional Collaborative Research Centre SFB-TR87 in the third funding phase, in which the basic mechanisms of the synthesis pathway for the production of hard coatings in high-performance plasmas are investigated. The validation and consistency of the methodology for the knowledge-based design of industry-relevant coating processes on complex substrates for a concrete stress collective will be completed in the third phase. One aim is to transfer the knowledge-based methodology for process development for the multilayer Cr-Al-O-N coating concept to (Ti;V)-Al-O-N. During the validation, results from different models developed in the SFB are brought together. The results are transferred to low-temperature processes for plastic substrates. Another aim is to increase the adhesion between the individual layers and to the substrate. Researching the etching phase of the PVD process, A1 designs the plasma etching processes for steel and plastic substrates. The substrate temperature, which is crucial for adhesion, is measured online in the process phases with the new temperature sensor and the influence of residual stresses on adhesion is being investigated. Furthermore the theoretically optimal layer thicknesses and residual stresses that A1 implements during coating production will be determine. The work will be extended by investigations of the corrosive interactions, the influence on plastic degradation and adhesion wear. The new evaluation methods for the interaction between polycarbonate melt and Cr-Al-O-N will be transferred to other plastics and coatings and validated. For extrusion, it is possible in the long term to predict the coating selection depending on the plastic, which is produced in knowledge-based plasma processes. Poster SFB-TR 87 A1
| Funding: | German Research Foundation (DFG) |
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| Project number: | SFB-TR 87 A1 - DFG TRR 87/3 |
| Duration: | July 1, 2018 to December 31, 2022 |
Influence of plasma properties on coating properties in pulsed high-performance plasmas
Short description:
In the 3rd funding phase of the subproject C6 in the transregional collaborative research center SFB-TR 87, the validation of process diagnostics methods takes place, which were developed in the 2nd funding phase. This aim is reached by transferring results from the Cr-Al-O-N system to (Ti;V)-Al-O-N. This will prove that the process development can be significantly shortened by plasma diagnostics. At the same time, the incorporation of nitrogen into the coating, which is relevant for the coating development, is analyzed. In addition, the focus of the project is also on the transfer and validation of the developed plasma diagnostic methods to a production-capable process diagnostics. For the first time, also the cleaning effect of the plasma etching in order to increase the adhesion to steel and plastic substrates is being investigated diagnostically. For this purpose, the quality and effectiveness of the plasma etching is correlated with plasma parameters and the substrate temperature in order to obtain the best possible plasma cleaning near the maximum permitted temperatures of the substrates. A further goal is the iterative development and validation of artificial neural networks (ANN). Here, the relationships process-plasma, plasma-coating and coating-system are considered. Overall, C6 contributes important work to overcoming the empirical approach to coating development using high-performance plasmas. Poster SFB-TR 87 C6
| Funding: | German Research Foundation (DFG) |
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| Project number: | SFB-TR 87 C6 – DFG TRR 87/3 |
| Duration: | July 1, 2018 to June 30, 2022 |
Investigation of the interactions of incremental surface layer forming and HPPMS coating on fine blanking dies in order to enable a load-applied surface integrity adjustment
Short description:
The aim of the research project is the investigation of a process combination of an incremental edge zone forming and a subsequent low temperature deposition of TiAlCrSiN coatings. By means of precise process control, a mechanically and thermally stable surface integrity in the edge zone of fineblanking punches made of powder metallurgical high-speed steel, which is advantageous for fatigue and wear resistance, is to be achieved. For this purpose, the process temperatures are determined in situ on the substrate side as a function of the process parameters, so that no relaxation of the previously induced work hardening and residual compressive stresses occurs. Poster BO 1979/72-1
| Funding: | German Research Foundation (DFG) |
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| Project number: | BO 1979/72-1 |
| Duration: | January 1, 2020 to June 30, 2022 |
Shot peening of tool surfaces, application of PVD coatings and plasma analysis of the pulsed arc evaporation to increase tool lifetime in aluminum die casting
Short description:
The aim of the research project is to increase the service lifetime of core tools in aluminum die casting by a targeted combination of surface modification and coating application. The coating system CrN/AlN+Al2O3 is further developed by the application of a phase-stable γ‑Al2O3 top layer in a pulsed arc evaporation process. Suitable process parameters are selected by means of plasma-diagnostically supported coating development. In industrial aluminum die casting, selected coatings are used for the production of engine blocks. In the subsequent damage analysis of the core tools, the cause-effect relationships of the various surface technology methods are analyzed. Poster IGF 20231 N
| Funding: | German Federation of Industrial Research Associations (AiF) |
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| Project number: | IGF 16/05 No. 20231 N |
| Duration: | August 1, 2019 to April 30, 2022 |
Investigations of temperature active, friction reducing coatings for turning titanium alloys
Short description:
Aim of the research project is the development and analysis of friction-reducing CrAlVN coating systems for the turning of TiAl6V4. Friction reduction while machining TiAl6V4 will be achieved by a temperature induced formation of easy to shear vanadium oxides on the coating surface. The deposition of the coating system is carried out in a hybrid direct current Magnetron Sputtering / High Power Pulse Magnetron Sputtering (dcMS/HPPMS) coating process using the industrial coating unit CC 800/9 HPPMS, CemeCon AG, Würselen. Following analyses of the coated cemented carbide cutting inserts are carried out in order to determine the influences of the temperature-active element vanadium on coating and compound properties. Furthermore, the interactions between the vanadium containing coating systems and the titanium alloy TiAl6V4 at temperatures up to T = 800 °C are analyzed by means of different heat treatments. An additional analysis of the thermal and mechanical loads while turning TiAl6V4 will contribute to the understanding of the performance and damage mechanisms of the coating system.
| Funding: | German Research Foundation (DFG) |
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| Project number: | BO 1979/69-1 |
| Duration: | April 1, 2019 to June 30, 2021 |
Dry metal forming of low-alloy steels by full forward extrusion using self-lubricating tool coating and structured workpiece
Short description:
The aim of the third phase of the research project is the first realization of dry forming of steel by full forward extrusion based on the basic knowledge of the interaction between self-lubricating (Cr,Al)N+X:S coatings (X = Mo, W) and structured semi-finished product surfaces. The hybrid dcMS/HPPMS (direct current Magnetron Sputtering/High Power Pulsed Magnetron Sputtering) coating process has to be adapted to the changing stress collective along the longitudinal axis of a double-shoulder forming die. Subsequently, dry forming tests with structured semi-finished products will be performed. Poster BO 1979/44-2
| Funding: | German Research Foundation (DFG) |
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| Project number: | BO 1979/44-2 |
| Duration: | January 1, 2018 to December 31, 2019 |
Development, analysis and proving of novel coatings for precision molding
Short description:
The aim of the research project is to increase the efficiency of precision molding through novel coatings and wafer-level glass pressing. With the help of novel innovative coatings, the service life of the pressing tools for a wide range of glasses be significantly increased, so that service lives of > 1,000 pressing cycles can be achieved. In wafer-level glass pressing, a large number of optical components are produced per pressing cycle. To increase the service life, nitride (Cr,Al,Si)N, (Cr,Al,C)N and oxinitride (Cr,Al)ON as well as amorphous carbon coating a-C (diamond-like carbon, DLC) are developed using high-performance plasmas (High Power Pulsed Magnetron Sputtering, HPPMS). In addition, the interactions between glass and coating were investigated. Poster ZF4059002HM6
| Funding: | Central innovation program for medium-sized enterprises (ZIM) |
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| Project number: | ZF4059002HM6 |
| Duration: | January 1, 2016 to August 31, 2019 |
Influence of HPPMS pulse parameters on stoichiometry and the formation of reaction layers on nitridic hard coatings for metal cutting
Short description:
The overall aim of the project is, to investigate an influence of the parameters on stoichiometry and the formation of reaction layers on hard coatings to improve the wear resistance and thermal stability of coated cutting tools in high-performance cutting. A novel hybrid process with combined dcMS (direct current Magnetron Sputtering) and HPPMS (High Power Pulsed Magnetron Sputtering) power supply is used. By using a coating concept with nanocomposite coating architecture, particularly favorable properties such as high penetration hardness and high oxidation resistance are to be achieved. Research into the influence of process parameters and a heat treatment on the stoichiometry of the reaction layers, the interaction with steel and the high-temperature behaviour are in the focus. Within the scope of the project, heat treatments are carried out in contact with a steel counterbody in an oxygen-containing ambient atmosphere. The interaction is investigated by X-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM), transmission electron microscopy (TEM) and X-ray diffraction (XRD). Poster DFG BO1979/48-1
| Funding: | German Research Foundation (DFG) |
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| Project number: | DFG BO1979/48-1 |
| Duration: | August 1, 2017 to July 31, 2019 |
Cluster of Excellence „Integrative Production Technology for High-Wage Countries “ - Project C3 „ Multi-Technology Products “ – Test case „Optic“
Short description:
The aim of the research project was the development of a continuous process chain for the production of structured, optically functional plastic components. Laser technology was used to introduce structures in the range of micro- or nanometer into the cavities of the injection molding tool. These were molded by brittle plastics, such as polycarbonate and polymethyl methacrylate, in the subsequent plastics processing process. By coating the laser-structured tool using the physical vapour deposition (PVD) process, it was possible to reduce wear and the adhesive force between the surface of the tool and the plastics. In addition, it has been shown that laser structures can only be molded by modifying the surface with a suitable PVD coating. Without the additional coating, the structures break from the uncoated mold during demolding and, in contrast to the coated mold, the polymer sticks to the structures. The replication ratio could be improved by 20 to 30 % depending on the structure type. Poster EXC-128
In the transition phase, PVD sensor coatings are developed for temperature measurement. The focus is on metallic sensor layers which are protected from wear by hard coatings as well as on sensor coatings which themselves consist of hard coatings. The sensor coatings are suitable for providing data from production in real time. By combining them with a thermally sprayed heating conductor coatings to create a sensor-actuator system, the coating systems can independently influence the temperature control of manufacturing processes. Poster EXC-128 transition phase
| Funding: | German Research Foundation (DFG) |
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| Project number: | EXC-128 |
| Duration: |
November 1, 2012 to October 31, 2017 November 1, 2017 to December 31, 2018 (transition phase) |
Dry metal forming of low-alloy steels by full forward extrusion using self-lubricating tool coating and structured workpiece
Short description:
The aim of the second phase of the research project is the development of models to investigate the tribological interactions during full forward extrusion between self-lubricating (Cr,Al)N+X:S tool coatings (X = Mo, W) and structured semi-finished product surfaces. Here, the process limits for the deposition of coatings using hybrid dcMS/HPPMS (direct current Magnetron Sputtering/High Power Pulsed Magnetron Sputtering) technology have to be adapted in order to achieve the coating application of real VVFP matrices and subsequent tool life investigations on an industrial forming press. Poster BO 1979/44-1
| Funding: | German Research Foundation (DFG) |
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| Project number: | BO 1979/44-1 |
| Duration: | November 1, 2015 to August 31, 2018 |
High Power Pulsed Magnetron Sputtering (HPPMS) coating deposition and process understanding
Short description:
Project A1 was a subproject of the transregional Collaborative Research Centre SFB-TR87 in the second funding phase, in which the basic mechanisms of the synthesis pathway for the production of hard coatings in high-performance plasmas are investigated. The overall aim of the subproject is the knowledge-based design of industry-relevant coating processes on complex substrates for a specific load collective, using the example of plastic extrusion. The layers synthesized in pulsed high-performance plasmas protect steel components of the plastic extrusion against abrasive and adhesive wear. In the second phase, a multi-layer architecture was developed for Cr-Al-O-N, which is produced by parameter variation within a coating process. Functions are assigned to each individual layer in order to meet partially conflicting extrusion requirements. In addition to the bond coat, the layer architecture consists of a high-strength and tough nanolaminate for abrasion protection and a thin oxinitride top layer for adhesion protection. The suitable nanolayer thicknesses in the nanolaminate were selected in another subproject. The adhesion of plastic melts made of polycarbonate was investigated in cooperation with another subproject by developing new model tests. The oxide structure of the reaction layer, which spontaneously forms on the hard material layer, was investigated. The special advantages of the types of power supply direct current Magnetron Sputtering (dcMS) and High Power Pulsed Magnetron Sputtering (HPPMS) were combined by the development of a hybrid dcMS/HPPMS process. With the temperature sensor newly developed in A1, it is now also possible to measure the temperature on the substrate surface online during the individual phases of the coating process. Poster SFB-TR 87 A1
| Funding: | German Research Foundation (DFG) |
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| Project number: | SFB-TR 87 A1 - DFG TRR 87/2 |
| Duration: | July 1, 2014 to June 30, 2018 |
Elastic-plastic Behaviour of Nanostructured Coatings
Short description:
The aim of subproject A4 was to investigate the mechanical behaviour of compounds, consisting of steel substrate 1.2083 and coating system M-Al-O-N (M = Cr, V), up to the beginning of failure. A4 provided important insights into the cause-effect relationships between coating’s technology, coating’s architecture and strength increase for process developments. The elastic-plastic compound behaviour was quantified by nanoindentation up to the beginning of the failure. CrN/AlN-Nanolaminates show an increasing strength and fracture toughness with decreasing nanolayer thickness. Furthermore, a significantly high brittle behaviour of the oxynitrides was demonstrated. By correlating the mechanical data of A4 with the plasma properties, important findings were provided for the process developments and also for the design of the structural zone models. Additionally, the results of A4 were used for training of the artificial neural networks (KNN). The most important result in the analysis of the considerable plastic behaviour of the hard coatings is the identification of the grain boundary sliding as the dominant mechanism. Coating thickness, residual stresses and the failure criterion were implemented in the developed model in A4 using the finite element method (FEM). Poster SFB-TR 87 A4
| Funding: | German Research Foundation (DFG) |
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| Project number: | SFB-TR 87 A4 - DFG TRR 87/2 |
| Duration: | July 1, 2014 to June 30, 2018 |
Influence of plasma properties on coating properties in pulsed high-performance plasmas
Short description:
The overall objective in the 2nd funding phase of the subproject C6 in the transregional collaborative research center SFB-TR 87 was the analysis of plasma properties in order to describe cause-effect relationships on the coating properties in a high-volume coating unit CC800/9-Modell, CemeCon AG, Würselen. The focus of C6 was on substrate-oriented plasma diagnostics. At the same time, another focus of the project was the development of first artificial neural networks (ANN). Plasma diagnostics have been further developed to meet the requirements of production-relevant processes. Significant improvements of high-performance plasmas such as High Power Pulsed Magnetron Sputtering (HPPMS) have been achieved and explained by shorter pulse-on times ton and higher frequencies f. In addition, analysis of the Debye sheath thickness can now contribute to a better understanding of the plasma influence on the coating properties on complex geometries. Poster SFB-TR 87 C6
| Funding: | German Research Foundation (DFG) |
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| Project number: | SFB-TR 87 C6 – DFG TRR 87/2 |
| Duration: | July 1, 2014 to June 30, 2018 |
Investigation of the influence of coatings on extruder screws to improve process control
Short description:
The aim of the research project was to evaluate the influence of novel PVD coatings on extruder screws to improve process control. This included the development of suitable coating processes for the production of nitride (Cr,Al)N and oxinitride (Cr,Al)ON hard coatings with coating processes such as arc evaporation (Arc), middle frequency magnetron sputtering (mfMS) and the hybrid dcMS/HPPMS-process. The investigations showed that the use of PVD coatings improved the coefficients of friction and the adhesion behavior compared to uncoated substrate material steel 34CrAlNi7-10 (1.8550). The high throughput of mass required for economic reasons with low specific energy requirements could be achieved or significantly improved compared to the uncoated extruder screw by using coated extruder screws. Poster ZN-497 / 2
| Funding: | Federation of Industrial Cooperative Research Associations (AiF) |
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| Project number: | ZN-497 / 2 |
| Duration: | January 1, 2013 to January 1, 2016 |