PVD Technology (Tools)

 

Ongoing projects

 

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)
Porject number: SFB-TR 87 A1 - DFG TRR 87/3
Duration: July 1, 2018 to June 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)
Porject number: BO 1979/69-1
Duration: April 1, 2019 to June 30, 2021

 
 

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.

Funding: German Research Foundation (DFG)
Porject number: BO 1979/72-1
Duration: January 1st, 2020 to December 31th, 2021

 
 

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.

Funding: German Federation of Industrial Research Associations (AiF)
Porject number: IGF 16/05 No. 20231 N
Duration: August 1, 2019 to April 30, 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)
Porject number: SFB-TR 87 C6 – DFG TRR 87/3
Duration: July 1, 2018 to June 30, 2022

 
 

Cluster of Excellence “Internet of Production” - Subproject WS-B1.I „Integrated Computational Materials Engineering”

Short description:

Within the subproject WS-B1.I, a multilayer coating system for precise temperature measurement and control in production processes is being developed. The coating system consists of an actuator coating for heat generation, which is applied by TS, and a sensor coating, produced by PVD.

For this purpose, thin PVD layers will be functionalized in the course of the project. By introducing a sensor function, it is possible to measure the process temperature directly at the interface between the mold and the molten aluminum with spatial and temporal resolution in the aluminum die casting process as the use case. The measurement signal is passed on to the TS heating layer in order to specifically control the process. At the same time, the PVD layer offers properties for wear protection of the applied tools. A digital shadow is used to view and control the coating process in detail in order to specifically set the properties required for the application.

Funding: German Research Foundation (DFG)
Porject number: EXC 2023/1
Duration: January 1, 2019 to December 31, 2025