Objective
To develop surface engineering techniques for the improved performance of metals and ceramics, including the improvement of wear and corrosion resistant surfaces and coatings, the improvements of component fatigue life and the increased chemical sensitivity of surfaces for gas sensor applications. The techniques used will embrace combinations of spray coatings, heat treatment by laser and electron beams and modification by ion beams.
Surface engineering techniques are being developed for the improved performance of metals and ceramics, including the improvement of wear and corrosion resistant surfaces and coatings, the improvement of component fatigue life and the increased chemical sensitivity of surfaces for gas sensor applications. The techniques used embrace combinations of spray coatings, heat treatment by laser and electron beams and modification by ion beams. An advanced coatings centre is being constructed. The following have been installed:
a hotwall chemcial vapour deposition (CVD) unit, providing the possibility to carry out thermally activated processes up to 1200 C or plasmaassisted processes up to 600 C;
a coldwall plasma assisted chemical vapour deposition (PACVD) unit for process development;
a plasma ion nitriding facility (PIN);
an atmospheric plasma spray installation;
a high velocity flame spray system (HVOF) together with a sophisticated robot based gun and workpiece manipulation system.
The installations of the surface modification centre have been improved and completed, including the installation of a sputter ion source in the implanter, the calibration of the power output of the laser, the measurement of absorption coefficients and the installation of the flame spray unit. A laboratory has been set up for corrosion in aqueous solutions at temperatures up to 200 C. The influence of an ion implantation on the mixing of aluminium deposits with an aluminium oxide (Al2O3) substrate has been studied as well as the hardening of stainless steel by the implantation of nitrogen. Other topics treated by ion implantation were the implantation of yttrium or iron chromium aluminium the mixing of yttrium coatings with iron chromium aluminium, the mixing of aluminium or nickel coatings with silicon dioxide, the implantation of nitrogen on diamond and the implantation of chromium on Inconel 800. Laser and electron beam melting have been used to produce differnet aluminium cooper alloys on a cooper substrate by a 2 step process. The important parameters for the production of surface alloys such as scanning speeed, scanning steps, specific power and substrate temperature have been determined. The hardness of austenitic stainless steels has been improved by laser surface melting. Plasma spray coatings have been the subject of study which aims at the improvement of the resistance against high temperature gas corrosion. Very successful coatings have been produced and are now under test. Some of the coatings are showing excellent resistance up to 1100 C.
Progress to end 1991
The current activities in this field are concentrated in the Advanced coatings centre (ACC) at Petten and the Surface modification facility in Ispra. A number of other new activities begin in 1992.
Advanced Coatings Centre.
This is a new venture and is being out in full cooperation with the neighbouring organisation ECN by pooling resources. Construction of the ACC advanced in 1991, the main activities being the installation of the following:
- a hotwall CVD unit, providing the possibility for carrying out thermally activated processes up to 1200 degrees celsius or plasma-assisted processes up to 600 degrees celsius
- a coldwall PACVD unit for process development
- a plasma ion nitriding facility (PIN)
- an atmospheric plasma spray installation
- a high velocity flame spray system (HVOF) together with a sophisticated robot-based gun/workpiece manipulation system.
The centre is expected to be fully operated early in 1992.
Surface Modification Centre
The installation of the surface Modification center have been improved and completed, including the installation of a sputter ion source in the implanter, the calibration of the power output of the laser, the measurement of absorption coefficients and the installation of the flame spray unit. A laboratory has been set up for corrosion in aqueous solutions at temperatures up to 200 degrees celsius. The influence of ion implantation on the mixing of aluminium deposits with an Al2O3 substrate has been studied as well as the hardening of stainless steel by the implantation of N. Other topics treated by ion implantation were the implantation of Yttrium or FeCrAl, the mixing of Y coatings with FeCrAl, the mixing of Au/Ni coatings with SiO2 the implantation of N on diamond and the implantation of Cr on Inconel 800.
Laser and electron beam melting have been used to produce different Al-Cu alloys on a copper substrate by a two step process. The important parameters for the production of surface alloys such as scanning speed, scanning steps, specific power and substrate temperature have been determined. The hardness of austenitic stainless steels has been improved by laser surface melting.
Plasma spray coatings have been the subject of study wich aims at the resistance against high temperature gas corrosion. Very succesful coatings have been produced and are now under test. Some of the coatings are showing excellent resistance up to 1100 degrees celsius.
Detailed description of work foreseen in 1992
Activities within the ACC and the surface Modification Laboratory will be closely linked. Work will concentrate on the following:
1. Advanced Coating Centre
- Development of TiN/TiC wear resistant coatings for temperature sensitive steels using CVD procedures, allowing deposition at or below 500 degrees celsius
- Development of oxidation resistant coatings for refractory metals and alloys using CVD and PACVD processes
- Improvement of sprayed MCrAIY coatings for high temperature applications by application of additional diffusion barriers and by close compositional control.
2. Surface Modification Laboratory
- development of hard wear resistant coatings based on B, C, N, Si and groups III, V of the periodic table.
- ion implantation for improved bonding of fibres in composites and in ceramic-metal joining
- laser and electron beam melting of spray coatings for improved hardness and homogeneity
- combined laser and ion implantation for improved fatigue performance
- the development of coatings to resists saturated solutions of H2S and CO2 for the petrochemical industry
3. Other projects
- the improvement of ceramics properties by microstructural engineering
- the developments and characterisation of new electrolytic, electrocatalytic and sensor materials
- interfacial engineering of ceramics and metals in order to obtain a pre-determined bond strength
Short description of evolution of work in 1993
All activities are expected to continue along the lines indicated above.
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Coordinator
21020 Ispra
Italy
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