Hierarchical Surface Protection, A New Paradigm Toward Functional Multi-Nano-Layered Coatings

Project Information

HIERARCHICAL FUNCOAT

Grant agreement ID: 894551

DOI

10.3030/894551

Project closed

EC signature date 21 April 2020

Start date 1 September 2021

End date 31 August 2023

Funded under

• EXCELLENT SCIENCE - Marie Skłodowska-Curie Actions

Total cost

€ 219 312,00

EU contribution

€ 219 312,00

Coordinated by

AARHUS UNIVERSITET
Denmark

Periodic Reporting for period 1 - HIERARCHICAL FUNCOAT (Hierarchical Surface Protection, A New Paradigm Toward Functional Multi-Nano-Layered Coatings)

Reporting period: 2021-09-01 to 2023-08-31

Summary of the context and overall objectives of the project

What is the issue being addressed?

The proposal introduces the concept of Hierarchical Surface Protection (HSP) to develop ultra-durable Functional Multilayer Coatings (FMCs) by combining the strengths of single-layer coatings without compromising weaknesses. It aims to pioneer design principles for hierarchical surface protection, addressing the lack of theoretical understanding and reliable deposition guidelines in the field.

Why is it important for society?

Engineering components are constantly exposed to complex environmental and service stresses, leading to material surface degradation such as wear, corrosion, and fatigue. Coating techniques have evolved over time to protect material surfaces, with advancements such as nanocomposite coatings and gradient coatings. Despite these developments, there remains a gap in design principles for developing multilayer coatings, hindering their optimization and widespread application.

What are the overall objectives?

The project's objectives include shedding light on material removal mechanisms in FMCs, establishing design principles for optimized coatings, and correlating research outcomes with industrial applications. These objectives collectively aim to advance the understanding of multi-layer coatings and facilitate their integration into industrial settings.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Work Package 1: Modelling the materials removal mechanisms in bilayer coatings (WC/DLC-Cr/DLC and Cr/DLC/WC) under simple stress conditions, such as adhesive wear and unidirectional indentation at the nano-scale. This included tasks such as initiating collaborations, performing molecular dynamics (MD) simulations, and exploring the effect of layer thickness on mechanical properties.

Work Package 2: Performing validating experiments and large-scale simulations of multilayers of Cr/DLC/WC FMC to extract mechanical properties. Tasks included optimizing layer geometry in MD models, designing the first multi-interface of the multilayer, and expanding the model for more interfaces.

Work Package 3: Performing mechanical tests, including nano-indentation and scratch tests, stress analysis, and indentation creep to validate numerical simulations. This involved deposition of concept-based functional multilayer coatings (FMCs) and performing quantitative analysis of their mechanical properties and wear response.
All the goals regarding MD simulation and experimental parts have been achieved, with deliverables such as open access publications and presentations in prominent conferences. Remaining results will be presented in April 2024. The fascinating results of the simulations and experiments have been published in high-ranking journals.
Conferences Attended:

21st International Conference and Exhibition on Materials Science and Engineering (2020): Presentation of optimal bilayer DLC/WC-Cr/DLC design and fabrication principles.
ECCOMAS Conference (2022): Presentation on simple static/dynamic loading modeling of multilayers of Ceramic/DLC-Metal/DLC coatings.
Wear and Friction Conference (2022, Switzerland): Presentation on multilayer coatings.
ITC 2023 (Fukuoka, Japan): Presentation of the first concept-based designed and deposited FMC, the biggest tribology conference globally.
ICMCTF (International Conference on Metallurgical Coatings and Thin Films, 2024): Scheduled presentation in April 2024.
Published Papers:

Paper 1: "Interface Amorphization Controls Maximum Wear Resistance of Multinanolayer DLC/WC Coatings" Published in ACS Applied Materials & Interfaces. https://pubs.acs.org/doi/abs/10.1021/acsami.3c18218
Paper 2: "Negligible Wear in Hierarchical Multi-layer Coatings Governed by Optimized Design Principle." Submitted to Nature Materials (under review).
These conferences and publications showcase the significant advancements made in the project and contribute to the dissemination of findings within the scientific community.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Our project, "Hierarchical Surface Protection: A New Paradigm Toward Functional Multi-Nano-Layered Coatings," revolutionized surface protection by developing functionally-gradient multi-layer coatings. Leveraging "Materials-by-Design," we addressed the limitations of single-layer coatings, achieving unprecedented wear resistance and self-healing capacities. Collaborating with Grundfos, a pump manufacturing giant, we began scaling up our successful coating design for shaft sealings, marking a significant advancement. Our integrated approach of computer simulations and experiments established a comprehensive understanding of material removal mechanisms, laying the groundwork for optimizing coatings for durability. By correlating our research with industrial applications, we bridged academia and industry, promising cost savings, energy efficiency, and reduced environmental impact. Our project's societal implications span automotive, aerospace, energy, and healthcare sectors, enhancing safety and sustainability worldwide. In summary, our transformative endeavor propelled surface protection technology forward, with ongoing scale-up efforts in collaboration with Grundfos indicating tangible real-world applications.

this is a paper published in ACS appl.Mat.intrface IF:10.11, I am the responsible author

image illustrate the precise experimental vs simulation results for the optimized coating design