Objective
Teer Coatings constructed, adapted and improved the novel magnetron system. Enterprise Ireland studied the basics of these depositions and deposited on tools. DaimlerChrysler deposited and improved automotive coatings for inner wall deposition. DWH and Wavin applied the coatings in field tests.
Teer Coatings had built single cylindrical magnetrons 40 and 22mm in diameter and a four cylindrical magnetron system and carried out deposition of various materials, e.g Tantalum for further improvement of the cylindrical magnetron. These improvement had a large impact on layer quality and uniformity. Furthermore Teer Coatings deposited coating for increased demand on tool components at the enduser DWH and Wavin.
As major result the novel magnetron system- in particular the arrangements of magnets at the deposition source- increases the utilisation of depositing material (impact on cost) and the quality of the coating. The uniformitiy of the coating has to be improved. Chromium based PVD- coatings show high adhesion on automotive Aluminium and Steel based components. In particular Cr-N-C based systems as deposited at Daimler Chrysler have low friction as figured out in model and field tests.
Enterprise Ireland carried out a range of deposition experiments using the cylindrical magnetron system and evaluated parameters such as the influence of cylinder diameter, pressure, bias frequency and the addition of inert gasses on coating performance. In addition to coatings sent to end users within the consortium a number of components were coated for evaluation by Irish SME engineering and polymer device manufactures. These coatings are now routinely used by a number of these SME's in there manufacturing process.
DWH achieved best resuLts (100% improvement) combing the elaborated PVD coatings with Carbon-spray for their mould application.
The physical properties of surfaces, such as wear
resistance and friction, have an enormous influence on
the performance of engineering components. Over the last
20 years physical vapour deposition (PVD) technology has
been used to deposit coatings to modify the surface
properties of both flat and geometrically complex shapes.
There is however a major industrial need to apply PVD
coatings onto the inside of cylinders and orifices which
currently cannot be achieved.
The difficulties are the physical size of the magnetron
electrodes used to apply the coatings and the requirement
for a minimum target to substrate distance of
approximately 30 mm to give sufficient ion bombardment to
obtain dense film. Current PVD technology is limited to
coating cylinders with internal diameters of greater than
approximately 150 mm. In this project cylindrical
magnetron electrodes based on novel designs will be
developed to coat inside cylinders with minimum diameters
of 50 mm.
Novel electrodes will be applied to the deposition of a
number of PVD coatings previously developed in
fundamental research projects. Six demonstrator
components with internal cylinders will be coated for
industrial end users in the automobile, tool
manufacturing, and plastic industries. The enhanced
performance targets will depend on the individual
component but the overall effect will be to increase
component wear resistance and reduce friction. The main
applications of the novel electrodes are:
* Daimler Benz - A 50% reduction in the oil consumption
of Mercedes car engines and an increase in coated
component wear resistance. A pilot plant coating system
will be developed to coat engine components to
demonstrate that the novel electrode deposition process
can be scaled up to simultaneously coat 10 components at
costs per component which are 50% cheaper than the
current coating prices.
* DWH - The target is to double the lifetime of the dies
used by this company for pressing and sintering ceramic
abrasive tool parts. In addition to eliminate the need
for die lubrication in pressing to result in a targeted
13% reduction in rejected parts.
* Wavin - the aim is to increase the efficiency of
plastic pipe extrusion and injection moulding equipment,
resulting in substantial savings in energy and plastic
raw material costs.
In addition to these three industrial end users the
consortium consists of a magnetron electrode and
deposition equipment manufacturer (Teer Coatings), and a
research centre (Forbairt) with expertise in the
deposition and characterisation of PVD coatings.
Fields of science (EuroSciVoc)
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
- engineering and technology mechanical engineering manufacturing engineering
- engineering and technology mechanical engineering tribology lubrication
- natural sciences chemical sciences inorganic chemistry transition metals
- natural sciences chemical sciences inorganic chemistry post-transition metals
- engineering and technology materials engineering coating and films
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Coordinator
81663 MUENCHEN
Germany
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