High dynamic stiffness mechanical structures with nanostructured composite coatings deposited by high power impulse magnetron sputtering

Nanostructured Cu:CuCNx composite coatings with high static and dynamic stiffness were synthesized by means of plasma-enhanced chemical vapor deposition (PECVD) combined with high power impulse magnetron sputtering (HiPIMS). Scanning electron microscope (SEM) images and energy-dispersive X-ray spectroscopy (EDS) mapping from cross-sectioned samples reveals a multi-layered nanostructure enriched in Cu, C, N, and O in different ratios. Mechanical properties of the coatings were investigated by Vickers micro-indention and model tests. It was observed that copper inclusions as well as copper interlayers in the CNx matrix can increase mechanical damping by up to 160%. Mechanical properties such as hardness, elastic modulus and loss factor were significantly improved by increasing the discharge power of the sputtering process. Moreover the coatings loss modulus was evaluated on the basis of indentation creep measurements under room temperature. The coating with optimum properties exhibited loss modulus of 2.6 GPa. The composite with the highest damping loss modulus were applied on the clamping region of a milling machining tool to verify their effect in suppressing regenerative tool chatter. The high dynamic stiffness coatings were found to effectively improve the critical stability limit of a milling tool by at least 300%, suggesting a significant increase of the dynamic stiffness.

[1]  M. Ohring.  The Materials Science of Thin Films , 1991 .

[2]  Nikhil Koratkar,et al.  Utilizing interfaces in carbon nanotube reinforced polymer composites for structural damping , 2006 .

[3]  N. Koratkar,et al.  Carbon Nanotube Films for Damping Applications , 2002 .

[4]  Scandvik coromant.  Modern Metal Cutting : a practical handbook , 1994 .

[5]  R W Siegel,et al.  Cluster-Assembled Nanophase Materials , 1991 .

[6]  Nikhil Koratkar,et al.  Energy dissipation in carbon nanotube composites: a review , 2008 .

[7]  John Robertson,et al.  Resonant Raman spectroscopy of disordered, amorphous, and diamondlike carbon , 2001 .

[8]  P. Raju,et al.  Material damping studies on carbon-carbon composites , 1992 .

[9]  Jang-Kyo Kim,et al.  Vibration damping characteristics of carbon fiber-reinforced composites containing multi-walled carbon nanotubes , 2011 .

[10]  J. Schneider,et al.  A novel pulsed magnetron sputter technique utilizing very high target power densities , 1999 .

[11]  Christian G'Sell,et al.  Elastic-plastic indentation creep of glassy poly(methyl methacrylate) and polystyrene: characterization using uniaxial compression and indentation tests , 1999 .

[12]  Govind,et al.  Studies of nanostructured copper/hydrogenated amorphous carbon multilayer films , 2011 .

[13]  S. A. Golovin,et al.  Peculiarities of the distribution of local microdeformations in cast iron with different forms of graphite , 1979 .

[14]  H. Garmestani,et al.  Hybrid carbon fiber/carbon nanotube composites for structural damping applications , 2013, Nanotechnology.

[15]  Fundamentals of High Power Impulse Magnetron Sputtering , 2006 .

[16]  Mikhail S. Blanter,et al.  Internal Friction in Metallic Materials: A Handbook , 2010 .

[17]  C. S. Bhatia,et al.  Probing the Role of an Atomically Thin SiNx Interlayer on the Structure of Ultrathin Carbon Films , 2014, Scientific Reports.

[18]  R. Lakes,et al.  Extreme damping in composite materials with negative-stiffness inclusions , 2001, Nature.

[19]  Luiz Claudio Pardini,et al.  Damping behavior of synthetic graphite beams , 2006 .

[20]  Nikhil Koratkar,et al.  Viscoelasticity in carbon nanotube composites , 2005, Nature materials.

[21]  Joaquim Ciurana,et al.  A new experimental methodology for identification of stability lobes diagram in milling operations , 2008 .

[22]  A. Anders.  Discharge Physics of High Power Impulse Magnetron Sputtering , 2011 .

[23]  D. K. Kharat,et al.  NiTi/Pb(Zr0.52Ti0.48)O3 thin film heterostructures for vibration damping in MEMS , 2013 .

[24]  D. Lundin,et al.  Anti-vibration Engineering in Internal Turning Using a Carbon Nanocomposite Damping Coating Produced by PECVD Process , 2014, Journal of Materials Engineering and Performance.

[25]  S. A. Tobias,et al.  A graphical method for the determination of the dynamic stability of machine tools , 1961 .

[26]  S. A. Golovin,et al.  Damping capacity of cast iron with different shapes of graphite inclusions , 1980 .

[27]  Richard W. Siegel,et al.  Nanostructured materials -mind over matter- , 1993 .

[28]  Frank Richter,et al.  Investigation of creep behaviour under load during indentation experiments and its influence on hardness and modulus results , 2001 .

[29]  Hejun Li,et al.  Damping characteristics of CVI-densified carbon–carbon composites , 2000 .

[30]  K. Sarakinos,et al.  An introduction to thin film processing using high-power impulse magnetron sputtering , 2012 .

[31]  D. Chung,et al.  Vibration damping using flexible graphite , 2000 .

[32]  Norbert Kaiser,et al.  Review of the fundamentals of thin-film growth. , 2002, Applied optics.

[33]  N. Tandon,et al.  A review of vibration and acoustic measurement methods for the detection of defects in rolling element bearings , 1999 .

[34]  J. Andersson,et al.  High power impulse magnetron sputtering : Current-voltage-time characteristics indicate the onset of sustained self-sputtering , 2007 .

[35]  U. Helmersson,et al.  High power impulse magnetron sputtering discharge , 2012 .

[36]  Wilfred Campbell,et al.  The Protection of Steam-Turbine Disk Wheels From Axial Vibration , 1924, Transactions of the American Society of Mechanical Engineers.

[37]  Roderic S. Lakes,et al.  Composite Materials Which Exhibit High Stiffness and High Viscoelastic Damping , 1995 .

[38]  D. Chung,et al.  Use of submicron diameter carbon filaments for reinforcement between continuous carbon fiber layers in a polymer-matrix composite , 1995 .

[39]  Yusuf Altintas,et al.  Identification of dynamic cutting force coefficients and chatter stability with process damping , 2008 .

[40]  Linda S. Schadler,et al.  Characterizing energy dissipation in single-walled carbon nanotube polycarbonate composites , 2005 .

[41]  R. Mehl,et al.  Fifty-year study of grain-boundary relaxation , 1999 .

[42]  R. K. Tripathi,et al.  Structural, nanomechanical, field emission and ammonia gas sensing properties of nitrogenated amorphous carbon films deposited by filtered anodic jet carbon arc technique. , 2014, Talanta.

[43]  Eric E. Ungar,et al.  The status of engineering knowledge concerning the damping of built-up structures , 1973 .