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Nanocomposite coatings of CrN–WS 2 were prepared at different Cr contents (approximately 8–39 at%) using an unbalanced magnetron sputtering system. Structural changes in CrN–WS 2 coatings with variation in Cr content were studied using X-ray diffraction. CrN–WS 2 coatings displayed a dense, compact microstructure with reduced columnar growth in the field emission scanning electron microscopy data. Nanoindentation and nanoscratch data showed that CrN–WS 2 coatings exhibited improved mechanical and adhesive properties, respectively. Micro-tribometer tests at a load of 2 N indicated that CrN–WS 2 coatings prepared at 31 at% Cr exhibited a stable friction coefficient of 0.20–0.24 even after 8 h.

Solid lubricant coatings of WS 2 and Cr–WS 2 (15–50 at.% Cr) prepared using an unbalanced magnetron sputtering system were evaluated for their mechanical and tribological properties. Nanoindentation results indicated that addition of Cr helped in improving the mechanical properties and the elastic recovery ability of Cr–WS 2 coatings. The adhesive strengths of Cr–WS 2 coatings were evaluated using a nanoscratch tester and from the nanoscratch profiles, critical load values and optical images, it was evident that the adhesion of Cr–WS 2 coatings increased with an increase in the Cr content. Further analysis of the nanoscratch data indicated that WS 2 coatings exhibited large amount of plastic deformation compared to Cr–WS 2 coatings which showed a combination of elastic–plastic deformation. However, micro-tribometer measurements at a load of 2 N showed that the tribological properties of Cr–WS 2 coatings deteriorated with an increase in the Cr content. For example, Cr–WS 2 coatings prepared at Cr content ≥ 33 at.% failed after a sliding distance of 1 m. On the other hand, WS 2 and Cr–WS 2 coatings prepared at low Cr contents (15–23 at.% Cr) exhibited a stable friction coefficient (50–60% relative humidity) in the range of 0.10–0.13 for a sliding distance of 14 m. Micro-Raman spectroscopy data of the worn films taken after a sliding distance of 14 m indicated the presence of WS 2 transfer films for WS 2 and Cr–WS 2 coatings prepared at low Cr contents. For Cr–WS 2 coatings with Cr content ≥ 33 at.%, the worn films consisted predominantly of WO 3 . After an extended sliding distance of 50 m, Cr–WS 2 coatings (15–23 at.% Cr) outperformed WS 2 coating which failed after 20 m. Further, the coatings prepared at low Cr contents did not show any failure even after a sliding distance of 200 m. At a higher load of 7 N, Cr–WS 2 coating with 15 at.% Cr exhibited the best performance with a friction coefficient of 0.07 up to a sliding distance of 72 m. These results indicate that the amount of Cr in the WS 2 matrix needs to be controlled judiciously to obtain improved mechanical and tribological properties in Cr–WS 2 solid lubricant coatings.

WS2 and Cr–WS2 nanocomposite coatings were deposited at different Cr contents (approximately 15–50 at. %) on silicon and mild steel substrates using an unbalanced magnetron sputtering system. X-ray diffraction (XRD) was used to study the structure of Cr–WS2 coatings and the bonding structure of the coatings was studied using X-ray photoelectron spectroscopy (XPS). The characterization of different phases present in Cr–WS2 coatings was carried out using micro-Raman spectroscopy. The XPS and Raman data indicated the formation of a thin layer of WO3 on the surface of Cr–WS2 coatings and the intensity of the oxide phase decreased with an increase in the Cr content, which was also confirmed using energy-dispersive X-ray analysis results. The surface morphologies of WS2 and Cr–WS2 coatings were examined using field emission scanning electron microscopy (FESEM) and atomic force microscopy. It has been demonstrated that incorporation of Cr in WS2 strongly influences the structure and morphology of Cr–WS2 coatings. The XRD and FESEM results suggested that increase in the Cr content of Cr–WS2 coatings resulted in a structural transition from a mixture of nanocrystalline and amorphous phases to a complete amorphous phase. The cross-sectional FESEM data of WS2 coating showed a porous and columnar microstructure. For the Cr–WS2 coatings, a mixture of columnar and featureless microstructure was observed at low Cr ontents (≤23 at.%),whereas, a dense and featureless microstructure was observed at high Cr contents. Detailed cross-sectional transmission electron microscopy (TEM) studies of Cr–WS2 coatings prepared at Cr content ≤23 at.% indicated the presence of both nanocrystalline (near the interface) and amorphous phases (near the surface). Furthermore, high-resolution TEM data obtained from the nanocrystalline region showed inclusion of traces of amorphous phase in the nanocrystalline WS2 phase. Potentiodynamic polarization measurements indicated that the corrosion resistance of Cr–WS2 coatings was superior to that of the uncoated mild steel substrate and the corrosion rate decreased with an increase in the Cr content.

Approximately 1.5–2.5 μm thick nanocomposite coatings of TiAlCrYN were deposited using a four-cathode reactive unbalanced pulsed direct current magnetron sputtering system from the sputtering of Ti, Al, Cr, and Y targets in Ar + N 2 plasma. The TiAlCrYN nanocomposite coatings were deposited on various substrates such as high speed steel (HSS) drill bits, mild steel and silicon. TiAlCrYN coatings with almost similar mechanical properties but with different Ti, Al, Cr and Y contents were prepared to study their thermal stability and machining performance. The structural and mechanical properties of the coatings were characterized using X-ray diffraction and nanoindentation technique, respectively. The elemental composition, bonding structure, surface morphology and cross-sectional data were studied using energy-dispersive X-ray analysis, X-ray photoelectron spectroscopy and field-emission scanning electron microscopy, respectively. Nanoscratch tests were performed to determine the adhesive strength of the coatings. The corrosion behavior of TiAlCrYN nanocomposite coatings on mild steel substrate was studied using potentiodynamic polarization in a 3.5% NaCl solution. Micro-Raman spectroscopy was used to characterize the structural changes as a result of heating of the nanocomposite coatings in air (600–1000 °C). TiAlCrYN coatings prepared at 17 at.% Ti, 13 at.% Al, 21 at.% Cr and 1 at.% Y exhibited thermal stability as high as 900 °C in air (denoted as Sample 3). For the performance evaluation, the TiAlCrYN coated HSS drill bits were tested under accelerated machining conditions. With a drill speed of 800 rpm and a feed rate of 0.08 mm/rev the TiAlCrYN coated HSS drill bits (Sample 3) averaged 657 holes, while drilling a 12 mm thick 304 stainless steel plate under dry conditions, before failure. Whereas, the uncoated drill bits failed after drilling 50 holes under the same machining conditions. Results indicated that for the HSS drill bits coated with TiAlCrYN, the tool life increased by a factor of more than 12.

Multilayer and superlattice coatings of TiN/CrN coating are deposited on Si(100) substrate at different modulation wavelength by reactive unbalanced magnetron sputtering and characterized using X-ray diffraction, nanoindentation, AFM. Nano-roughness of films is in good correlation with hardness and modulus and this effect has been used for optimization of deposition parameters. Preliminary results have shown slightly better mechanical properties for multilayered TiN/CrN coatings compared to single layer TiN and CrN coatings. The XRD results have shown a preferred orientation in direction for TiN/CrN multilayer coatings at modulation wavelengths below 80 nm. At 100 nm layer thickness, TiN revealed small amount of crystals with orientation and their content significantly increases with increase in layer thickness while CrN layers only show preferred orientation of . Multilayered coatings exhibit better mechanical properties due to presence of large number of interfaces which act as barrier to dislocations. Fracture toughness and tribological properties of these coatings are also expected to show significant improvement and the investigation in this area is under progress.

Ionic liquids are salts that are liquid at ambient temperatures, and they produce virtually no hazardous vapors. As lubricating liquids, ionic liquid lubricants are of interest for reducing wear in circumstances where conventional lubricants are impractical such as in aerospace applications and high temperature vacuum bearings. The synthetic flexibility of ionic liquids allows control of the liquidous temperature range, good polymer compatibility, and high thermal stability. In this paper, a variety of ionic liquids were synthesized to build a library for testing. The liquids were thermally characterized by DSC and TGA, and mechanically characterized by pin-on-disk and 4-ball testing. Several chiral ionic liquids were synthesized as candidates for MEMS testing. The chiral nature of the liquids should help prevent crystallization in MEMs applications. Additionally, nanomaterials incorporated into the lubricants imparted lower friction coefficients and enhanced thermal stability.Copyright © 2005 by ASME

The nanoscratch behaviour of TiN/CrN nanolaminates has been investigated in the present study. The critical load (LcL) during the loading process characterises the fracture resistance of the coating, whereas that during unloading (LcU), characterises the adhesion strength between the coating and the substrate. For all coatings, the nanoscratch profiles indicate three distinct regimes: elastic deformation, elastic?plastic deformation and delamination with material removal. Multilayer coatings show significantly higher critical loads than monolayer coatings. SEM characterisation indicates the cracking mechanisms are different for monolayer and multilayer coatings explaining why the multilayer coatings withstand higher critical loads.