Diamond Like Carbon (DLC) Coatings by Sulzer Sorevi : Cavidur. Marc HERVE 2010

Transcription

1 Diamond Like Carbon (DLC) Coatings by Sulzer Sorevi : Cavidur Marc HERVE 2010

2 Historic of Sorevi Start of industrial production Opening of the second plant of Sorevi in Bons en Chablais Acquisition of Bekaert s DLC coating activities by Sulzer Creation of Sorevi Move to Ester Technopole Entrance of Sorevi Into the Bekaert Group slide 2

3 DLC around the world BELGIUM Zulte Production & Sales Germany Herford Production & Sales USA 2 plants : Amherst & Raleigh Production & Sales FRANCE SOREVI 2 plants : Limoges & Bons en Chablais Production & Sales slide 3

4 Location in France 2 plants : - Limoges - Bons en Chablais slide 4

5 All Sulzer Metco plants around the world slide 5

6 What is DLC? diamond tetrahedral sp 3 bonds three-dimensional network graphite trigonal sp 2 bonds two-dimensional network Very hard High E (average)=1143 GPa Similar strong bonds and dense atomic arrangement distance (0.154 nm) amorphous sp 2 +sp 3 Very weak Within graphene plane Strong bonds, (0.141 nm) and E=1060 GPa Normal graphene plane Weak bonds, (0.335 nm), and E= 36 GPa slide 6

7 What is DLC? Cavidur W Cavidur N J. Robertson Materials Science and Engineering R37 (2002) slide 7

8 Process Turbomolecular Pump RF supply Substrate Mixed process : PVD + PACVD P.V.D. : Physical Vapour Deposition P.A.C.V.D. : Plasma Assisted Chemical Vapour Deposition 1 meter Metal evaporation DLC layer Adhesion layers Multi layers coating Turbomolecular Pump Gaz inlet Substrat slide 8

9 Cavidur coatings Low temperature coating High temperature coating Cavidur B Cavidur BA Cavidur N Cavidur NF Cavidur W Micro Hardness (Gpa) Friction coefficient* 0,08 0,08 0,1 0,09 0,1 Thickness (µm) 2,5-3 2, Adhesion** Lc (N) Coating temperature*** ( C) Max temperature of use ( C) * Against steel in dry conditions ** under constant load *** the max temperature depends of the design of the components The hardness for the Cavidur NF depends of the final adaptation layer slide 9

10 Others coatings (PVD) CrN TiN TiCN AlTiN Micro Hardness (Gpa) Friction coefficient* 0,5 0,65 0,4 0,55 Thickness (µm) 3 to 5 3 to 4 3 to 4 3 to 4 Adhesion** Lc (N) Coating temperature*** ( C) Max temperature of use ( C) * Against steel in dry conditions ** under constant load slide 10

11 Wear resistance Front suspension tube coated with DLC 1st property : the very high hardness of the coating protects the coated part 2 nd property : due to the smooth surface of the coating the counter part is not weared slide 11

12 Roughness after coating 1 µm PACVD ~5000 X DLC PVD Ion/Sputter Beam 1000 X TiN PVD Arc Evaporation 1000 X TiN slide 12

13 PET preforms Applications for DLC Optical discs Injection moulding Syringes Racing engine components Mass production engine parts slide 13

14 More than just a coating... Sulzer-Sorevi is a surface engineering company Counterpart Coating Surface Substrate Working environment => Customized solutions slide 14

15 Racing applications Fast moving / high loaded components that perform better with Cavidur vidur. Camshafts Finger followers Finger shafts Bucket tappets Flat lifters Roller lifters Rocker arms Rocker arm shafts Lash caps Valves Piston rings Pistons Wrist pins Connecting-rods Oil pump shafts.. slide 15

16 Racing applications Cavidur N enables to increase component life time at a high level of stable performance and to cut friction losses. For different kind of power train technology (fingers, tappets, lifters) Cavidur N or S are optimised solutions: - higher life time - power increase - reliability Thanks to the smooth friction behaviour, the coating can be applied successfully both on the camshaft and its counter part: Up to 8 to 10 horse power gain slide 16

17 Comparison between different camshaft treatments (Cavidur N fingers) Gain of power necessary to rotate the cylinder head compared to uncoated fingers and standard camshaft Cavidur N coating on Engine RPM Fingers 35,80% 35,20% 31,70% 26,40% Fingers + camshaft 45,80% 46,30% 44,90% 34,50% slide 17

18 Racing applications Depending of the requirements of the customer, we can apply the coating of the different areas of the valve heat to reduce cold welding and pitting degradation stem to reduce friction and wear also on the guide Sorevi developed also a very smooth CrN coating for the valve head in order to reduce cold welding and to protect the quality of the surface (reduce leaks). This coating could be applied in case of hammering problems on the head. Due to its high toughness, Cavidur N is well adapted on gudgeon pins : To protect against wear due to friction and micro vibrations To allow new design for lighter parts To remove the bushing into the conrods slide 18

19 Racing applications Advantages of Cavidur B coating : Good adhesion High hardness but smooth and non aggressive surface Very low friction Benefits : No wear High and stable level of compression Reduction of the blow-by Faster rise in the RPM Extension of the lifetime Cavidur B coated pistons already validated in : Formula 1 WRC Go Kart Motorbike Mini model car slide 19

20 Performance Diagram slide 20

21 Process flow Reception Incoming inspection Cleaning Inspection Cleaning Degazing Polishing Tumbling Cleaning Control of the sample Shipment Packaging Coating Fixturing Visual control 100% slide 21

22 Control Scratch test ** under constant load Nature of the coating Critical load, Lc N TiN 40 CAVIDUR 33 * Indentation Test Mercedes 150Kgs load on High Speed Steel coupon * 55 N with progressive loads Calotest Thickness mesurement slide 22

23 Sulzer - Sorevi 5 Allée Skylab Parc d Ester BP 6810 F Limoges France Marc HERVE Tel : marc.herve@sulzer.com Fax : Mobile : slide 23