Stamping Tooling Optimization Coating Fatigue Test Darryl Young-Ford Motor Company
Team Members and Contributors Ion Bond Century-Sun Metal Treating Richter Precision Industries Oerlikon Balzers Tecnie Corporation Dr Xueyuan Nie-University of Windsor Tareena Mulholland-General Motors Bohler-Uddeholm Chrysler LLC Severstal North America, Inc. United States Steel Corporation Nucor Corporation ArcelorMittal Dofasco
Why a Coating Fatigue Test? Laboratory Tests Correlation Problems Semi-Industrial Tests Expensive
Why a Coating Fatigue Test?
Why a Coating Fatigue Test? Stampers need a test for thin film ceramic coatings which is Accurate Fast Inexpensive
Questions will be taken after Dr. Nie s portion of the presentation
Coating Impact-Sliding Xueyuan Nie University of Windsor
Coating Impact-Sliding Coatings: TiN TiAlN CrN TiC Substrate: D2 M2 Hardened steel Nitrided steel Examples of Hard Coating/Substrate System Micro/nanostructured Coatings (cross-sectional TEM images) Single layered Nano-multilayered Nano-crystalline
State of the Art Testing Methods Coating Impact-Sliding Wear test of PVD/CVD coatings Two basic wear & friction test configurations: Linear Reciprocating Ball-on-Flat (ASTM G133) Pin-on-Disk (ASTM G99) - wear rate and COF Adhesion & scratch resistance test: - L c1 and L c2 Rockwell indent-adhesion test: Vertical indenting - one indentation - deforming substrate - cracking the coating
Coating Impact-Sliding Ball-on-plate Impact (Phase I) Typical failure zones encountered after the impact fatigue test. Cohesive failures Adhesive failures Fatigue cracks Material transfer
Coating Impact-Sliding Inclined Impact-sliding Fatigue Test (phase II) Impact Head sliding Tail Test Conditions: Loads: 80N impact 200N press Impact ball: SAE 52100 steel Lubricant: No Cycles: 1500
AlTiN Coating Impact-Sliding Test conditions: 1500 cycles, Steel Ball. SEM observations on All coatings/d2 CrN TiC
1500 cycles, Steel Ball TiAlN coating/d2 fatigue cracks chipping Coating Impact-Sliding fatigue cracks material transfer material transfer Failure Behaviors: Fatigue cracks Pealing Chipping Material transfer chipping
1500 cycles, Steel Ball CrN coating/d2 fatigue cracks Coating Impact-Sliding peeling fatigue cracks Failure Behaviors: Fatigue cracks Pealing Chipping Material transfer chipping
1500 cycles, Steel Ball TiC coating/d2 Coating Impact-Sliding material transfer Failure Behaviors: Chipping Material transfer chipping material transfer
10000 cycles, Steel Ball TiC coating/d2 Coating Impact-Sliding chipping fatigue cracks Failure Behaviors: Fatigue cracks Chipping Material transfer material transfer
Coating Impact-Sliding 1500 cycles, Steel Ball All coatings/d2 at heads (upper row) and tails (lower row) B-AlTiN B-CrN B-TiC B-AlTiN B-CrN
Coating Impact-Sliding 1500 cycles, Steel Ball CrN/D2 at the head part Peeling Fatigue cracking Cross-sectional SEM images of the impact crater
Coating Impact-Sliding 1500 cycles, Steel Ball CrN/D2 at the tail part Chipping the sliding direction Fatigue cracking & Material transfer Cross-sectional SEM images of the sliding track
Coating Impact-Sliding 1500 cycles, Steel Ball All coatings/d2 failure behaviors + ranks Coatings Head Middle Tail Subtotal (impact) Subtotal (sliding) Total Rank (impact) Rank (sliding) Rank TiAlN xxxxx/xx/o xxxx/xx/xx xxxx/o/o 5/2 (7) CrN xxx/xx/o x/o/o xx/o/o 3/2 (5) TiC x/o/o x/o/o x/o/o 1/0 (1) 8/2 (10) 3/0 (3) 2/0 (2) 17 3 3 3 8 2 2 2 3 1 1 1 *Notation of x/x/x: (pealing + chipping) / fatigue crack/ material transfer The more number of x, the severer failures The ranking matches the results from industrial trials and experience
Summary Coating Impact-Sliding 1. Impact-Sliding Fatigue Wear test has been developed and successfully used to test PVD and CVD coatings 2. Peeling, chipping, fatigue cracking, and ball material transfer appeared in the impact-sliding trails, although severity of those coating failure behavior may be different for different coatings. 3. Based on the inclined impact-sliding fatigue test results obtained at the given testing conditions, the TiC and CrN coatings on D2 substrate were considered as the excellent coating/substrate system for stamping applications where extremely high impact-sliding loads are involved. 4. It seems that the TiAlN coatings had less fatigue resistance and did not perform well at the impact-sliding loading condition. 5. The testing method can be used to evaluate the commercially-available coatings (and coating suppliers). It can also be used as a testing tool in developing new coatings and processes, and for coating quality control.
Coating Impact-Sliding Acknowledgement Pat J. Villano Auto/Steel Partnership Tareena Mulholland/Jody Hall General Motors Corporation Darryl Young Ford Motor Company Mike Klein/DJ Zhou Chrysler LLC Prof. Allan Matthews - University of Sheffield Thank You