Tailoring the Hybrid Magnetron Sputtering Process (HiPIMS and dcMS) to Manufacture Ceramic Multilayers: Powering Conditions, Target Materials, and Base Layers
Bruno César Noronha Marques de Castilho,
Felipe de Sousa Mazuco,
Alisson Mendes Rodrigues,
Pedro Renato Tavares Avila,
Raira Chefer Apolinario,
Philipp Daum,
Fabiana Pereira da Costa,
Romualdo Rodrigues Menezes,
Gelmires de Araújo Neves,
Christian Greiner,
Haroldo Cavalcanti Pinto
Affiliations
Bruno César Noronha Marques de Castilho
São Carlos School of Engineering—EESC, University of São Paulo—USP, São Carlos 13563-120, Brazil
Felipe de Sousa Mazuco
MAHLE Metal Leve S.A., Rodovia Anhanguera, Sentido Interior—Capital, km 49,7, Jundiai 13210-877, Brazil
Alisson Mendes Rodrigues
Laboratory of Materials Technology (LTM), Department of Materials Engineering, Federal University of Campina Grande (UFCG), Campina Grande 58429-900, Brazil
Pedro Renato Tavares Avila
São Carlos School of Engineering—EESC, University of São Paulo—USP, São Carlos 13563-120, Brazil
Raira Chefer Apolinario
São Carlos School of Engineering—EESC, University of São Paulo—USP, São Carlos 13563-120, Brazil
Philipp Daum
IAM-ZM MicroTribology Center µTC, Strasse am Forum 5, 76131 Karlsruhe, Germany
Fabiana Pereira da Costa
Laboratory of Materials Technology (LTM), Department of Materials Engineering, Federal University of Campina Grande (UFCG), Campina Grande 58429-900, Brazil
Romualdo Rodrigues Menezes
Laboratory of Materials Technology (LTM), Department of Materials Engineering, Federal University of Campina Grande (UFCG), Campina Grande 58429-900, Brazil
Gelmires de Araújo Neves
Laboratory of Materials Technology (LTM), Department of Materials Engineering, Federal University of Campina Grande (UFCG), Campina Grande 58429-900, Brazil
Christian Greiner
IAM-ZM MicroTribology Center µTC, Strasse am Forum 5, 76131 Karlsruhe, Germany
Haroldo Cavalcanti Pinto
São Carlos School of Engineering—EESC, University of São Paulo—USP, São Carlos 13563-120, Brazil
The mechanical and wear behavior of CrN/CrAlN multilayers were improved by tailoring the experimental conditions of a hybrid magnetron sputtering process based on a high-power impulse (HiPIMS) and two direct current magnetron sputtering (dcMS) power supplies. To this end, the influence of the base layer and of the combination of Cr and CrAl targets, which were switched to the dcMS and HiPIMS power supplies in different configurations, were investigated with respect to the growth of ceramic CrN/CrAlN multilayers onto commercial gas-nitrided diesel piston rings. The microstructure, grain morphology, and mechanical properties were evaluated by field emission scanning electron microscopy (FE-SEM), atomic force microscopy (AFM), X-ray diffraction (XRD), and instrumented nanoindentation. Bench wear tests simulating the operation of a combustion engine were conducted against a gray cast iron cylinder liner under reciprocating conditions using 0W20 oil as a lubricating agent enriched with Al2O3 particles. The results revealed a significant increase in hardness, resistance to plastic strain, and wear resistance when two CrAl targets were switched to a HiPIMS and a dcMS power supply, and a Cr target was powered by another dcMS power supply. The compressive coating stresses were slightly reduced due to the soft Cr base layer that enabled stress relief within the multilayer. The proposed concept of hybrid magnetron sputtering outperformed the commercial PVD coatings of CrN for diesel piston rings manufactured by cathodic arc evaporation.
