Search Results (21)

Background/Objectives: Polymethyl methacrylate (PMMA) is widely used in medical and dental applications because of its favorable mechanical properties and ease of processing. However, its clinical performance is limited by low surface hardness, hydrophobicity, and susceptibility to microbial colonization and biofilm formation. This study aimed to investigate the effects of amorphous titanium dioxide (TiO₂) nanolayers deposited by atomic layer deposition (ALD) on the surface morphology and antibacterial properties of PMMA-based materials. Methods: Amorphous TiO₂ coatings were deposited on bone cement PMMA and dental PMMA substrates using ALD with TiCl₄ and H₂O precursors at 80 °C. The low deposition temperature enabled the conformal of thermally sensitive polymer substrates. Surface characterization was performed using atomic force microscopy (AFM) and scanning electron microscopy (SEM) to evaluate coating morphology and nanoscale topography. Antibacterial activity was assessed against S. aureus and P. aeruginosa through planktonic growth and biofilm formation assays, with additional evaluation of ultraviolet (UV) activation and surface polishing. Results: AFM analysis revealed that amorphous TiO₂ coating on standardly laboratory practice-polished PMMA increased the arithmetical mean roughness (Ra) from 1.82 nm to 14.60 nm, and maximum height (Rmax) from 36.20 nm to 298.00 nm. Polishing before coating significantly increased surface roughness and height variation, resulting in complex micro- and nanotopography. Microbiological analyses demonstrated variable antibacterial effects depending on bacterial species and surface characteristics. Comparison of planktonic growth, biofilm formation and OD590 ratio showed that amorphous TiO2 coating on polished PMMA reduced biofilm formation and planktonic growth in P. aeruginosa with a decreased OD ratio, while S. aureus biofilm formation was reduced. S. aureus had a consistently higher OD590 than P. aeruginosa. UV treatment alone did not produce consistent antibacterial enhancement. Conclusions: The study findings suggest that the surface topography had a greater role than UV treatment in determining bacterial adhesion. Surface roughness was strongly associated with S. aureus adhesion., whereas P. aeruginosa showed minimal response to the tested surface modifications. These findings suggest that TiO₂ coating after standard polishing alone may not provide consistent antibacterial activity under the tested conditions and point to the importance of nanoscale surface design in developing antimicrobial polymer biomaterials. Full article

By alternately depositing hydrogen-free amorphous carbon (a-C) and hydrogenated amorphous carbon (a-C:H) nanolayers on HSLA-100 steel through arc-ion plating, multilayer diamond-like carbon (DLC) architectures were engineered, with the modulation period adjusted from 1 to 10 cycles. SEM and Raman spectroscopy served as the analytical tools for characterizing the microstructure. For assessing key functional behaviors, nanoindentation was used to test mechanical properties, dry-sliding tribometry and in-situ tribocorrosion tests targeted tribological and tribocorrosion performance, and polarization tests focused on corrosion resistance. Introducing C₂H₂ increased the sp³ fraction and hardness relative to pure a-C. The ten-period film (S5) yielded the highest H/E (0.0767) and H³/E² (0.171), reflecting the best hardness–toughness synergy. All coatings lowered the dry friction coefficient to 0.08–0.10 and cut wear by more than 1 order of magnitude versus the substrate; the ten-period film (S5) showed the minimum dry wear rate (1.39 × 10⁻⁷ mm³·N⁻¹·m⁻¹) and tribocorrosion wear rate (4.53 × 10⁻⁷ mm³·N⁻¹·m⁻¹) in 3.5 wt% NaCl. The superior performance is due to interlayer interfaces that dissipate stresses, arrest crack propagation, and block electrolyte ingress through defects. These findings indicate that the rational stacking of a-C/a-C:H significantly improves the tribological and tribocorrosion resistance of HSLA-100, providing a reliable protective approach for components used in marine services. Full article

We used high-power impulse magnetron sputtering (HiPIMS) to deposit tungsten carbide films for superior wear protection in abrasive environments. In order to sample different W-to-C ratios more efficiently, a combinatorial approach was chosen. A single sputter target with two equal segments was used, consisting of an upper tungsten and lower graphite segment. This allowed us to vertically sample various elemental compositions in just one deposition run without creating graphitic nano-layers by rotating the substrate holder. The substrate bias voltage, being one of the most effective process parameters in physical vapor deposition (PVD), was applied in both constant and pulsed modes (the latter synchronized to the target pulse). A direct comparison of the different modes has not been performed so far for HiPIMS W-C (separated W and C targets). The resulting coating properties were mainly analyzed by nano-hardness testing and X-ray diffraction. In general, the W₂C phase prevailed in tungsten-rich coatings with pulsed bias, leading to slightly higher tungsten contents. Hardness reached maximum values of up to 35 GPa in the center region between the two segments, where a mix of W₂C and WC_1-x phases occurs. With pulsed bias, voltage hardnesses are slightly higher, especially for tungsten-rich films. In those cases, compressive stress was also found to be higher when compared to constant bias. Erosive wear testing by blasting with alumina grit showed that the material removal rate followed basically the coating’s hardness but surprisingly reached minimum wear loss for W₂C single-phase films just before maximum hardness. In contrast to previous findings, low friction that requires higher carbon contents of at least 50 at. % is not favorable for this type of wear. Full article

Traditional binary coatings like TiN and CrN display limited thermal stability and wear resistance under extreme conditions. High-entropy alloy nitride (HEAN) coatings offer a promising solution due to their customizable composition and unique properties, including high hardness, corrosion resistance, and thermal stability. This study focused on (AlCrNbTaTi)N HEAN coatings to address a critical need for materials capable of enduring extreme mechanical and tribological demands by examining the impact of aluminum content on their structural and mechanical properties, providing insights for optimizing coatings in harsh conditions through a self-assembled nanolayer structure with enhanced resilience and performance. The coatings were deposited via a cathodic arc by employing an AlCrNbTaTi alloy target composed of aluminum (20, 50, 60, 70%) and equal molar ratios of Cr, Nb, Ta, and Ti. The coatings were characterized through grazing incidence X-ray diffraction, SEM, HR-TEM, a nano-indentation test, and a friction and wear test. The results indicated that with increasing Al content, the structure of (AlCrNbTaTi)N coatings shifted from FCC to an amorphous state, leading to a reduction in the hardness and elastic modulus, accompanied by an increase in the wear rate and friction coefficient. The (AlCrNbTaTi)N coating, with an equal atomic ratio of metallic elements, showed potential as a hard tool coating. It demonstrated outstanding mechanical and tribological properties, with a 34.5 GPa hardness, 369 GPa modulus, 0.35 friction coefficient, and 8.2 × 10⁻¹⁹ m²·N⁻¹ wear rate. The findings highlight the potential of (AlCrNbTaTi)N coatings to extend tool life and improve operational efficiency, helping advance materials engineering for industrial applications. Full article

In this study, we used the depth-sensing indentation technique to determine the cracking resistance of different PVD hard coatings deposited on tool steel substrates. By comparison, with the load–displacement curves, measured at the sites of carbide inclusion and a tempered martensite matrix in the D2 tool steel substrate surface, we observed different fracture mechanisms on TiAlN hard coating prepared by sputtering. Additional information about the deformation and fracture phenomena was obtained from the SEM images of FIB cross-sections of both types of indents. We found that the main deformation mechanism in the coating is the shear sliding along the columnar boundaries, which causes the formation of steps on the substrate surface under individual columns. Using nanoindentation test, we also analyzed the cracking resistance of a set of nl-(Cr,Al)N nanolayer coatings with different Cr/Al atomic ratios, which were sputter deposited in a single batch. From the indentation curves, we determined the loads (F_c) at which the first pop-in appears and compared them with the plasticity index H³/E². A good correlation of both parameters was found. We also compared the indentation curves of the TiAlN coating, which were prepared by cathodic arc evaporation using 1-fold, 2-fold and 3-fold rotation of the substrates. Additionally, on the same set of samples, the fracture toughness measurements were performed by micro-cantilever deflection test. The impact of growth defects on the cracking resistance of the hard coatings was also confirmed. Full article

Reports of the influence of surface roughness on the adhesion and tribological performance of contemporary nitride coatings with different layer designs are still scarce in the literature. Therefore, in this study, we evaluated the behavior of a single-layer TiAlN, a bilayer TiAlN/CN_x, and a nanolayer AlTiN/TiN coating. Coatings were deposited in an industrial magnetron sputtering unit on the substrates of EN 100Cr6 steel, prepared to four degrees of surface roughness (Sa = 10–550 nm). The coatings’ adhesion was determined by scratch tests performed perpendicular and parallel to the machining marks. Dry reciprocating sliding tests in air were employed to evaluate the coatings’ tribological behavior against an Al₂O₃ ball. Before and after the tests, coating properties were characterized by 3D profilometry, confocal microscopy, and energy dispersive spectroscopy. Deposition of all coatings significantly altered the surface topography and increased the roughness of the samples. No general rule could be established for the effect of surface roughness on tribological behavior and adhesion of different hard coatings. For very fine surface finishes the adhesion and tribological performance of TiAlN and TiAlN/CN_x coatings was independent of the surface roughness. For the roughest surfaces, a decrease in adhesion and an increase in the wear rate were observed. The AlTiN/TiN coating exhibited the largest sensitivity of adhesion to roughness and scratching direction. The coefficient of friction and wear rate increased when AlTiN/TiN roughness exceeded Sa ≈ 100 nm. Full article

This work uses the direct current magnetron sputtering (DCMS) of equi-atomic (AlTiZrHfTa) and Si targets in dynamic sweep mode to deposit nano-layered (AlTiZrHfTa)N_x/SiN_x refractory high-entropy coatings (RHECs). Transmission electron microscopy (TEM), field emission scanning electron microscopy (FESEM), thermogravimetric analysis (TGA), X-ray diffraction (XRD), and X-ray photoelectron spectroscopy (XPS) are used to investigate the effect of Si addition on the oxidation behavior of the nano-layered coatings. The Si-free nitride coating exhibits FCC structure and columnar morphology, while the Si-doped nitride coatings present a FCC (AlTiZrHfTa)N/amorphous-SiN_x nano-layered architecture. The hardness decreases from 24.3 ± 1.0 GPa to 17.5 ± 1.0 GPa because of the nano-layered architecture, whilst Young’s modulus reduces from 188.0 ± 1.0 GPa to roughly 162.4 ± 1.0 GPa. By increasing the thickness of the SiN_x nano-layer, k_p values decrease significantly from 3.36 × 10⁻⁸ g² cm⁻⁴ h⁻¹ to 6.06 × 10⁻⁹ g² cm⁻⁴ h⁻¹. The activation energy increases from 90.8 kJ·mol⁻¹ for (AlTiZrHfTa)N_x nitride coating to 126.52 kJ·mol⁻¹ for the (AlTiZrHfTa)N_x/SiN_x nano-layered coating. The formation of a FCC (AlTiZrHfTa)-N_x/a-SiN_x nano-layered architecture results in the improvement of the resistance to oxidation at high temperature. Full article

In the present study, (Cr,Al)N nanolayer coatings with different Al/Cr atomic ratios were deposited by magnetron sputtering on different substrate materials (H11 and D2 tool steel, alumina). To prepare the (Cr,Al)N coatings with different Al/Cr atomic ratios in the same batch, we used two targets composed of two triangle-like segments together with two standard Al and Cr targets. This approach enabled us to study the evolution of structural and mechanical properties in dependence on composition. The elemental composition of the coatings was determined by energy-dispersive X-ray analysis (EDS). The phase composition of the (Cr,Al)N coatings was determined utilizing X-ray diffraction (XRD), while scanning electron microscopy (SEM) was employed to assess their morphology and microstructure. The coating surface topography was analyzed by atomic force microscopy (AFM). In order to evaluate the effect of the Al/Cr atomic ratio on the oxidation behavior, the (Cr,Al)N coatings were oxidized in ambient atmospheres at temperatures between 700 and 850 °C and subsequently analyzed by means of cross-sectional SEM and transmission electron microscopy (TEM). The oxidation rate, determined by weight gain over time, was utilized to quantify the oxidation process. The oxidation tests showed that the Al-rich (Cr,Al)N nanolayer coatings exhibit a considerably better oxidation resistance than the Cr-rich ones. We found that the oxide scale formed on the Al-rich coating is composed of double layers: a Cr-oxide top layer and an inner (Cr,Al) mixed oxide layer. In contrast, the oxide scale of the Cr-rich coating mainly consists of the Cr₂O₃ layer. In particular, we focused on the oxidation process occurring at the locations of growth defects. We noticed that the first oxidation products on the coated substrate occurred at a temperature that was much lower than the temperature for the (Cr,Al)N coating oxidation initiation. These products (iron oxides) formed only at the sites of those growth defects that extended through the entire coating thickness. Full article

The studies are focused on the properties of the multilayer composite coating based on the (Ti,Y,Al)N system with high content of yttrium (about 40 at.%) of yttrium (Y). The hardness and elastic modulus were defined, and the resistance to fracture was studied during the scratch testing. Two cubic solid solutions (fcc phases), including c-(Ti,Y,Al)N and c-(Y,Ti,Al)N, are formed in the coating. The investigation of the wear resistance of the (Ti,Y,Al)N-coated tools during the turning of steel in comparison with the wear resistance of the tools with the based on the (Ti,Cr,Al)N system coating and the uncoated tools found a noticeable increase (by 250%–270%) in rake wear resistance. Active oxidation processes are observed in the (Ti,Y,Al)N coating during wear. It can be assumed that yttrium oxide is predominantly formed with a possible insignificant formation of titanium and aluminum oxides. At the same time, complete oxidation of c-(Y,Ti,Al)N nanolayers is not observed. Some hypotheses explaining the rather high performance of a coating with a high yttrium content are considered. Full article

The utilization of anodized aluminum (Al) components would contribute greatly to combat against dry friction if good tribological properties could be attained. Despite its hardness, the wear rate of anodic coatings presents a major problem in many applications, including automotive, aerospace and high-tech industries. Recently, nanolayers of Ti demonstrated high tribological effectiveness and unusually low dry friction on anodic coatings. However, few researchers focus on the tribological characterization of nanolayers of other elements. In this study, nanolayers of Ti, Zr, Hf, Cu, Cr, Nb and Sn were deposited on anodized 1050 and 6082 alloys by magnetron sputtering and Atomic Layer Deposition. Major attention was devoted to surface roughness and hardness measurements, because of their importance for static friction. The results showed that structural, chemical and other intrinsic properties of nanolayers of Group IVB elements in many cases led to significant friction reduction, when compared to those of Cu, Cr and Hf. Nanolayers of 15 nm to 75 nm thicknesses appeared most effective tribologically, while 180 nm or thicker layers progressively lost their ability to sustain low dynamic friction. Deposition of nanoscale structures could provide advantages for the anodized Al industry in protection against incidental friction and wear. Full article

The properties and oxidation wear patterns in the composite nanostructured coating of Zr-ZrN-(Zr,Mo,Al)N were studied during the turning of Inconel 718 alloy at the cutting speeds of v_c = 125 and 200 m/min. The hardness of the coating, its elastic modulus, and critical fracture load during the scratch testing were determined. The study focused on the tribological properties of the Zr-ZrN-(Zr,Mo,Al)N coating at temperatures of 400–900 °C paired with an insert made of Inconel 718, which exhibited a certain advantage over the reference coatings of Zr-ZrN and Ti-TiN-(Ti,Cr,Al)N of similar thickness. The coating of Zr-ZrN-(Zr,Mo,Al)N provided for the longest tool life at the cutting speed of v_c = 125 m/min (the tool life was four times longer in comparison with that of the uncoated tool and 15% longer in comparison with that of the Ti-TiN-(Ti,Cr,Al)N-coated tool) and at the cutting speed of v_c = 200 m/min (the tool life was 2.5 times longer in comparison with that of the uncoated tool and 75% longer in comparison with that of the Ti-TiN-(Ti,Cr,Al)N-coated tool). While at the cutting speed of v_c = 125 m/min, the surface coating layers exhibit only partial oxidation of the external layers (to a depth not exceeding 250 nm), with mostly preserved cubic nitride phases, and then the cutting speed of v_c = 200 m/min leads to almost complete oxidation (to the depth of at least 500 nm), however, with a partially preserved nanolayered structure of the coating. Full article

The microstructure and surface topography of PVD hard coatings are among the most important properties, as they significantly determine their mechanical, tribological and other properties. In this study, we systematically analyzed the microstructure and topography of a TiAlN/CrN nanolayer coating (NL-TiAlN/CrN), not only because such coatings possess better mechanical and tribological properties than TiAlN and CrN monolayer coatings, mainly because the contours of the individual layers, in the cross-sectional STEM or SEM images of such coatings, make it easier to follow topographic and microstructural changes that occurred during its growth. We investigated the effects of the substrate rotation modes on the microstructure and surface topography of the NL-TiAlN/CrN coating, as well as on the periodicity of the nanolayer structure. The influence of the substrate material and the ion etching methods were also studied, while special attention was given to the interlayer roughness and influence of non-metallic inclusions in the steel substrates on the growth of the coating. The topographical features of the NL-TiAlN/CrN coating surface are correlated with the observations from the cross-sectional TEM and FIB analysis. Selected non-metallic inclusions, covered by the NL-TiAlN/CrN coating, were prepared for SEM and STEM analyses by the focused ion beam. The same inclusions were analyzed prior to and after deposition. We found that substrate rotation modes substantially influence the microstructure, surface topography and periodicity of the NL-TiAlN/CrN layer. Non-metallic inclusions in the substrates cause the formation of shallow craters or protrusions, depending on their net removal rates during the substrate pretreatment (polishing and ion etching), as compared to the matrix. Full article

In this paper, we analyze the possibilities of the protection of tools for wood machining with PVD (Physical Vapor Deposition) hard coatings. The nanolayered TiN/AlTiN coating, nanocomposite TiAlSiN coatings, and single layer TiN coating were analyzed in order to use them for protection of tools for wood machining. Both nanostructured coatings were deposited in an industrial magnetron sputtering system on the cutting blades made of sintered carbide WC-Co, while TiN single layer coating was deposited by evaporation using thermionic arc. In the case of TiN/AlTiN nanolayer coatings the thickness of the individual TiN and AlTiN layer was in the 5–10 nm range, depending on the substrate vertical position. The microstructure and chemical composition of coatings were studied by scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) method. Additionally, in the case of the TiN/AlTiN coating, which was characterized by the best durability characteristics, the transmission electron microscope (TEM) and X-ray photoelectron spectroscopy (XPS) methods were applied. The coatings adhesion to the substrate was analyzed by scratch test method combined with optical microscopy. Nano-hardness and durability tests were performed with uncoated and coated blades using chipboard. The best results durability characteristics were observed for TiN/AlTiN nanolayered coating. Performance tests of knives protected with TiN and TiAlSiN hard coatings did not show significantly better results compared to uncoated ones. Full article

This paper discusses the results of studies focused on the wear resistance, patterns of wear and plastic properties of Cr,Mo-(Cr,Mo,)N-(Cr,Mo,Al)N coating, containing 20 at.% Mo. The coating had a nanolayer structure with a modulation period λ = 50 nm. The studies revealed the hardness, fracture resistance in scratch testing, as well as elemental and phase composition of the coating. The studies of the tool life of carbide cutting tools with the Cr,Mo-(Cr,Mo,)N-(Cr,Mo,Al)N coating proved their longer tool life compared to that of uncoated tools and tools with the reference Cr-(Cr,Al)N coating of equal thickness and equal content of aluminum (Al). The studies included the comparison of the tools coated with Cr,Mo-(Cr,Mo,)N-(Cr,Mo,Al)N and Cr-(Cr,Al)N. The experiments focused on the specific features of the coating nanostructure and were conducted using a transmission electron microscope (TEM), revealing the different mechanisms of fracture. The penetration of particles of the material being machined between nanolayers of the coating results in interlayer delamination. When exposed to a moving flow of the material being machined, plastic deformation (bending) of the coating nanolayers occurs. The diffusion of iron into the coating (up to 200 nm) and diffusion of Cr and Mo into the cut material to a depth of up to 250 nm are observed. The presented information can help in the design of metal cutting tools and the choice of coatings for them. Full article

The article describes the results of the investigation focused on the properties of the Zr,Hf-(Zr,Hf)N-(Zr,Hf,Me,Al)N coatings, where Me means chromium (Cr), titanium (Ti), or molybdenum (Mo). These coatings have three-layer architecture, including adhesion, transition, and wear-resistant layers, while the latter, in turn, has a nanolayer structure. Despite the fact that the coatings under study have close values of hardness and critical fracture load L_C2, there are noticeable differences in wear resistance during the turning of steel. The tools with the coatings under study demonstrated better wear resistance compared to an uncoated tool and the tool with the commercial ZrN coating. The best wear resistance was detected for a tool with the Zr,Hf-(Zr,Hf)N-(Zr,Hf,Ti,Al)N coating. The study of the pattern of cracking in the structure of the coatings has found that, during the cutting process, active cracking occurs in the coating with Cr, which leads to the fracture of the coating, while the process of cracking is noticeably less active in the coatings with Ti or Mo. Full article