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Abstract
As previously reported (Fox et al., Proc. PSE Conf., Garmisch Partenkirchen, 1418 September, 1998), the properties of
MoS coatings can be improved by the co-deposition of a small amount of titanium. These MoS /Ti coatings, known as
2
2
MoST@ produced by closed field unbalanced magnetron sputtering, are harder, much more wear resistant and less sensitive to
atmospheric water vapour. These coatings have given excellent industrial results for a wide range of cutting and forming
applications. Two forms of these MoS /titanium composite coatings have been developed: MoS /titanium composite ( low titanium,
2
2
10 at%) and MoS /titanium composite (high titanium, 20 at%).
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The MoS /titanium composite ( low titanium) exhibits a coating hardness of 500 HV, a coefficient of friction of 0.02 during
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100 N applied load reciprocating wear testing, and a low wear rate, while the MoS /titanium composite (high titanium) exhibits
2
a coating hardness similar to that of TiN, a coefficient of friction of 0.04 during 100 N applied load reciprocating wear testing,
and an extremely low wear rate.
The choice of coatings is dependent upon the application. Recent industrial performance data related to the characteristics of
these MoS /titanium composite (high titanium) self-lubricant coatings, which are utilised now in large-scale production, are
2
presented. 2000 Elsevier Science S.A. All rights reserved.
Keywords: Cutting; Forming; Low friction; MoS ; Solid lubricant; Unbalanced magnetron
2
1. Introduction
There is currently an increase in demand for dry
machining [2]. Over the last century, the production
engineer has required higher production rates and has
often had to machine new materials of higher strength.
Metallurgists have responded with new cutting, forming
tools and components with improved performance.
The development of tool material from carbon tool
steel, high-speed steel, carbides, ceramics and nitrides,
together with techniques of applying wear-resistant coatings, has allowed cutting, forming tools or components
k
Paper presented at the 26th International Conference on
Metallurgical Coatings and Thin Films, April 1215, 1999, San Diego,
CA, USA
* Corresponding author. Tel.: +44-1299-251-399;
fax: +44-1299-250-171.
E-mail address: renevier.nathalie@teercoatings.co.uk
(N.M Renevier)
0257-8972/00/$ - see front matter 2000 Elsevier Science S.A. All rights reserved.
PII: S0 2 5 7- 8 9 7 2 ( 9 9 ) 0 0 42 4 - 7
N.M Renevier et al. / Surface and Coatings Technology 123 (2000) 8491
place over the last decade, particularly with developments in the physical deposition (PVD) process.
Whilst the major successes in coatings for industrial
applications are titanium nitride ( TiN ), titanium carbide
( TiC ), titanium carbonitride ( TiCN ), titanium aluminium nitride ( TiAlN ), these coatings are not totally
successful for all applications for several reasons [3],
where a total systems approach needs to be employed
in surface engineering.
For centuries, liquid lubricants were used to limit the
contact pressure and facilitate sliding. Contact is inevitable, and lubricants are used to reduce the temperature
produced by friction. But, in many cases the presence
of liquid is not recommended or forbidden for contamination reasons. Effects are particularly important in
vacuum or at high temperature, for food, medical apparatus, or the nuclear industry.
Lubrication costs are often high and therefore
uneconomic. An additional problem with liquid lubricant is the efficient distribution of the lubricant on the
required surface.
Dry machining can appear a risky solution to this
problem, as users are reluctant to damage their tools
under dry conditions. However, the risks of damage to
the tools by using solid lubricants in place of liquid
lubricants are minimal. This is because, in effect the solid
lubricant coating creates a third component within the
system, which gives some advantages of a liquid lubricant.
In some cases the use of a solid lubricant deposited
where a traditional lubricant cannot perform allows an
increase in the performance of tools and components.
In future, solid lubrication may be imposed by legislation (for example for environmental protection) and
also for cost savings (as the treatment of used lubricants
is very expensive).
MoS coatings have been proposed for the improve2
ment in the performance of cutting tools, and such
coatings have been shown to give significant improvements [4].
At Teer Coatings core strategies of innovation and
continuous improvement are being used to address these
preoccupations. Hence, two new complementary types
of coating were developed, known as MoST@ [1,5] and
Graphit-iC@ [6,7]. As previously reported [1], MoST@
coatings are MoS /titanium composite coatings formed
2
by co-deposition of small amounts of titanium in a
MoS based matrix. MoS /titanium composite coatings,
2
2
produced by closed field unbalanced magnetron sputtering, are harder, much more wear resistant and less
sensitive to atmospheric water vapour than MoS . These
2
coatings have given excellent industrial results in a wide
range of cutting and forming applications. The properties are dependent on the titanium content. Two successful forms of the range of MoST@ coatings have been
developed: MoS /titanium composite ( low titanium)
2
and MoS /titanium composite (high titanium).
2
The MoS /titanium composite ( low titanium) exhibits
2
85
2. Background
MoS coatings are often deposited using RF sputter2
ing [811], producing MoS coatings with a duplex
2
structure consisting of a dense, coherent film of about
100 nm followed by a loose, columnar, powdery film
which is easily removed [12]. Most of these coatings
were suitable only in vacuum and at 0% humidity.
DC magnetron sputtering is used for the deposition
of MoS coatings in this study. The quality of the
2
coatings is improved by applying a negative potential
to the substrates so that the growing film is bombarded
by energetic ions, densifying the structure and improving
adhesion. Unbalancing the magnetic field of the magnetron [13] increases the intensity of the bombardment and
further improvements are achieved by using a multimagnetron system in which unbalanced magnetrons are
used in the closed field arrangement [13,14]. Unlike RF
techniques, such methods give dense, coherent coatings.
MoS properties degrade when in humid air, causing
2
an increase in friction coefficient and a decrease in
lifetime. To reduce the water vapour content in the
vacuum chamber a titanium target was sputtered during
ion cleaning of the substrates prior to deposition to
produce a gettering effect. The titanium was then used
to deposit an interlayer which led to an improvement in
coating adhesion (critical load above 120 N ). A natural
progression of this work led to incorporation of titanium
into the coating itself, resulting in improved friction (m
of 0.020.1 at 40% humidity) and wear properties.
These MoS /metal composite coatings were hard (1000
2
2000 HV ) and also less sensitive to water vapour than
pure MoS coatings.
2
Properties of the original MoS /metal composite
2
coating [MoS /titanium composite ( low titanium,
2
10 at% and high titanium, 20 at%)] have been previously
reported [15]. These coatings are not only suitable in
vacuum and at 0% humidity, but also up to 50%
humidity, allowing terrestrial uses. These MoS compos2
ite coatings have been tested in a variety of industrial
applications, showing excellent results for a wide range
of cutting, forming and component applications. This
paper reports industrial results from MoS /titanium
2
composite (high titanium, 20 at%) coating.
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N.M Renevier et al. / Surface and Coatings Technology 123 (2000) 8491
A resume of laboratory test results using microhardness and nanohardness testing, scratch adhesion testing,
pin on disc and reciprocating friction and wear tests is
presented in an attempt to be au fait with the tribological
properties. The structures of the coatings have been
extensively studied by a variety of techniques, including
optical microscopy, transmission electron microscopy
( TEM ), X-ray diffraction ( XRD) and scanning electron
microscopy (SEM ) and a summary of this work is
reported to understand the structure of such complex
coatings.
2.1. Deposition system
MoS /titanium composite coatings were deposited by
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DC magnetron sputtering using standard Teer
CFUBMSIP equipment [16 ] (Fig. 1). The magnetrons
within the coating chamber were arranged so that three
MoS targets and one titanium target were used and the
2
substrates rotated between the targets. The amount of
metal content was controlled by the power applied to
the targets.
To reduce the water vapour content in the vacuum
chamber a titanium target was sputtered, under argon
during ion cleaning of the substrates prior to deposition
to produce a gettering effect. The titanium target was
then used to deposit a 100 nm interlayer, which led to
an improvement in coating adhesion. Titanium was used
as an interlayer to improve the load bearing capacity
and the adherence properties.
This step is followed by a second interlayer by
sputtering from two MoS targets and the titanium
2
target simultaneously, the power to the titanium target
is gradually reduced. This layer consists of a 200 nm
mixed MoS /titanium in a multilayer structure.
2
The main bulk of the coatings of about 800 nm,
known as MoST@ coatings in the case of titanium
(a)
(b)
Fig. 1. (a) Schematic representation and (b) general view of a four magnetron coating chamber configured with closed field unbalanced magnetron
sputter ion plating (CFUBMSIP).
N.M Renevier et al. / Surface and Coatings Technology 123 (2000) 8491
87
These results were confirmed by extensive nanoindentation tests on the MoS /titanium composite (high
2
titanium) coating, confirming the Fischerscope
measurements.
2.3. Coating analysis
(a)
(b)
Fig. 2. Results of (a) MoS and (b) MoST coatings tested at 40%
2
humidity, under water and under oil. Number of cycles, coefficient of
friction, track width and wear rate are reported.
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N.M Renevier et al. / Surface and Coatings Technology 123 (2000) 8491
Fig. 5. Number of cutting holes produced (a) at 10 m/min in dry conditions, (b) at 20 m/min in dry conditions, (c) at 20 m/min lubricated
with an oil mixture. TiCN (1): low carbon content, TiAlN: high aluminium content, TiCN+MoST: TiCN with low carbon content.
N.M Renevier et al. / Surface and Coatings Technology 123 (2000) 8491
89
(a)
(b)
Fig. 6. Average resultant force (a) and surface finishing (b) while end
milling AISI 304 stainless steel using TiCN (using coolant) and
TiCN+MoST (dry and using coolant) coated inserts.
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N.M Renevier et al. / Surface and Coatings Technology 123 (2000) 8491
Fig. 10. Number of parts produced with MoST@ in lubricated conditions (water-soluble 20%).
Fig. 8. Number of parts produced with MoST@ in lubricated conditions (water-soluble 20%).
N.M Renevier et al. / Surface and Coatings Technology 123 (2000) 8491
91
hard thin film characteristics, as is evident from numerous publications reported elsewhere. A hard coating
under MoS /titanium composite seems to be the best
2
choice. The exact reasons are unknown, but the improvement is probably associated with the additional support
offered by the hard coating.
MoS /titanium composite is a good candidate for a
2
clean world process, and gives greater productivity in
machining, forming and for components. MoS /
2
titanium composite coating has great potential for success in dry machining, but the reduced wear resistance
under oil is a limitation, which needs further study.
Fig. 11. Number of parts produced with MoST@ in lubricated
conditions.
Acknowledgements
The authors would like to express their gratitude to
the Department of Trade and Industry of the United
Kingdom for their support through a SPUR award in
the financing of this project. The authors would also
like to thank the following people and companies. Dr.
R. Gilmore of ISPRA (Italy), Dr. V Rigato of Thin
Films (Italy), Nachi Fujikoshi Steel Corporation
(Japan), Adachi New Industrial Company Ltd. (Japan),
Third Millenium Ltd. ( UK ) and Dayton Progress
Corporation ( USA).
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