Ultracoatings: Enabling Energy and Power Solutions in High Contact Stress Environments through next-generation Nanocoatings Final Technical Report.

摘要

The primary objective of this project was the development of thin film nanocoatings derived to address improved durability and performance in high contact stress (1 GPa and above) environments. A review of commercially available, industrial-grade, low friction coatings showed that, prior to the development of nanocomposite materials like AlMgB(sub 14)-TiB(sub 2), interfacial contact pressures nearing 1GPa (approx. 150ksi) inherently limit surface engineering solutions like WC, TiN, TiAlN, and so forth. Previous work on AlMgB(sub 14) composites and their vapor-deposited coating derivatives led the way to additional research on a variety of novel compositions, including, but not limited to (Ti, Zr)B(sub 2), a single phase composite shown to exhibit extreme wear resistance. Other materials explored by Ames Laboratory included AlMgB(sub 14)-IrB, AlMgB(sub 14)-HfB(sub 2), AlB(sub 12)-CrB(sub 2), and Al(sub 4)SiC(sub 4)-TiC. In each composite, the constituent phases were selected because of their similar surface energies, intrinsic wetting characteristics, and potential for high strength. The key focus of the project is to transfer the benefits of these materials to industrial scale applications and enable operation and sustained performance in extreme environments. The Ultracoatings technology, as it was titled, would be capable of sustaining higher load-carrying capacity than current state-of-the-art coating compositions, while maintaining low friction. Examples of applications benefiting from such technological advancements would include transmission gears, heavy-duty clutches, aerospace pump components and conveyance systems, hydraulics, automotive supercharger components, engine timing chains, and components used in Pratt & Whitney Rocketdynes coal gasifer. In each of the respective industrial application spaces, energy savings would be realized through the reduction of wear and, subsequently, eliminating re-work or replacement of components during their expected field service.