J. WANG et al.: EFFECT OF AN ELECTROMAGNETIC FIELD ON THE MICROSTRUCTURE AND PROPERTIES ... 833–838 EFFECT OF AN ELECTROMAGNETIC FIELD ON THE MICROSTRUCTURE AND PROPERTIES OF Cr(Ti)AlN HARD COATINGS PREPARED WITH ARC-ION PLATING VPLIV ELEKTROMAGNETNIH POLJ NA MIKROSTRUKTURO IN LASTNOSTI TRDIH PREVLEK NA OSNOVI Cr(Ti)AlN, PRIPRAVLJENIH S PLATIRANJEM V IONSKEM OBLOKU Jin Wang 1* , Dayan Ma 2 ,QiLiu 2 , Yetang Jin 1 ,XuW ang 1 1 School of Mechanical Engineering, Qingdao University of Technology, Qingdao 266520, China 2 State Key Laboratory for Mechanical Behavior of Materials, Xi’an Jiaotong University, Xi’an 710049, China Prejem rokopisa – received: 2019-04-03; sprejem za objavo – accepted for publication: 2019-06-27 doi:10.17222/mit.2019.072 A series of CrAlN and TiAlN hard coatings were prepared using industrial arc-ion plating with or without the embedded axial electromagnetic filtration technology. The microstructure evolution and mechanical properties of the hard coatings were compared after annealing. The results show that the grain size of the hard coatings prepared with an arc induced by an electromagnetic field decreases significantly, and the quantity of pits and hard particles reduces, leading to an improvement of compactness. Furthermore, the wear resistance and the thermal stability of the coatings prepared with electromagnetic fields improve significantly. Keywords: arc-ion plating, axial electromagnetic field, microstructure evolution, mechanical property, wear resistance Avtorji so pripravili vrsto CrAlN in TiAlN trdih prevlek na industrijski napravi za ionsko oblo~no platiranje, brez ali v prisotnosti osne elektromagnetne filtracijske tehnologije. Nato so med seboj primerjali razvoj mikrostruktur in mehanske lastnosti izdelanih trdih prevlek po njihovem naknadnem `arjenju. Rezultati raziskave so pokazali, da se je velikost kristalnih zrn trdih prevlek, izdelanih v prisotnosti elektromagnetnih polj, pomembno zmanj{ala. Zmanj{ala se je tudi koli~ina jamic in trdih delcev, kar je izbolj{alo kompaktnost trdih prevlek. Poleg tega se je znatno izbolj{ala tudi odpornost proti obrabi in termi~na stabilnost prevlek, izdelanih v elektromagnetnih poljih. Klju~ne besede: platiranje v obloku ionov, osno elektromagnetno polje, razvoj mikrostrukture, mehanske lastnosti, odpornost proti obrabi 1 INTRODUCTION Arc-ion plating is a deposition process with a high ion energy and high speed, suitable for many kinds of materials, and a simple cleaning process before prepa- ration. 1–4 The deposition technology is widely used in the industrial surface engineering of hot-working dies. However, it is known that the inevitable appearance of hard particulates in the process of preparation have negative influences on the application effectiveness of the coating dies. Recently, the arched electromagnetic field was developed in order to reduce the size and number of hard particles in coatings. TiN coatings have been deposited by adding an arched electromagnetic field on the cathode arc source, and the mechanical properties of the coatings have been greatly improved. 5,6 However, the ion-deposi- tion rate of the arched electromagnetic field is too slow to be applied in industry. In order to handle the problem of the low deposition rate, the axial electromagnetic field was developed. The extra-axial magnetic field can make the arc spot move at a high speed, steadily and regularly within circular and radial shrinkage. 7,8 As the tempera- ture of the target surface decreases, restricting the growth of grains, the grain size decreases. Simultaneously, the size of hard particulates decreases, resulting in an im- provement of the compactness of the coatings. Q. Zhang 9,10 prepared AlTiN coatings using a cathode arc- source device with an axial magnetic field. The hardness of the coatings increased significantly. At present, the design and analysis of electromag- netic fields are receiving a lot of attention. However, there is still little research on the effect of electromag- netic fields on the comprehensive properties of coatings. In this study, a series of ternary coatings were synthe- sized using traditional arc-ion plating with an axial electromagnetic field. The corresponding mechanical, tribological and high-temperature oxidation-resistance properties were characterized. Materiali in tehnologije / Materials and technology 53 (2019) 6, 833–838 833 UDK 620.1:537.8:621.793.8:621.3.014.31 ISSN 1580-2949 Original scientific article/Izvirni znanstveni ~lanek MTAEC9, 53(6)833(2019) *Corresponding author's e-mail: wangjin@qut.edu.cn (Jin Wang) 2 EXPERIMENTAL PART 2.1 Preparation of ternary composite coatings The coatings were deposited on samples of H13 steel using the industrial technology of arc ion plating with a magnetic filter ring for generating an axial electro- magnetic field, as shown in Figure 1. The samples were polished on a metallographic grinding machine, and then placed in an anhydrous ethanol solution for ultrasonic cleaning for 20 min. After the cleaning, the samples were placed into a vacuum chamber with a background pressure of 3×10 –4 Pa for the deposition of coatings. The deposition process was followed by glowing, Cr bom- bardment, deposition of the bottom layer and deposition of the functional layer. Specific parameters of each step are shown in Table 1. A 99.9 % pure Cr target, a Cr 0.33 Al 0.67 target and four Ti 0.33 Al 0.67 targets, which were circular thin targets with a diameter of 100 mm and a thickness of 15 mm, were employed. To distinguish whether the electromagnetic fields were used in the preparation of hard coatings, formulas CrAlN(EM) and TiAlN(EM) were used to indicate that they were prepared with electromagnetic fields while CrAlN and TiAlN indicate that they were prepared without electromagnetic fields. 2.2 Test methods The deposited samples were annealed at 700 °C in a programmable protective-atmosphere box furnace for 30 min. The thickness and hardness of the coatings were measured with a ball marker (JS-QHY-2) and a micro-Vickers hardness tester (HXD-1000TM / LCD). The anti-crack critical load Lc1 and failure load Lc2 of the coatings were measured with a scratch tester (WS-2005) for the quantitative adhesion analysis. The friction coefficients on the surfaces of the coatings were measured with a UMT multi-purpose friction-and-wear testing machine to analyze the wear resistance. The surface morphologies and microstructures of the coatings were analyzed with a scanning electron microscope (SEM) (ZEISS MERLIN COMPACT) and Nordlys Max EDS. The phase structures of the coatings were analyzed with X-ray diffraction (XRD) (Rigaku D/max-2550/PC). The grain sizes of the coatings were calculated with the Scherrer formula. 3 RESULTS AND DISCUSSION 3.1 Microstructure of coatings The XRD pattern of each coating after annealing in air is shown in Figure 2. The main structure of each coating is a NaCl-type face-centered-cubic structure (FCC). The CrAlN and CrAlN(EM) coatings mainly consist of the fcc-Cr(Al)N phase with preferred (200) orientation. The TiAlN and TiAlN (EM) coatings mainly consist of the fcc-Ti(Al)N phase, also showing a pre- ferred orientation of the crystal plane (200). In addition, J. WANG et al.: EFFECT OF AN ELECTROMAGNETIC FIELD ON THE MICROSTRUCTURE AND PROPERTIES ... 834 Materiali in tehnologije / Materials and technology 53 (2019) 6, 833–838 Table 1: Processes and parameters for the four kinds of coatings Pressure (Pa) Tempera- ture (°C) Time (min) Bias (V) Target current (A) Gas (sccm) Electromagnetic voltage (V) Cr CrAl TiAl N 2 Ar Glowing 0.3 450 40 800 ––––2 0– Cr bombardment 0.3 450 30 200 110 – – – 20 – CrN 1.5 450 15 110 110 – – 240 15 – 1-CrAlN 3.0 450 – 70 – 70 – 350 0 – 2-TiAlN 3.0 450 – 70 – – 70 350 0 – 3-CrAlN(EM) 3.0 450 – 70 – 70 – 350 0 15 4-TiAlN(EM) 3.0 450 – 70 – – 70 350 0 15 Figure 1: Schematic diagram of the electromagnetic arc source Figure 2: XRD patterns for the coatings annealed in air the metastable h-AlN phase appears in all the coatings. The h-AlN diffraction-peak intensity of the CrAlN and TiAlN coatings increases gradually, but the (111) and (200) plane diffraction-peak intensity of the CrN and TiN phase decreases compared with that of the CrAlN(EM) and TiAlN(EM) coatings. This suggests that the nucleation energy of h-AlN was reduced and the growth of the (111) and (200) planes was promoted by the addition of the axial electromagnetic field. It was shown that when the amount of Al is high (50–77 %) and the temperature is high, the energy required for the Al atoms to be embedded in the lattice is higher than that for the H-AlN nucleation, and the H-AlN phase is easily formed. 11–13 In this study, the EDS analysis of various coatings indicates that the Al amount is above 50 %, which is in agreement with the results of the reference studies (Figure 3). The grain size was calculated with the Scherrer formula. The grain sizes of the CrAlN (EM) and TiAlN (EM) coatings are 14.8 nm and 15.2 nm, respectively. In comparison, the grain sizes of the CrAlN and TiAlN coatings are 16.8 nm and 17.9 nm, respectively. The results imply that the grain size can be refined with an axial electromagnetic field. When the electromagnetic voltage increases within a certain range, the arc-spot movement accelerates, the target ionization rate in- creases, the density and energy of plasma improve relatively. The ion-bombardment energy increases with the acceleration of the substrate bias voltage, which leads to more defects on the coating surface, 14 resulting in an increase of the preferential nucleation sites and a de- crease of the grain size. The oxidation resistance of various coatings was also analyzed with XRD as shown in Figure 2. The diffrac- tion peaks of Al 2 O 3 and Cr 2 O 3 mainly appear for the CrAlN and CrAlN(EM) coatings. The diffraction peaks of Al 2 O 3 and TiO 2 are mainly in the TiAlN and TiAlN(EM) coatings. In contrast, the order of oxidation diffraction peaks from high to low is as follows: TiAlN, CrAlN, TiAlN(EM) and CrAlN(EM). This is due to the mixed oxides of Al 2 O 3 and Cr 2 O 3 , which are formed on the surfaces of the coatings, and are more compact than the structures of the CrAlN and CrAlN(EM) coatings. They can be an effective barrier to the oxygen diffusion into the interior at a high temperature, increasing the oxidation resistance of the coatings. 15,16 However, the mixed oxides in the TiAlN and TiAlN (EM) coatings are Al 2 O 3 and TiO 2 .TiO 2 is a columnar structure with voids around it, resulting in a decrease in the oxidation resist- ance of the coatings. 17 As shown in Figure 4, the surface morphology of the coatings was analyzed with SEM, and it was found that there are more pits and hard particles on the surfaces of the CrAlN and TiAlN coatings than on the surfaces of the CrAlN(EM) and TiAlN(EM) coatings (Figures 4a to 4ff). After the annealing at 700 °C, the oxidation around the pits and hard particulates on the surfaces of the CrAlN and TiAlN coatings, and the size and number of hard particulates increase (Figure 4c and 4g). However, the surface morphology of the CrAlN(EM) and TiAlN(EM) coatings shows no change after high-tem- J. WANG et al.: EFFECT OF AN ELECTROMAGNETIC FIELD ON THE MICROSTRUCTURE AND PROPERTIES ... Materiali in tehnologije / Materials and technology 53 (2019) 6, 833–838 835 Figure 4: SEM images of TiAlN and CrAlN coatings before and after annealing Figure 3: Element amounts in the four coatings before and after the annealing perature annealing (Figure 4d, 4h). Furthermore, the EDS analysis of the O element (Figure 3) shows that the atomic percentage of O in the CrAlN, TiAlN, CrAlN(EM) and CrAlN(EM) coatings is 17.56, 17.56, 6.49 and 6.78 %, respectively. The results are in agree- ment with those of the surface morphology and XRD. The results also show that CrAlN(EM) and CrAlN(EM) have better oxidation resistance than CrAlN and TiAlN. Figure 5 shows the SEM cross-sectional morphology of the coating elements after the annealing. It is observed that the internal structure of the coatings is an equiaxed nanocrystalline rather than the traditional columnar structure. The reason is that the columnar epitaxial growth of the grains was limited by adjusting the bias voltage, electromagnetic coil voltage, target current and vacuum in the process of the coating preparation. 18,19 Furthermore, no obvious oxide layers are observed in the cross-sectional morphologies of the coatings, indicating that the oxidation reaction occurred only in the local regions of the coating surfaces, and the coatings did not fail completely. 3.2 Tribological properties The wear-scar morphologies and the average friction coefficients of the coatings before and after the anneal- ing are shown in Figures 6 and 7. Before the annealing, the friction coefficients of the CrAlN and TiAlN coatings are relatively high, and there are many pits in the wear scar; the wear mechanism is mainly adhesive wear. However, the number and size of the pits on the surfaces of the wear scars of the CrAlN(EM) and TiAlN(EM) coatings significantly decrease and the friction coeffi- cients decrease. After the annealing, although the friction coefficients of the CrAlN and TiAlN coatings decrease greatly, they are still higher than those of the CrAlN (EM) and TiAlN (EM) coatings. This can be explained with the fact that the internal structures of the CrAlN and TiAlN coatings are not compact, resulting in the Al element contacts with the O element to form Al 2 O 3 with self-lubricating in the process of annealing, which plays a role of solid lubrication. When in contact with O, the Cr element can form Cr 2 O 3 with high hardness and heat resistance, which is beneficial to chip removal. 20,21 The columnar amorphous TiO 2 formed due to the contact of J. WANG et al.: EFFECT OF AN ELECTROMAGNETIC FIELD ON THE MICROSTRUCTURE AND PROPERTIES ... 836 Materiali in tehnologije / Materials and technology 53 (2019) 6, 833–838 Figure 6: Wear morphologies of coatings before and after annealing Figure 5: Cross-sectional SEM images of different coatings annealed in air at 700 °C for 30 min Figure 7: Average friction coefficients of coatings before and after annealing Ti with O not only has a poor chip-removal ability, but also has voids, leading to continuous oxidation. 22 It is worth noting that the wear mechanism of the CrAlN (EM) coating changes from the adhesive wear to the abrasive wear, not only due to the formation of Al 2 O 3 , but also due to the changes in the parameters of the electromagnetic filter device. 3.3 Mechanical properties After the testing, the thickness of the CrAlN, CrAlN(EM) and TiAlN, TiAlN(EM) are (5.32, 5.29, 5.08 and 5.21) μm. Figure 8 shows the hardness of the coatings before and after the annealing. The microhard- ness levels of the CrAlN(EM) and TiAlN(EM) coatings are higher than those of the CrAlN and TiAlN, respect- ively. The improvement of the coating hardness is mainly caused by the Hall-Petch effect merged with the Al solid solution in CrN or TiN, resulting in solid-solution strengthening, fine-grain strengthening and an abundant formation of the ceramic phase with an increase in the N amount. 23,24 In this study, the amounts of Al and N are almost the same according to the EDS analysis, indi- cating that the improved hardness of the CrAlN(EM) and TiAlN(EM) coatings is due to fine-grain strengthening. The axial magnetic field increases the energy of the deposited ions and enhances the nucleation rate of the grains, resulting in grain refinement. After the annealing, the hardness of the CrAlN(EM) and TiAlN(EM) coatings still remains stable, while the hardness of the CrAlN and TiAlN coatings decreases. This suggests that the addition of the axial electromagnetic field reduces the soft hcp-AlN phase and residual stress of the CrAlN(EM) and TiAlN(EM) coatings. The adhesive force of each coating was quantitatively analyzed with the scratch method. The critical load of the crack resistance (Lc1) and the failure critical load (Lc2) before and after the annealing are shown in Fig- ure 9. Critical loads Lc1 and Lc2 of the CrAlN(EM) and TiAlN(EM) coatings with a small grain size, compact structure, and low compressive stress are significantly higher than those of the CrAlN and TiAlN coatings. Lc1 and Lc2 are mainly determined with the residual stress of the coatings, which can cause the coatings to be exfoliated by separating the coating from the substrate and subsequent wrinkling. High-temperature annealing can increase the residual stress of the coatings. There- fore, Lc1 and Lc2 of the CrAlN and TiAlN coatings de- crease significantly after annealing. The electromagnetic field increases the compactness of the coatings and reduces the residual stress. Therefore, after annealing, Lc1 and Lc2 of CrAlN(EM) and TiAlN(EM) are significantly higher than those of CrAlN and TiAlN, and the stability of the binding force of CrAlN(EM) and TiAlN(EM) is better. 4 CONCLUSIONS A series of CrAlN and TiAlN coatings were prepared using arc-ion plating with and without an axial electromagnetic field. The effects of the axial magnetic field on the microstructure and mechanical properties of the two coatings were compared. The main conclusions are as follows: 1) Axial electromagnetic field can significantly refine the grain size of the two coatings and improve their oxidation resistance. 2) Axial electromagnetic field can significantly reduce the pits and hard particles on the surfaces of the two coatings, reducing the friction coefficient and improving the wear resistance. 3) Axial electromagnetic field can increase the hardness of the two coatings and improve the bond between the coatings and the substrate. 4) After annealing, the mechanical properties of the two coatings prepared with the axial electromagnetic field can still be maintained. J. WANG et al.: EFFECT OF AN ELECTROMAGNETIC FIELD ON THE MICROSTRUCTURE AND PROPERTIES ... 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