–
Evaluation of the friction and wear behavior of a-C:H coatings for lubricant-reduced sheet metal forming
REBLITZ Jonas, ZETTL Bastian, SEYNSTAHL Armin, ORGELDINGER Christian, TREMMEL Stephan, MERKLEIN Marion
download PDFAbstract. Industrial companies are confronted with increasing demands for sustainability, challenges in the availability of raw materials as well as rising energy and labor costs. Thus, technological measures for improving the ecologic and economic potential of production are required. An important production stage for the manufacturing of metal-based products is sheet metal forming which consists of several production steps. Initially, the semi-finished sheets are lubricated with oil to reduce friction in the actual forming stage and afterwards they have to be cleaned. One approach for the decrease of production costs and increase of sustainability is the avoidance or reduction of oil-based lubricants and hence subsequent cleaning of the sheet metal parts. However, reducing the amount of lubrication leads to higher friction and wear. Consequently, the part quality as well as tool lifetime are significantly decreased. To meet these challenges, surface modifications for the reduction of wear can be applied. In this study, diamond like carbon (DLC) tool coatings were combined with minimum quantities of a solid lubricant on semi-finished parts to analyze the potential of the coatings for beneficial friction conditions. In this context, suitable a-C:H coating systems were needed to be identified. The associated friction and wear behavior was evaluated as a function of the lubricant amount for different variants of semi-finished parts. Initially, several a-C:H coatings were generated with varying deposition parameters. Promising variants regarding layer adhesion were analyzed for sheet metal forming in terms of tribological behavior. The resulting coefficients of friction (CoF) and wear resistance were investigated with strip drawing tests. For the comparison of the results over different industrially relevant sheet metals, two aluminum alloys as well as one steel material with different zinc coatings were evaluated. For all materials, the amount of solid lubricant was varied in a range below 0.8 g/m2 up to a completely dry condition without lubrication.
Keywords
Physical Vapor Deposition (PVD), DLC Coatings, Sheet Metal, Tribology
Published online 9/15/2024, 11 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: REBLITZ Jonas, ZETTL Bastian, SEYNSTAHL Armin, ORGELDINGER Christian, TREMMEL Stephan, MERKLEIN Marion, Evaluation of the friction and wear behavior of a-C:H coatings for lubricant-reduced sheet metal forming, Materials Research Proceedings, Vol. 44, pp 663-673, 2024
DOI: https://doi.org/10.21741/9781644903254-71
The article was published as article 71 of the book Metal Forming 2024
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
References
[1] Information on https://www.consilium.europa.eu/en/policies/energy-prices-and-security-of-supply/
[2] Information on https://www.statista.com/statistics/595803/electricity-non-household-price-germany/
[3] Information on https://ec.europa.eu/eurostat/statistics-explained/index.php?title=Natural_gas_price_
statistics#Natural_gas_prices_for_non-household_consumers
[4] Information on https://www.destatis.de/EN/Themes/Labour/Labour-Costs-Non-Wage-Costs/_node.html
[5] F. Vollertsen, F. Schmidt, Dry Metal Forming: Definition, Chances and Challenges, Int. J. Precis. Eng. Manuf.-Green Tech. 1 (2014) 59-62. https://doi.org/10.1007/s40684-014-0009-0
[6] S. Schöler, F. Özkaya, C. Kock, H. J. Maier, B.-A. Behrens, Selective thermally oxidised tool surfaces for dry deep drawing, Dry Met. Forming OAJ FPR 6 (2020) 001–029.
[7] T. Jähnig, A. Mousavi, T. Roch, E. Beyer, A.F. Lasagni, A. Brosius, Macro and microstructuring of deep drawing tools for dry forming processes, Dry Met. Forming OAJ FPR 6 (2020) 030–068.
[8] T. Jähnig, A.F. Lasagni, Laser interference patterned ta-C-coated dry forming tools, Industr. Lubric. Tribol. 72/8 (2020) 1001–1005. https://dx.doi.org/10.1108/ILT-08-2019-0314
[9] J. Henneberg, B. Rothammer, R. Zhao, M. Vorndran, J. Tenner, K. Krachenfels, T. Häfner, S. Tremmel, M. Schmidt, M. Merklein, Analysis of tribological behavior of surface modifications for a dry deep drawing process, Dry Met. Forming OAJ FMT 5 (2019) 013–024.
[10] W.C. Oliver, G.M. Pharr, Measurement of hardness and elastic modulus by instrumented indentation: Advances in understanding and refinements to methodology, J. Mater. Res. 19 (2004) 3–20. https://doi.org/10.1557/jmr.2004.19.1.3
[11] C. Chouquet, C. Ducros, S. Barrat, A. Billard, F. Sanchette, Mechanical properties of a-C:H/Si-containing a-C:H multilayered coatings grown by LF-PECVD, Surf. Coat. Tech. 203 (2008) 745 – 749. https://doi.org/10.1016/j.surfcoat.2008.08.008
[12] E. Barba, A. Claver, F. Montalà, J.F. Palacio, C.J. Luis-Pérez, N. Sala, C. Colominas, J.A. Garcia, Study of the Industrial Application of Diamond-Like Carbon Coatings Deposited on Advanced Tool Steels, Coatings 14 (2024) 159. https://doi.org/10.3390/coatings14020159
[13] A.S. Grenadyorov, K.V. Oskomov, N.F. Kovsharov, A.A. Solovyev, Effect of precursor flow rate on physical and mechanical properties of a-C:H:SiOx films deposited by PACVD method, J. Phys. 1115 (2018) 042046. https://doi.org/10.1088/1742-6596/1115/4/042046
[14] A.S. Grenadyorov, A.A. Solovyev, K.V. Oskomov, M.O. Zhulkov, Dependence of Mechanical and Tribological Properties of a-C:H:SiOx Films on the Bias Voltage Amplitude of the Substrate, Technic. Phys. 66 (2021) 1111 – 1117. https://dx.doi.org/10.1134/S1063784221080089
[15] J. Henneberg, B. Rothammer, R. Zhao, M. Vorndran, J. Tenner, K. Krachenfels, T. Häfner, S. Tremmel, M. Schmidt, M. Merklein, Lubricant free forming with tailored tribological conditions, Dry Met. Forming OAJ FPR 6 (2020) 228–261.
[16] Z. Huang, Z. Chen, W. Lang, X. Wang, Adhesion Studies of CrC/a-C:H Coatings Deposited with Anode Assisted Reactive Magnetron Sputtering Combined with DC-Pulsed Plasma Enhanced Chemical Vapor Deposition, Materials 14 (2021) 2954. https://doi.org/10.3390/ma14112954
[17] K. Krachenfels, B. Rothammer, S. Tremmel, M. Merklein, Experimental investigation of tool-sided surface modifications for dry deep drawing processes at the tool radii area, Procedia Manuf. 29 (2019) 201-208. https://doi.org/10.1016/j.promfg.2019.02.127
[18] R. Zhao, J. Steiner, K. Andreas, M. Merklein, S. Tremmel, Investigation of tribological behaviour of a-C:H coatings for dry deep drawing of aluminuium alloys, Tribol. Int. 118 (2018) 484-490. https://dx.doi.org/10.1016/j.triboint.2017.05.031
