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Surface Engineering in Sheet Metal Forming
Uppsala University, Teknisk-naturvetenskapliga vetenskapsområdet, Technology, Department of Materials Science.
2005 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

In recent years, surface engineering techniques have been developed in order to improve the tribological performance in many industrial applications. In sheet metal forming processes, the usage of liquid lubricants can be decreased by using self lubricated tribo surfaces which will result in more environmentally friendly workshops. In the present work two different concepts, i.e. the deposition of thin organic coatings on the steel sheet and PVD coatings on the tool, have been evaluated. The sheet materials investigated include Zn and 55%Al-Zn metal coated steel sheet, which in general are difficult materials to form under dry conditions since they are sticky and thus have a high tendency to adhere to the tool surface. The PVD coatings include CrN, TiN and various DLC coatings. The work comprises tribo testing and post test characterisation using surface analytical techniques in order to evaluate the tribological properties of the tribo surfaces. The tribological tests of different tribo couples were conducted by using modified scratch testing and ball-on-disc testing. From these test results different friction and wear mechanisms have been identified.

The deposition of thin organic coatings on the steel sheet metal has been found to be promising in order to control the friction and to avoid metal-metal contact resulting in galling. However, it has been found that the tribological characteristics of organic coated steel sheet are strongly influenced by coating chemical composition, the substrate surface topography and the coating thickness distribution.

The performance of the PVD coatings depends mainly on the chemical composition and topography of the coated surface. By choosing PVD coatings such as diamond like carbon (DLC) low and stable friction coefficients can be obtained in sliding contact against Zn. Surface irregularities such as droplet-like asperities may cause an initial high friction coefficient. However, after a running in process or by polishing the PVD coating low friction coefficients can be obtained resulting in a stable sliding contact.

The combination of imaging (optical profilometry, LOM, SEM) and chemical analytical techniques (EDS, AES, ToF-SIMS) gave valuable information concerning the friction and wear properties of the tribo surfaces investigated.

Place, publisher, year, edition, pages
Uppsala: Acta Universitatis Upsaliensis , 2005. , p. viii + 68
Series
Digital Comprehensive Summaries of Uppsala Dissertations from the Faculty of Science and Technology, ISSN 1651-6214 ; 7
Keywords [en]
Materials science, Friction, wear, metal coated steel sheet, dry lubricants, galling, PVD coatings
Keywords [sv]
Materialvetenskap
National Category
Materials Engineering
Research subject
Materials Science
Identifiers
URN: urn:nbn:se:uu:diva-4764ISBN: 91-554-6136-0 (print)OAI: oai:DiVA.org:uu-4764DiVA, id: diva2:165677
Public defence
2005-02-18, Teknikdalens aula, Teknikdalen, Forskargatan 3, Borlänge, 13:00
Opponent
Supervisors
Available from: 2005-01-28 Created: 2005-01-28Bibliographically approved
List of papers
1. Tribological Behaviour of Thin Organic Permanent Coatings Deposited on Hot-dip Coated Steel Sheet - a Laboratory Study
Open this publication in new window or tab >>Tribological Behaviour of Thin Organic Permanent Coatings Deposited on Hot-dip Coated Steel Sheet - a Laboratory Study
2000 In: Surface and Coatings Technology, Vol. 132, p. 169-180Article in journal (Refereed) Published
Identifiers
urn:nbn:se:uu:diva-92546 (URN)
Available from: 2005-01-28 Created: 2005-01-28Bibliographically approved
2. Friction and Wear Mechanisms of Thin Organic Permanent Coatings During Sliding Conditions
Open this publication in new window or tab >>Friction and Wear Mechanisms of Thin Organic Permanent Coatings During Sliding Conditions
2001 In: Wear, Vol. 247, p. 88-99Article in journal (Refereed) Published
Identifiers
urn:nbn:se:uu:diva-92547 (URN)
Available from: 2005-01-28 Created: 2005-01-28Bibliographically approved
3. Tribological Performance of Thin Organic Coatings Deposited on Galvanized Steel – Influence of Coating Composition and Thickness on Friction and Wear
Open this publication in new window or tab >>Tribological Performance of Thin Organic Coatings Deposited on Galvanized Steel – Influence of Coating Composition and Thickness on Friction and Wear
2001 In: Wear, Vol. 251, p. 1075-1084Article in journal (Refereed) Published
Identifiers
urn:nbn:se:uu:diva-92548 (URN)
Available from: 2005-01-28 Created: 2005-01-28Bibliographically approved
4. Tribological characterisation of an organic coating by the use of ToF-SIMS
Open this publication in new window or tab >>Tribological characterisation of an organic coating by the use of ToF-SIMS
2003 In: Applied Surface Science, Vol. 203-204, p. 596-599Article in journal (Refereed) Published
Identifiers
urn:nbn:se:uu:diva-92549 (URN)
Available from: 2005-01-28 Created: 2005-01-28Bibliographically approved
5. Tribological behaviour of thin organic coatings on 55%Al-Zn steel sheet - Influence of transfer and tribo film formation
Open this publication in new window or tab >>Tribological behaviour of thin organic coatings on 55%Al-Zn steel sheet - Influence of transfer and tribo film formation
In: WearArticle in journal (Refereed) Submitted
Identifiers
urn:nbn:se:uu:diva-92550 (URN)
Available from: 2005-01-28 Created: 2005-01-28Bibliographically approved
6. Improved anti-galling properties in sheet metal forming by the use of surface engineering
Open this publication in new window or tab >>Improved anti-galling properties in sheet metal forming by the use of surface engineering
In: Proceedings of Nordtrib 2002, 10th Nordic Symposium on Tribology, Stockholm, SwedenChapter in book (Other academic) Published
Identifiers
urn:nbn:se:uu:diva-92551 (URN)
Available from: 2005-01-28 Created: 2005-01-28Bibliographically approved
7. PVD coatings for sheet metal forming processes – A tribological evaluation
Open this publication in new window or tab >>PVD coatings for sheet metal forming processes – A tribological evaluation
2006 (English)In: Surface & Coatings Technology, ISSN 0257-8972, E-ISSN 1879-3347, Vol. 200, no 14-15, p. 4654-4663Article in journal (Refereed) Published
Abstract [en]

The use of liquid-based lubricants in sheet metal forming mutually has a negative impact on the environment and on the whole economy, and, consequently, there is an urgent need to find a solution to make the forming processes dry or nearly dry. The deposition of a low-friction PVD coating on the forming tool has during the last years proved to be an interesting choice when it comes to create an “unlubricated” forming process. In the present study, five different PVD coatings (one CrN and four metal-carbide-doped DLC coatings) have been evaluated in sliding contact against hot dip Zn and 55% Al–Zn-coated steel sheet using a ball-on-disc test. From the investigation, it was found that all DLC coatings have potential to prevent material pickup during dry forming of hot dip Zn-coated steel. However, the as-deposited surface morphology, showing surface irregularities such as droplets and dimples, of the coatings will strongly influence the tribological performance, and, consequently, a polishing treatment or a running-in process, resulting in a smooth surface, will significantly reduce the tendency to material pickup. In sliding contact against 55% Al–Zn-coated steel, all PVD coatings display material pickup and high friction values, the only exception being a CrC-doped DLC coating in the as-polished condition. The CrN coating showed poor performance in sliding contact against both steel sheet materials due to a high tendency to material pickup. The study focuses on the tribo-induced changes of the surface condition of the PVD coating and the steel sheet surface during the sliding event. The changes in surface chemistry and topography of the tribo surfaces were characterised using scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), Auger electron spectroscopy (AES) and light interference profilometry.

National Category
Engineering and Technology
Identifiers
urn:nbn:se:uu:diva-92552 (URN)10.1016/j.surfcoat.2004.10.127 (DOI)
Available from: 2005-01-28 Created: 2005-01-28 Last updated: 2017-12-14Bibliographically approved

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Citation style
  • apa
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