On the Physical Vapour Deposition (PVD): Evolution of Magnetron Sputtering Processes for Industrial Applications

Improved Reversibility of Thin-Film Solid Oxide Cells at 500 °C by Tailoring Sputtering Processes for Depositing Yttria-Stabilized Zirconia Electrolyte

The present study investigates the impact of sputtering configurations on the microstructure and crystallinity of thin-film yttria-stabilized zirconia electrolytes for anodized aluminum oxide-supported all-sputtered thin-film reversible solid oxide cells. Employing various sputtering parameters, such as target-substrate distance and substrate rotation speed, the present study reveals distinct surface characteristics and crystalline structures of thin-film yttria-stabilized zirconia. The microstructure analysis includes scanning electron microscopy and atomic force microscopy examinations, uncovering the influence of the process parameters on the surface morphology, roughness, and grain size. X-ray diffraction data illustrate the texture preferences and crystallite characteristics. The electrochemical characterization of the reversible solid oxide cells demonstrates that the optimized sputtering configuration significantly outperforms the others in both SOFC and SOEC modes, showing exceptional current densities of 964 mA/cm2 at 1.3 V in electrolysis mode at 500 °C. Electrochemical impedance spectroscopy further reveals improved charge transfer reactions at the interface of the electrolyte. The enhanced electrochemical performance is attributed to the unique microstructure and crystallinity of the thin film of yttria-stabilized zirconia. The record-breaking electrolysis performance of this work at 500 °C underscores the potential of tailored sputtering parameters in optimizing the reversible solid oxide cell performance.

Engineering Oxide Epitaxy beyond Substrate Constraint

Orientation engineering is a crucial aspect of thin film growth, and it is rather challenging to engineer film epitaxy beyond the substrate constraint. Guided by density functional theory calculations, we use SrRuO3 (SRO) as a buffer layer and successfully deposit [111]-oriented CoFe2O4 (CFO) on [001]-, [110]-, and [111]-oriented SrTiO3 (STO) substrates. This enables subsequent growth of [111]-oriented functional oxides, such as PbTiO3 (PTO), overcoming the constraint of the substrate. This strategy is quite general and applicable to lanthanum aluminate and yttria-stabilized zirconia substrates as well. X-ray Φ scans and atomic resolution aberration-corrected scanning transmission electron microscopy (AC-STEM) reveal detailed epitaxial relations in each of the cases, with four variants of [111]-CFO found on [001]-STO and two variants found on [110]-STO, formed to mitigate the large lattice misfit strain between the film and substrate. Our strategy thus provides a general pathway for orientation engineering of oxide epitaxy beyond substrate constraint.

Unleashing the promise of emerging nanomaterials as a sustainable platform to mitigate antimicrobial resistance

The emergence and spread of antibiotic-resistant (AR) bacterial strains and biofilm-associated diseases have heightened concerns about exploring alternative bactericidal methods. The WHO estimates that at least 700 000 deaths yearly are attributable to antimicrobial resistance, and that number could increase to 10 million annual deaths by 2050 if appropriate measures are not taken. Therefore, the increasing threat of AR bacteria and biofilm-related infections has created an urgent demand for scientific research to identify novel antimicrobial therapies. Nanomaterials (NMs) have emerged as a promising alternative due to their unique physicochemical properties, and ongoing research holds great promise for developing effective NMs-based treatments for bacterial and viral infections. This review aims to provide an in-depth analysis of NMs based mechanisms combat bacterial infections, particularly those caused by acquired antibiotic resistance. Furthermore, this review examines NMs design features and attributes that can be optimized to enhance their efficacy as antimicrobial agents. In addition, plant-based NMs have emerged as promising alternatives to traditional antibiotics for treating multidrug-resistant bacterial infections due to their reduced toxicity compared to other NMs. The potential of plant mediated NMs for preventing AR is also discussed. Overall, this review emphasizes the importance of understanding the properties and mechanisms of NMs for the development of effective strategies against antibiotic-resistant bacteria.

Copper(I) Iodide Thin Films: Deposition Methods and Hole-Transporting Performance

The pursuit of p-type semiconductors has garnered considerable attention in academia and industry. Among the potential candidates, copper iodide (CuI) stands out as a highly promising p-type material due to its conductivity, cost-effectiveness, and low environmental impact. CuI can be employed to create thin films with >80% transparency within the visible range (400-750 nm) and utilizing various low-temperature, scalable deposition techniques. This review summarizes the deposition techniques for CuI as a hole-transport material and their performance in perovskite solar cells, thin-film transistors, and light-emitting diodes using diverse processing methods. The preparation methods of making thin films are divided into two categories: wet and neat methods. The advancements in CuI as a hole-transporting material and interface engineering techniques hold promising implications for the continued development of such devices.

Tribocorrosion and Surface Protection Technology of Titanium Alloys: A Review

Titanium alloy has the advantages of high specific strength, good corrosion resistance, and biocompatibility and is widely used in marine equipment, biomedicine, aerospace, and other fields. However, the application of titanium alloy in special working conditions shows some shortcomings, such as low hardness and poor wear resistance, which seriously affect the long life and safe and reliable service of the structural parts. Tribocorrosion has been one of the research hotspots in the field of tribology in recent years, and it is one of the essential factors affecting the application of passivated metal in corrosive environments. In this work, the characteristics of the marine and human environments and their critical tribological problems are analyzed, and the research connotation of tribocorrosion of titanium alloy is expounded. The research status of surface protection technology for titanium alloy in marine and biological environments is reviewed, and the development direction and trends in surface engineering of titanium alloy are prospected.

Comparison of CrN Coatings Prepared Using High-Power Impulse Magnetron Sputtering and Direct Current Magnetron Sputtering

Chromium Nitride (CrN) coatings have widespread utilization across numerous industrial applications, primarily attributed to their excellent properties. Among the different methods for CrN coating synthesis, direct current magnetron sputtering (DCMS) has been the dominant technique applied. Nonetheless, with the expanded applications of CrN coatings, the need for enhanced mechanical performance is concurrently escalating. High-power impulse magnetron sputtering (HiPIMS), an innovative coating deposition approach developed over the past three decades, is gaining recognition for its capability of yielding coatings with superior mechanical attributes, thereby drawing significant research interest. Considering that the mechanical performance of a coating is fundamentally governed by its microstructural properties, a comprehensive review of CrN coatings fabricated through both techniques is presented. This review of recent literature aims to embark on an insightful comparison between DCMS and HiPIMS, followed by an examination of the microstructure of CrN coatings fabricated via both techniques. Furthermore, the exploration of the underlying factors contributing to the disparities in mechanical properties observed in CrN coatings is revealed. An assessment of the advantages and potential shortcomings of HiPIMS is discussed, offering insight into CrN coating fabrication.

PVD for Decorative Applications: A Review

Physical Vapor Deposition (PVD) is a widely utilized process in various industrial applications, serving as a protective and hard coating. However, its presence in fields like fashion has only recently emerged, as electroplating processes had previously dominated this reality. The future looks toward the replacement of the most hazardous and toxic electrochemical processes, especially those involving Cr(VI) and cyanide galvanic baths, which have been restricted by the European Union. Unfortunately, a complete substitution with PVD coatings is not feasible. Currently, the combination of both techniques is employed to achieve new aesthetic features, including a broader color range and diverse textures, rendering de facto PVD of primary interest for the decorative field and the fashion industry. This review aims to outline the guidelines for decorative industries regarding PVD processes and emphasize the recent advancements, quality control procedures, and limitations.

Development of a novel radial-torsional hollow ultrasonic motor and contact interface coating test

A novel miniature radial-torsional hollow ultrasonic motor is proposed in this work, which is mainly composed of a base, a hollow rotor, a stator. One piece of piezoelectric wafer bonded on the bottom face of the stator is used to excite the radial in-plane vibration mode of the outer ring, which is converted into the revolved motion of the inner ring through the connection beams. The revolved motion of the inner ring can drive the rotor pressed on the inner ring to rotate through friction. The finite-element method was performed to verify the working principle of the motor and optimize the key dimensions of the motor. One prototype motor with the appearance size of Φ35 mm × 12 mm and weight of 20.1 g is fabricated and characterized. In addition, Si₃N₄ thin film is coated on the contact interface of the stator by the magnetron sputtering coating machine to improve the output performance of the ultrasonic motor. The experiment results show that the locked-rotor torque of the motor with coated stator can reach 0.42 mN m, which is 55.56 % higher than that of the uncoated motor.

Study on the Micro-Abrasion Wear Behavior of PVD Hard Coating under Different SiC Abrasive Particles/Distilled Water Ratios

Microscale abrasion has been intensively used to study the wear behavior o several hard coatings, enabling the observation of different wear mechanisms. Recently, a study arguing whether the surface texture of the ball could influence the dynamics of abrasive particles throughout the contact was presented. In this work, the influence of the abrasive particles concentration able to change the texture of the ball was studied to understand its influence on the wear modes-rolling or grooving. Thus, tests were carried out using samples with a thin coating of TiN, deposited using the Physical Vapor Deposition (PVD) technique, and AISI 52100 steel balls etched over 60 s to induce a change in their texture and roughness were used. Three abrasive slurries were prepared with black silicon carbide (SiC) particles (average particle size of 4 μm) with different concentrations, 0.25, 0.35, and 0.45 g/cm³. The rotation speed used in the tests was 80 rpm and the normal loads applied in the study were 0.2 N and 0.5 N, and 1 N. After the wear tests, the coated samples and tracks on the surface of the balls were observed by SEM and 3D microscopy to understand the abrasive particle dynamics, evaluating the wear mode transition as well as the function of both applied load and slurry concentration. The tracks in the balls showed particles embedded on their surface. A lower concentration of abrasion was conducted to higher specific wear rate. Moreover, a predominant two-body wear mechanism was induced when the abrasive concentration was increased. There was an increase in the roughness of the scar and the surface of the balls with an increase in the abrasive particles' concentration.

Metallization of Recycled Glass Fiber-Reinforced Polymers Processed by UV-Assisted 3D Printing

An ever-growing amount of composite waste will be generated in the upcoming years. New circular strategies based on 3D printing technologies are emerging as potential solutions although 3D-printed products made of recycled composites may require post-processing. Metallization represents a viable way to foster their exploitation for new applications. This paper shows the use of physical vapor deposition sputtering for the metallization of recycled glass fiber-reinforced polymers processed by UV-assisted 3D printing. Different batches of 3D-printed samples were produced, post-processed, and coated with a chromium metallization layer to compare the results before and after the metallization process and to evaluate the quality of the finishing from a qualitative and quantitative point of view. The analysis was conducted by measuring the surface gloss and roughness, analyzing the coating morphology and thickness through the Scanning Electron Microscopy (SEM) micrographs of the cross-sections, and assessing its adhesion with cross-cut tests. The metallization was successfully performed on the different 3D-printed samples, achieving a good homogeneity of the coating surface. Despite the influence of the staircase effect, these results may foster the investigation of new fields of application, as well as the use of different polymer-based composites from end-of-life products, i.e., carbon fiber-reinforced polymers.

Development of an Alternative Alloying Concept for Additive Manufacturing Using PVD Coating

New alloys are needed to adapt the material properties and to improve the weldability of arc-based additive manufacturing processes. The classic development of welding filler materials is time-consuming and cost-intensive. For this reason, an alternative alloy concept is investigated and qualified here. This is based on the thin-film coating of welding filler materials by means of PVD coating. An HSLA steel DIN EN ISO 14341-A G 50 7 M21 is used as the base material. This is alloyed with the elements Al, Cr, Nb, Ni and Ti by means of PVD thin-film coating. This procedure represents an alternative alloy concept. In the scope of the qualification, the influence of the process and material properties is investigated, and the alternative alloying concept is compared with the classical alloying concept of secondary metallurgy. The investigations have shown that the thin film coating on the surface of the welding filler metal affects the process properties in the form of a changed arc length. Furthermore, the mechanical properties and the effect on the microstructure morphology were investigated. These were compared in the same chemical composition with a Mn4Ni2CrMo produced by secondary metallurgy. The results are in agreement with regard to the mechanical properties and the effect on the microstructure morphology.

Investigations on the Wear Performance of Coated Tools in Machining UNS S32101 Duplex Stainless Steel

Due to their high mechanical property values and corrosion resistance, duplex stainless steels (DSSs) are used for a wide variety of industrial applications. DSSs are also selected for applications that require, especially, high corrosion resistance and overall good mechanical properties, such as in the naval and oil-gas exploration industries. The obtention of components made from these materials is quite problematic, as DSSs are considered difficult-to-machine alloys. In this work, the developed wear during milling of the UNS S32101 DSS alloy is presented, employing four types of milling tools with different geometries and coatings. The influence of feed rate and cutting length variations on the tools’ wear and their performance was evaluated. The used tools had two and four flutes with different coatings: TiAlN, TiAlSiN and AlCrN. The cutting behavior of these tools was analyzed by collecting data regarding the cutting forces developed during machining and evaluating the machined surface quality for each tool. After testing, the tools were submitted to SEM analysis, enabling the identification of the wear mechanisms and quantification of flank wear, as well as identifying the early stages of the development of these mechanisms. A comparison of all the tested tools was made, determining that the TiAlSiN-coated tools produced highly satisfactory results, especially in terms of sustained flank wear.

Design Aspects of Additive Manufacturing at Microscale: A Review

Additive manufacturing (AM) technology has been researched and developed for almost three decades. Microscale AM is one of the fastest-growing fields of research within the AM area. Considerable progress has been made in the development and commercialization of new and innovative microscale AM processes, as well as several practical applications in a variety of fields. However, there are still significant challenges that exist in terms of design, available materials, processes, and the ability to fabricate true three-dimensional structures and systems at a microscale. For instance, microscale AM fabrication technologies are associated with certain limitations and constraints due to the scale aspect, which may require the establishment and use of specialized design methodologies in order to overcome them. The aim of this paper is to review the main processes, materials, and applications of the current microscale AM technology, to present future research needs for this technology, and to discuss the need for the introduction of a design methodology. Thus, one of the primary concerns of the current paper is to present the design aspects describing the comparative advantages and AM limitations at the microscale, as well as the selection of processes and materials.

Nanostructured Coatings: Review on Processing Techniques, Corrosion Behaviour and Tribological Performance

Corrosion and tribology are surface phenomena. Modifying surfaces of materials without resorting to altering their bulk properties is an effective route to alleviate corrosion, friction and wear, encountered in engineering applications. With the advancements in the field of nanotechnology, surface protective coatings with nanomaterials can be readily developed to explore their functionality in mitigating chemical/physical damage of surfaces. Surface protection enhances performance and operating lifetimes of industrial machinery components. This review presents insights on various types of recently developed nanostructured coatings, their synthesis routes, corrosion behaviour and tribological performance. It provides the state-of-the-art information on the development of nanostructured coatings, namely, ceramic coatings, metallic coatings and nanocomposite coatings with metal and polymer matrices. Biomimetic approaches in making nanostructured coatings and challenges encountered in the development of nanostructured coatings are highlighted.

Synthesis and Investigation of Antibacterial Activity of Thin Films Based on TiO2-Ag and SiO2-Ag with Potential Applications in Medical Environment

Multiple antibiotic resistance has now become a major obstacle to the treatment of infectious diseases. In this context, the application of nanotechnology in medicine is a promising alternative for the prevention of infections with multidrug-resistant germs. The use of silver as a powerful antibacterial agent has attracted much interest. TiO2 and SiO2 thin films enhanced with Ag particles have been developed with the aim of maintaining the transparency of the polymer films. Antibacterial activity was evaluated for a Gram-negative species-Escherichia coli-in concentrations of 105 and 104 CFU/mL in different conditions-activation by UV irradiation, single layer and double layer. Increased antibacterial efficacy of TiO2-deposited foil was found for the tests that had been exposed to UV activation. In the case of bilayer tests, the efficiency was higher compared to those in a single layer, as the contact surface between the films and the bacterial suspension increased. Films can be used as a potential method to limit bacterial growth on hospital surfaces, such as telephone screens and medical equipment, given their optimized characteristics and proven antibacterial efficacy.

A Comparative Research on Corrosion Behavior of Electroplated and Magnetron Sputtered Chromium Coatings

Chromium deposits rank among the most widespread metal coatings for functional and decorative purposes. However, electrodeposition from Cr(VI) aqueous solution, which is the industrial process currently used to achieve thin chromium deposits, presents several environmental issues, urging the development of alternative solutions. In this study, which aims to compare the functional and aesthetical properties of decorative coatings, 800 nm thick chromium layers were deposited directly onto copper substrates by means of magnetron sputtering (MS) and direct current electrodeposition (ED). The obtained coatings were characterized regarding their thickness, morphology, color index, chemical composition, and corrosion resistance viewpoints. With respect to the electroplated samples, which constitute the benchmark, the magnetron sputtered ones appeared to be darker but showed a pleasing reflective appearance and superior thickness homogeneity, as well as the absence of voids and macrocracks, as evidenced by scanning electron microscopy (SEM) investigation. Regarding the anticorrosion performances of the chromium layers, electrochemical and standard salt spray test (NSS test) were carried out at room temperature in 3.5% NaCl solution, and evidenced similar, if not better, results for the magnetron sputtered coatings. On the whole, the data displayed here demonstrates the suitability of magnetron sputtering technology for use as an industrially feasible finishing technology for both aesthetic and mild-condition anticorrosion purposes.

Silver-Containing Thin Films on Transparent Polymer Foils for Antimicrobial Applications

The increasing occurrence of infections caused by pathogens found on objects of everyday use requires a variety of solutions for active disinfection. Using active materials that do not require daily maintenance has a potential advantage for their acceptance. In this contribution, transparent films, with silver as the main antimicrobial agent and a total thickness of a few tens of nm, were deposited on flexible self-adhesive polymer foils used as screen protectors. TiO2 and SiO2 were used as transparent matrix to embed the Ag nanoparticles, ensuring also their mechanical protection and controlled growth. HiPIMS (High-Power Impulse Magnetron Sputtering) was used for the sputtering of the Ag target and fine control of the Ag amount in the layer, whereas TiO2 and SiO2 were sputtered in RF (Radio Frequency) mode. The thin film surface was investigated by AFM (Atomic Force Microscopy), providing information on the topography of the coatings and their preferential growth on the textured polymer foil. XRD (X-Ray Diffraction) revealed the presence of specific Ag peaks in an amorphous oxide matrix. UV-Vis-NIR (Ultraviolet-Visible-Near Infrared) spectroscopy revealed the presence of nanostructured Ag, characterized by preferential absorption in the 400 to 500 nm spectral range. The antimicrobial properties were assessed using an antimicrobial test with the Escherichia coli strain. The highest efficiency was observed for the Ag/SiO2 combination, in the concentration range of 104–105 CFU/mL.

Nanoscale self-assembly: concepts, applications and challenges

Self-assembly offers unique possibilities for fabricating nanostructures, with different morphologies and properties, typically from vapour or liquid phase precursors. Molecular units, nanoparticles, biological molecules and other discrete elements can spontaneously organise or form via interactions at the nanoscale. Currently, nanoscale self-assembly finds applications in a wide variety of areas including carbon nanomaterials and semiconductor nanowires, semiconductor heterojunctions and superlattices, the deposition of quantum dots, drug delivery, such as mRNA-based vaccines, and modern integrated circuits and nanoelectronics, to name a few. Recent advancements in drug delivery, silicon nanoelectronics, lasers and nanotechnology in general, owing to nanoscale self-assembly, coupled with its versatility, simplicity and scalability, have highlighted its importance and potential for fabricating more complex nanostructures with advanced functionalities in the future. This review aims to provide readers with concise information about the basic concepts of nanoscale self-assembly, its applications to date, and future outlook. First, an overview of various self-assembly techniques such as vapour deposition, colloidal growth, molecular self-assembly and directed self-assembly/hybrid approaches are discussed. Applications in diverse fields involving specific examples of nanoscale self-assembly then highlight the state of the art and finally, the future outlook for nanoscale self-assembly and potential for more complex nanomaterial assemblies in the future as technological functionality increases.

Investigation of a Possible Material-Saving Approach of Sputtering Techniques for Radiopharmaceutical Target Production

Magnetron sputtering (MS) is a relatively new deposition technique, which is being considered among the cyclotron solid target (CST) manufacturing options now available, aiming at the medical radioisotopes yield for radiopharmaceutical production. However, the intrinsic high material losses during the deposition process do not permit its use with extremely expensive target materials, such as isotopically enriched metals/oxides. In this study, R&D technology for a new recovering shield is instead proposed to assess the dissipation of target material during the sputtering processes and, thus, an estimate of the material recovery that may be feasible and the related amount. The weight-loss analysis method is used to assess the material losses level inside the chamber during processing. In all tests carried out, a high-purity copper (99.99%) was used as a target material. As a result of this study, the material distribution for both magnetron and diode sputtering depositions can be calculated. The feasibility of the ultra-thick coatings growing, devoted to CST production, is demonstrated.

Wear Behavior and Machining Performance of TiAlSiN-Coated Tools Obtained by dc MS and HiPIMS: A Comparative Study

Duplex stainless steels are being used on applications that require high corrosion resistance and excellent mechanical properties, such as the naval and oil-gas exploration industry. The components employed in these industries are usually obtained by machining; however, these alloys have low machinability when compared to conventional stainless steels, usually requiring the employment of tool coatings. In the present work, a comparative study of TiAlSiN coating performance obtained by these two techniques in the milling of duplex stainless-steel alloy LDX 2101 was carried out. These coatings were obtained by the conventional direct current magnetron sputtering (dc MS) and the novel high power impulse magnetron sputtering (HiPIMS). The coatings were analyzed and characterized, determining mechanical properties for both coatings, registering slightly higher mechanical properties for the HiPIMS-obtained coating. Machining tests were performed with varying cutting length and feed-rate, while maintaining constant values for axial and radial depth of cut and cutting speed. The surface roughness of the material after machining was assessed, as well as the wear sustained by each of the tool types, identifying the wear mechanisms and behavior of these tools, as well as registering the flank wear values presented for each of the tested tools. The HiPIMS-obtained coating exhibited a very similar behavior when compared to the other, producing similar surface roughness quality. However, the HiPIMS coating exhibited less wear for higher cutting lengths, proving to be a better choice in this case, especially regarding tool life.

Metallization of Thermoplastic Polymers and Composites 3D Printed by Fused Filament Fabrication

Fused filament fabrication allows the direct manufacturing of customized and complex products although the layer-by-layer appearance of this process strongly affects the surface quality of the final parts. In recent years, an increasing number of post-processing treatments has been developed for the most used materials. Contrarily to other additive manufacturing technologies, metallization is not a common surface treatment for this process despite the increasing range of high-performing 3D printable materials. The objective of this work is to explore the use of physical vapor deposition sputtering for the chromium metallization of thermoplastic polymers and composites obtained by fused filament fabrication. The thermal and mechanical properties of five materials were firstly evaluated by means of differential scanning calorimetry and tensile tests. Meanwhile, a specific finishing torture test sample was designed and 3D printed to perform the metallization process and evaluate the finishing on different geometrical features. Furthermore, the roughness of the samples was measured before and after the metallization, and a cost analysis was performed to assess the cost-efficiency. To sum up, the metallization of five samples made with different materials was successfully achieved. Although some 3D printing defects worsened after the post-processing treatment, good homogeneity on the finest details was reached. These promising results may encourage further experimentations as well as the development of new applications, i.e., for the automotive and furniture fields.

Wear Characterization of Chromium PVD Coatings on Polymeric Substrate for Automotive Optical Components

The automotive industry is a pioneer in solutions that meet market expectations. However, in the automotive industry, some less environmentally friendly technologies are still used, such as electroplating. Due to legislative restrictions in several countries, thin coatings made in a vacuum have been replacing coatings traditionally made by electroplating, mainly in decorative terms. This work is more focused on the use of these coatings made in vacuum for optical applications, namely on headlights and exterior backlit components. Although these components are protected during the period of use, there may be situations of contact during the assembly of the components or their repair, necessary to safeguard and to ensure that these coatings have the scratch and wear resistance needed to withstand any treatment deficiency during the operations referred to above. Therefore, this work is essentially focused on the study of the wear resistance of Cr coatings made by PVD (Physical Vapour Deposition) on polymeric substrates. To this end, the coatings previously studied have now been subjected to micro-abrasion tests, with a view to assessing their wear resistance. For this purpose, alumina abrasive has been used, and the wear mechanisms observed in the coatings were studied. The abrasion and scratch tests showed that the most stable film has the one provided with 10-layers, showing greater wear resistance as well, greater adhesion to the substrate and less cohesive failures in the performed tests. Given the nature of the substrate and the coating, the results obtained are very promising, showing that these 10-layer Cr thin coatings can overcome any careless operation during manufacturing, assembly and repair processes, when applied in lightning or backlit components in motor vehicles.

Assessment of Coating Quality Obtained on Flame-Retardant Fabrics by a Magnetron Sputtering Method

Innovative textile materials can be obtained by depositing different coatings. To improve the thermal properties of textiles, aluminum and zirconium (IV) oxides were deposited on the Nomex^® fabric, basalt fabric, and cotton fabric with flame-retardant finishing using the magnetron sputtering method. An assessment of coating quality was conducted. Evenly coated fabric ensures that there are no places on the sample surface where the values of thermal parameters such as resistance to contact heat and radiant heat deviate significantly from the specified ones. Energy-dispersive spectroscopy was used for the analysis of modified fabric surfaces. Non-contact digital color imaging system DigiEye was also used. The criterion allowing one to compare surfaces and find which surface is more evenly coated was proposed. The best fabrics from the point of view of coating quality were basalt and cotton fabrics coated with aluminum as well as basalt fabric coated with zirconia. The probability of occurrence of places on the indicated sample surfaces where the values of thermal parameters (i.e., resistance to contact heat and radiant heat) deviated significantly from the specified ones was smaller for Nomex^® and cotton fabrics coated with zirconia and Nomex^® fabric coated with aluminum.

Characterization of Thin Chromium Coatings Produced by PVD Sputtering for Optical Applications

PVD (physical vapor deposition) and CVD (chemical vapor deposition) have gained greater significance in the last two decades with the mandatory shift from electrodeposition processes to clean deposition processes due to environmental, public safety, and health concerns. Due to the frequent use of coatings in several industrial sectors, the importance of studying the chromium coating processes through PVD–sputtering can be realized, investing in a real alternative to electroplated hexavalent chromium, usually denominated by chromium 6, regularly applied in electrodeposition processes of optical products in the automotive industry. At an early stage, experimental tests were carried out to understand which parameters are most suitable for obtaining chromium coatings with optical properties. To study the coating in a broad way, thickness and roughness analysis of the coatings obtained using SEM and AFM, adhesion analyzes with the scratch-test and transmittance by spectrophotometry were carried out. It was possible to determine that the roughness and transmittance decreased with the increase in the number of layers, the thickness of the coating increased linearly, and the adhesion and resistance to climatic tests remained positive throughout the study. Thus, this study allows for the understanding that thin multilayered Cr coatings can be applied successfully to polymeric substrates regarding optical applications in the automotive industry.

Influence of the Silver Content on Mechanical Properties of Ti-Cu-Ag Thin Films

In this work, the ternary titanium, copper, and silver (Ti-Cu-Ag) system is investigated as a potential candidate for the production of mechanically robust biomedical thin films. The coatings are produced by physical vapor deposition—magnetron sputtering (MS-PVD). The composite thin films are deposited on a silicon (100) substrate. The ratio between Ti and Cu was approximately kept one, with the variation of the Ag content between 10 and 35 at.%, while the power on the targets is changed during each deposition to get the desired Ag content. Thin film characterization is performed by X-ray diffraction (XRD), nanoindentation (modulus and hardness), to quantitatively evaluate the scratch adhesion, and atomic force microscopy to determine the surface topography. The residual stresses are measured by focused ion beam and digital image correlation method (FIB-DIC). The produced Ti-Cu-Ag thin films appear to be smooth, uniformly thick, and exhibit amorphous structure for the Ag contents lower than 25 at.%, with a transition to partially crystalline structure for higher Ag concentrations. The Ti-Cu control film shows higher values of 124.5 GPa and 7.85 GPa for modulus and hardness, respectively. There is a clear trend of continuous decrease in the modulus and hardness with the increase of Ag content, as lowest value of 105.5 GPa and 6 GPa for 35 at.% Ag containing thin films. In particular, a transition from the compressive (−36.5 MPa) to tensile residual stresses between 229 MPa and 288 MPa are observed with an increasing Ag content. The obtained results suggest that the Ag concentration should not exceed 25 at.%, in order to avoid an excessive reduction of the modulus and hardness with maintaining (at the same time) the potential for an increase of the antibacterial properties. In summary, Ti-Cu-Ag thin films shows characteristic mechanical properties that can be used to improve the properties of biomedical implants such as Ti-alloys and stainless steel.

Characteristics and Wear Mechanisms of TiAlN-Based Coatings for Machining Applications: A Comprehensive Review

The machining process is still a very relevant process in today’s industry, being used to produce high quality parts for multiple industry sectors. The machining processes are heavily researched, with the focus on the improvement of these processes. One of these process improvements was the creation and implementation of tool coatings in various machining operations. These coatings improved overall process productivity and tool-life, with new coatings being developed for various machining applications. TiAlN coatings are still very present in today’s industry, being used due to its incredible wear behavior at high machining speeds, high mechanical properties, having a high-thermal stability and high corrosion resistance even at high machining temperatures. Novel TiAlN-based coatings doped with Ru, Mo and Ta are currently under investigation, as they show tremendous potential in terms of mechanical properties and wear behavior improvement. With the improvement of deposition technology, recent research seems to focus primarily on the study of nanolayered and nanocomposite TiAlN-based coatings, as the thinner layers improve drastically these coating’s beneficial properties for machining applications. In this review, the recent developments of TiAlN-based coatings are going to be presented, analyzed and their mechanical properties and cutting behavior for the turning and milling processes are compared.

Biomimetic vs. Direct Approach to Deposit Hydroxyapatite on the Surface of Low Melting Point Polymers for Tissue Engineering

Polymers are widely used in many applications in the field of biomedical engineering. Among eclectic selections of polymers, those with low melting temperature (T_m < 200 °C), such as poly(methyl methacrylate), poly(lactic-co-glycolic acid), or polyethylene, are often used in bone, dental, maxillofacial, and corneal tissue engineering as substrates or scaffolds. These polymers, however, are bioinert, have a lack of reactive surface functional groups, and have poor wettability, affecting their ability to promote cellular functions and biointegration with the surrounding tissue. Improving the biointegration can be achieved by depositing hydroxyapatite (HAp) on the polymeric substrates. Conventional thermal spray and vapor phase coating, including the Food and Drug Administration (FDA)-approved plasma spray technique, is not suitable for application on the low T_m polymers due to the high processing temperature, reaching more than 1000 °C. Two non-thermal HAp coating approaches have been described in the literature, namely, the biomimetic deposition and direct nanoparticle immobilization techniques. In the current review, we elaborate on the unique features of each technique, followed by discussing the advantages and disadvantages of each technique to help readers decide on which method is more suitable for their intended applications. Finally, the future perspectives of the non-thermal HAp coating are given in the conclusion.

Effects of Substrate Rotation Speed on Structure and Adhesion Properties of CrN/CrAlSiN Multilayer Coatings Prepared Using High-Power Impulse Magnetron Sputtering

We investigated the effects of substrate rotation speed on the structural and mechanical properties of CrN/CrAlSiN multilayer coatings produced using high-power impulse magnetron sputtering (HiPIMS) on silicon and high-speed steel (HSS) substrates. Structural analysis and characterization of the multilayer coatings were performed using an X-ray diffractometer (XRD), field emission scanning electron microscopy (FE-SEM), an electron probe microanalyzer (EPMA), and a transmission electron microscope (TEM). The thickness of the bi-layer film depended on the substrate rotation speed, as follows: 12 (1.5 rpm), 9.5 (2 rpm), 6 (3 rpm), 4 (4 rpm), and 3.2 nm (5 rpm). The results revealed that the hardness and coating–substrate adhesion strength increased inversely with the thickness of the bi-layer. TEM analysis revealed smaller columnar structures in thinner CrN/CrAlSiN multilayer coatings. The highest results for hardness (20.1 GPa), elastic modulus (336 GPa), and adhesion strength (77 N) were obtained at a substrate rotation speed of 5 rpm. We also investigated the adhesion properties of the multilayer structures and formulated a hypothesis to explain adhesion strength.

Recent Advances on Coated Milling Tool Technology—A Comprehensive Review

The milling process is one of the most used processes in the manufacturing industry. Milling, as a process, as evolved, with new machines and methods being employed, in order to obtain the best results consistently. Milling tools have also seen quite an evolution, from the uncoated high-speed steel tool, to the now vastly used, coated tools. Information on the use of these coated tools in recent scientific researches was collected. The coatings that are currently being researched are going to be presented, highlighting some novel advances in the nanocomposite and diamond coatings area, as these coatings are seeing a growing use in the industry, with very satisfactory results, with performance and tool-life increase. Wear mechanism of various types of coatings are also a popular topic on recent research, as the cutting behavior of these coated tools provides valuable information on the tool’s-life. Furthermore, analysis of these mechanisms enables for the selection of the best coating type for the correct application. Recently, the employment of coated tools paired with sustainable lubrication methods as seen some use. As this presents the opportunity to enhance the coated tool’s and the process’s performance, obtaining better results, in terms of better tool-life and better surface finish quality, in a more sustainable fashion.

Technical Characteristics and Wear-Resistant Mechanism of Nano Coatings: A Review

Nano-coating has been a hot issue in recent years. It has good volume effect and surface effect, and can effectively improve the mechanical properties, corrosion resistance and wear resistance of the coatings. It is important to improve the wear resistance of the material surface. The successful preparation of nano-coatings directly affects the application of nano-coatings. Firstly, the preparation methods of conventional surface coatings such as chemical vapor deposition and physical vapor deposition, as well as the newly developed surface coating preparation methods such as sol-gel method, laser cladding and thermal spraying are reviewed in detail. The preparation principle, advantages and disadvantages and the application of each preparation method in nano-coating are analyzed and summarized. Secondly, the types of nano-coating materials are summarized and analyzed by inorganic/inorganic nanomaterial coatings and organic/inorganic nanomaterial coatings, and their research progress is summarized. Finally, the wear-resistant mechanism of nano-coatings is revealed from three aspects: grain refinement, phase transformation toughening mechanism and nano-effects. The application prospects of nano-coatings and the development potential combined with 3D technology are prospected.

Recent Advances in Turning Processes Using Coated Tools—A Comprehensive Review

Turning continues to be the largest segment of the machining industry, which highlights the continued demand for turned parts and the overall improvement of the process. The turning process has seen quite an evolution, from basic lathes using solid tools, to complex CNC (Computer Numerical Control) multi-process machines, using, for the most part, coated inserts and coated tools. These coatings have proven to be a significant step in the production of high-quality parts and a higher tool life that have captivated the industry. Continuous improvement to turning coated tools has been made, with many researches focusing on the optimization of turning processes that use coated tools. In the present paper, a presentation of various recently published papers on this subject is going to be made, mentioning the various types of coatings that have recently been used in the turning process, the turning of hard to machine materials, such as titanium alloys and Inconel, as well as the interaction of these coatings with the turned surfaces, the wear patterns that these coatings suffer during the turning of materials and relating these wear mechanisms to the coated tool’s life expectancy. Some lubrication conditions present a more sustainable alternative to current methods used in the turning process; the employment of coated tool inserts under these conditions is a current popular research topic, as there is a focus on opting for more eco-friendly machining options.

Numerical Simulation Applied to PVD Reactors: An Overview

The technological evolution in the last century also required an evolution of materials and coatings. Therefore, it was necessary to make mechanical components subject to heavy wear more reliable, improving their mechanical strength and durability. Surfaces can contribute decisively to extending the lifespan of mechanical components. Chemical vapor deposition (CVD) and physical vapor deposition (PVD) technologies have emerged to meet the new requirements that have enabled a remarkable improvement in the morphology, composition and structure of films as well as an improved adhesion to the substrate allowing a greater number of diversified applications. Thin films deposition using PVD coatings has been contributing to tribological improvement, protecting their surfaces from wear and corrosion, as well as enhancing their appearance. This process can be an advantage over other processes due to their excellent properties and environmental friendly behavior, which gives rise to a large number of studies in mathematical modelling and numerical simulation, like finite element method (FEM) and computational fluid dynamics (CFD). This review intends to contribute to a better PVD process knowledge, in the fluids and heat area, using CFD simulation methods focusing on the process energy efficiency improvement regarding the industrial context with the sputtering technique.

Sputtering Physical Vapour Deposition (PVD) Coatings: A Critical Review on Process Improvement and Market Trend Demands

Physical vapour deposition (PVD) is a well-known technology that is widely used for the deposition of thin films regarding many demands, namely tribological behaviour improvement, optical enhancement, visual/esthetic upgrading, and many other fields, with a wide range of applications already being perfectly established. Machining tools are, probably, one of the most common applications of this deposition technique, sometimes used together with chemical vapour deposition (CVD) in order to increase their lifespan, decreasing friction, and improving thermal properties. However, the CVD process is carried out at higher temperatures, inducing higher stresses in the coatings and substrate, being used essentially only when the required coating needs to be deposited using this process. In order to improve this technique, several studies have been carried out optimizing the PVD technique by increasing plasma ionization, decreasing dark areas (zones where there is no deposition into the reactor), improving targets use, enhancing atomic bombardment efficiency, or even increasing the deposition rate and optimizing the selection of gases. These studies reveal a huge potential in changing parameters to improve thin film quality, increasing as well the adhesion to the substrate. However, the process of improving energy efficiency regarding the industrial context has not been studied as deeply as required. This study aims to proceed to a review regarding the improvements already studied in order to optimize the sputtering PVD process, trying to relate these improvements with the industrial requirements as a function of product development and market demand.