Frictional behaviour and wear performance of a nitrocarburised coating sliding against AISI 1019 steel

This work employed a commercial nitrocaburising process to diffuse a coating onto M2 grade high speed tool steel. Properties of the nitrocaburised coating (CN) such as thickness, roughness and hardness were characterised using a variety of techniques including Glow-Discharge Optical Emission Spectrometry (GD-OES) and Scanning Electron Microscopy (SEM). A tribological test has been developed in which two nominally identical crossed cylinders slide over each other under selected test conditions. The test has been employed to investigate the wear performance of both CN coated and uncoated M2 specimens and frictional behaviour of the sliding interface between the tool and a AISI 1019 steel workpiece under unlubricated (dry) and lubricated conditions. Fourier Transform Infrared Spectroscopy (FTIR) was used to monitor the formation of chemical species from the oxidation of lubricant during tribological testing.

Fluidized bed CrN coating formation on prenitrocarburized plain carbon steel

CrN coatings were formed on plain carbon steel by prenitrocarburizing, followed by thermoreactive deposition and diffusion (TRD) in a fluidized bed furnace at 570 °C. During TRD, Cr was transferred from Cr powder in the fluidized bed to the nitrocarburized substrates by gas-phase reactions initiated by reaction of HCl gas with the Cr. The microstructural processes occurring in the white layer, caused by N diffusion toward the surface during this stage were studied. This study compares TRD atmospheres employing inert gas and HCl or inert gas, H2, and HCl. Surface characterization was performed by scanning electron microscopy (SEM), x-ray diffraction (XRD), and glow-discharge optical-emission spectroscopy (GDOES).

Cr(N,C) diffusion coating formation on pre-nitrocarburised H13 tool steel

The microstructural processes of Cr(N,C) coating formation by thermoreactive deposition and diffusion (TRD) on pre-nitrocarburised H13 tool steel were studied. Both nitrocarburising and TRD were performed in fluidized bed furnaces at 570 °C. During TRD, chromium was transferred from chromium powder in the fluidized bed, to the nitrocarburised substrates by gas-phase reactions initiated by reaction of HCl gas with the chromium. Addition of 30% H2 to the input inert gas was found to increase the rate of coating formation, although hydrogen reduction resulted in rapid loss of nitrogen to the surface. The reason for the increased rate of coating formation could not be established without further investigation, although several possible explanations have been proposed. It was found that porosity and the formation of an iron nitride ‘cover layer’ during nitrocarburising were the biggest influences on the microstructure of the Cr(N,C) coating. Microstructural characterization of the coatings was performed by scanning electron microscopy (SEM), X-ray diffraction (XRD) and glow discharge optical emission spectroscopy (GDOES).

Interaction between the coating characteristics of galvanneal steel and forming parameters during flat die drawing

Galvanneal steel is considered to be better for automotive applications than its counterpart, galvanized steel, mainly because of its superior coating and surface properties. Galvanneal steel is produced by hot dipping sheet steel in a bath of molten zinc with small, controlled, levels of aluminium, followed by annealing which creates a Fe-Zn intermetallic layer. This intermetallic layer of the coating improves spot weldability and improves subsequent paint appearance. However, if the microstructure of the coating is not properly controlled and forming parameters are not properly selected, wear of the coating could occur during stamping. Frictional sliding of the sheet between the tool surfaces results in considerable amount of coating loss. An Interstitial Free steel with a Galvanneal coating of nominally 60g/m2 was used for the laboratory experiments. Flat Face Friction (FFF) tests were performed with different forming conditions and lubricants to simulate the frictional sliding in stamping. Glow-Discharge Optical Emission Spectrometry (DG-OES) was used to measure the change in the coating thickness during sliding. Optical microscopy was considered for imaging the surfaces as well as an optical method to compare the changes in the coating thickness during the forming. The change to the Galvanneal coating thickness was found to be a function of forming parameters.

Enhanced degradation efficiency of toluene using titania/silica photocatalysis as a regeneration process

Three kinds of titania/silica pellets were prepared using the sol-gel method with surface areas of 50.4m² g-1, 421.1m².g^-1 and 89.1m².g^-1. An annular reactor was designed and built to determine the degradation efficiency of toluene and to investigate the relationship between the adsorption and desorption-photocatalytic processes. Surface area is an important factor influencing the adsorption-photocatalytic efficiency. Higher surface areas of pellets contribute to high rates of conversion of toluene. Un-reacted toluene and reaction intermediates accumulating on their surface deactivated the titania/silica catalyst. To overcome this problem, the adsorption and regeneration process were alternated in a dual reactor system. Connecting or disconnecting the toluene feed gas enabled one reactor to adsorb toluene, while the second reactor was regenerated by photocatalysis. Using UV irradiation and titania/silica pellets with high BET surface area (421.1 m².g^-1), the alternating adsorption/regeneration processes kept the degradation efficiency of toluene at 90% after 8 hours operation. By improving the adsorption-photocatalysis efficiency, and minimising the generation and accumulation of intermediate on the surface of pellets, the method extended catalyst life and maintained a high degradation efficiency of toluene.

Synthesis, polymerization and wool coating studies of 3-iso-butylpyrrole and 3-iso-pentylpyrrole

In a four-step method starting from pyrrole, the synthesis of 3-iso-butylpyrrole and 3-iso-pentylpyrrole, was achieved in 45 and 44% yields, respectively. Polymerization studies of these branched alkyl pyrroles are described and the results compared with those obtained for the unbranched structural isomers n-butyl and n-pentylpyrrole. A series of conductive textiles were produced by the chemical polymerization of the iso-alkylpyrroles using both solution and vapour polymerization techniques. Fabrics coated with poly-iso-alkylpyrrole formed using the solution polymerization method had a lower surface resistance than those formed using the vapour polymerization method. These conductivity results were in direct contrast to those previously obtained for 3-n-alkylpyrroles on fabrics. A remarkable crystal-like growth on the surface of the textile fabric was observed when solution polymerization of 3-iso-pentylpyrrole was employed—reinforcing the notion that subtle changes in monomer structure can drastically affect bulk polymer properties.

Polymerising pyrrole on polyester textiles and controlling the conductivity through coating thickness

The surface resistance of polypyrrole (PPy)-coated polyester fabrics was investigated and related to coating thickness, which was controlled by adjusting the reactant concentrations. The thickness of the coating initially increased rapidly followed by a steady increase when the concentration of pyrrole (Py) was larger than a concentration of approximately 0.4 mg/ml. The surface resistance decreased from 10⁶ to 10³ Ω with increase in pyrrole concentration within 0.2 mg/ml until the concentration reached a value of about 0.4 mg/ml, above which the rate of decrease diminished. The effect of initial treatment with monomer or oxidant prior to polymerisation reaction with regards to thickness and surface resistance was minimal. The immersion time of the textile into the monomer solution prior to polymerisation reaction did not have a significant effect on the abrasion resistance.

Non-isothermal crystallisation kinetics of self-assembled polyvinylalcohol/silica nano-composite

A novel polyvinylalcohol/silica (PVA/SiO₂) nano-composite is prepared with the self-assembly monolayer (SAM) technique. The SiO₂ nano-particles are homogenously distributed throughout the PVA matrixes as nano-clusters with an average diameter ranged from 15 to 240 nm depending on the SiO₂ contents. Using differential scanning calorimetry (DSC), the non-isothermal crystallisation behaviour and kinetics of the PVA/SiO₂ nano-composites are investigated and compared to those of the pure PVA. There are strong dependences of the degree of crystallinity (X_c), peak crystallisation temperature (T_p), half time of crystallisation (t_1/2), and Ozawa exponent (m) on the SiO₂ content and cooling rate. The crystallisation activation energy (E) calculated with the Kissinger model is markedly lower when a small amount of SiO₂ is added, then gradually increases and finally becomes higher than that of the pure PVA when there is more than 10% SiO₂ in the composite.

Dymanic mechanical analysis of polyvinylalcohol/silica nanocomposite

Polyvinylalcohol/Silica (PVA/SiO₂) nanocomposites with different SiO₂ contents are synthesized by employing a novel self-assembly monolayer (SAM) technique. The influence of the silica on dynamic mechanical properties of the nanocomposites is investigated by conducting dynamic mechanical analysis (DMA) and quasi-thermal mechanical analysis (Q-TMA). It is found that the storage modulus (E′), loss factor (tga), glass transition temperature (T_g), and activation energy (E_a) of prepared nanocomposites all show a strong dependence on the SiO₂ content. The Q-TMA results indicate that under a constant force, the elasticity of nanocomposites decreases with SiO₂ content, and the softening temperature moves to a higher temperature when more SiO₂ is added.

Improvement of adhesion of conductive polypyrrole coating on wool and polyester fabrics using atmospheric plasma treatment

In this paper wool and polyester fabrics were pretreated with atmospheric plasma glow discharge (APGD) to improve the ability of the substrate to bond with anthraquinone-2-sulfonic acid doped conducting polypyrrole coating. A range of APGD gas mixtures and treatment times were investigated. APGD treated fabrics were tested for surface contact angle, wettability and surface energy change. Effect of the plasma treatment on the binding strength was analyzed by studying abrasion resistance, surface resistivity and reflectance. Investigations showed that treated fabrics exhibited better hydrophilicity and increased surface energy. Surface treatment by an APGD gas mixture of 95% helium/5% nitrogen yielded the best results with respect to coating uniformity, abrasion resistance and conductivity.

Photochromic wool fabrics with enhanced durability and photochromic performance

In our previous work, we have produced a photochromic wool fabric by applying a thin layer of hybrid silica-photochromic dye onto the wool surface. The coating showed a very fast optical response, but had little influence on the fabric handle, however durability was low. In this context, we reported that durability of the hybrid layer can be improved by introducing epoxy groups into the silica matrix via co-hydrolysis and co-condensation of an alkyl trialkoxysilane (ATAS) and 3-glycidoxypropyltrimethoxysilane (GPTMS). The presence of epoxy groups in the silica enhanced both washing and abrasion durabilities. Also, the optical response speed was slightly increased as well. Effects of the type of alkyl silane and the GPTMS:alkyl silane ratio on the coating durability, fabric handle and optical response were examined.

Natural rubber nanocomposite reinforced with nano silica

Inorganic nano fillers have demonstrated great potential to enhance the properties of natural rubber (NR). The present article reports the successful development of a NR nanocomposite reinforced with nano silica (SiO2). Its dynamic mechanical properties, thermal aging resistance, and morphology are investigated. The results show that the SiO2 nanoparticles are homogenously distributed throughout the NR matrix in a form of spherical nano-cluster with an average size of 80 nm when the SiO2 content is 4 wt%. With the introduction of SiO2, the thermal resistance and the storage modulus of NR host significantly increase, and the activation energy of relaxation of the nanocomposite, compared to the raw NR, increases from 90.1 to 125.8 kJ/mol.