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Magnetron Sputtering vs. Electrodeposition for Hard Chrome Coatings: A Comparison of Environmental and Economic Performances.

ABSTRACT: The coating of materials with specific films is widely used to improve material properties and many technologies exist to perform it. In the last few years, the replacement of wet electrodeposition processes has been continuously encouraged in the EU due to the problematic waste management linked to those processes. In this paper, magnetron sputtering is studied as an alternative to conventional electrodeposition by comparing the technologies' environmental impacts and costs. From the study, it appears that while magnetron sputtering greatly reduces hexavalent chromium emissions over the production, it has an increased electricity consumption mostly due to its lower production capacity, thus leading to more greenhouse gas emissions. Furthermore, a short discussion on the quantification of the impact of hexavalent chromium emissions is conducted. Regarding costs, the electrodeposition process has a lower cost of investment and of consumables, but requires more work time for the different steps of the process, making the total price per functional unit roughly equal. However, the cost per functional unit strongly depends on assumptions on the required work time, for which a sensitivity study is performed. Finally, the impacts of these two competing coating processes are discussed to complete the technological comparison for the case of hard chromium deposition.

SUBMITTER: Merlo A

PROVIDER: S-EPMC8307072 | biostudies-literature |

REPOSITORIES: biostudies-literature

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Self-passivating (Re,Al)B<sub>2</sub> coatings synthesized by magnetron sputtering.

Project description:(Re0.67Al0.10)B2 and (Re0.74Al0.11)B2 solid solution as well as Re0.85B2 thin films were deposited by hybrid RF-DC magnetron sputtering. X-ray diffraction (XRD) showed that all films exhibit the ReB2 (P63/mmc) crystal structure. X-ray photoelectron spectroscopy (XPS) analyses performed on atmosphere exposed thin film surfaces suggest that ReB2 corrodes, consistent with literature, by forming perrhenic acid (HReO4) already after two days, while (Re0.74Al0.11)B2 forms a self-passivating Al-oxide layer preventing corrosion in a time period ? 60 days. Hence, it is evident that Al additions to ReB2 significantly increase the chemical stability during atmosphere exposure.

| S-EPMC6197250 | biostudies-literature

Nanoindentation dataset of silicon and hafnia doped silicon coatings produced by magnetron sputtering.

Project description:Mechanical properties of three different coatings comprising of pure silicon, 36 mol% HfO2-doped silicon and 60 mol% HfO2-doped silicon on SiC substrate material were obtained by nanoindentation. The coatings aim at oxidation protective layers in environmental barrier coating systems for SiC/SiC ceramic matrix composites (CMC). The examined coatings were produced by physical vapour deposition (magnetron sputtering) and have been tested under cycling conditions between room temperature and 1523?K until 100?h accumulated hot time. In order to measure the hardness and the reduced Young's modulus, a Berkovich tip has been used with a constant depth modulus of 100?nm and 160?nm. Two depth moduli have been chosen to investigate a possible volume impact on the mechanical properties. Six successfully produced indents have been averaged to examine the hardness and reduced Young's modulus. The testing has been done on polished cross sections thereby minimising the impact of the substrate material on the measured values. This article provides data related to "Hafnia-doped Silicon Bond Coats manufactured by PVD for SiC/SiC CMCs".

| S-EPMC7306585 | biostudies-literature

Co-electrodeposition of hard Ni-W/diamond nanocomposite coatings.

Project description:Electroplated hard chrome coating is widely used as a wear resistant coating to prolong the life of mechanical components. However, the electroplating process generates hexavalent chromium ion which is known carcinogen. Hence, there is a major effort throughout the electroplating industry to replace hard chrome coating. Composite coating has been identified as suitable materials for replacement of hard chrome coating, while deposition coating prepared using traditional co-deposition techniques have relatively low particles content, but the content of particles incorporated into a coating may fundamentally affect its properties. In the present work, Ni-W/diamond composite coatings were prepared by sediment co-electrodeposition from Ni-W plating bath, containing suspended diamond particles. This study indicates that higher diamond contents could be successfully co-deposited and uniformly distributed in the Ni-W alloy matrix. The maximum hardness of Ni-W/diamond composite coatings is found to be 2249 ± 23 Hv due to the highest diamond content of 64 wt.%. The hardness could be further enhanced up to 2647 ± 25 Hv with heat treatment at 873 K for 1 h in Ar gas, which is comparable to hard chrome coatings. Moreover, the addition of diamond particles could significantly enhance the wear resistance of the coatings.

| S-EPMC4770281 | biostudies-other

Optically Active TiO2:Er Thin Films Deposited by Magnetron Sputtering.

Project description:Titanium dioxide photoanodes for hydrogen generation suffer from a profound mismatch between the optical absorption of TiO2 and the solar spectrum. To solve the problem of low solar-to-chemical efficiency, optically active materials are proposed. In this work, TiO2 thin films containing erbium were deposited by radio frequency RF magnetron sputtering under ultrahigh vacuum conditions UHV. Morphology, structural, optical and electronic properties were studied. TiO2:Er thin films are homogenous, with uniform distribution of Er ions and high transparency over the visible VIS range of the light spectrum. However, a profound 0.4 eV blue shift of the fundamental absorption edge with respect to undoped TiO2 was observed, which can be attributed either to the size effect due to amorphization of TiO2 host or to the onset of precipitation of Er2Ti2O7 nanocrystals. Near-infrared NIR to VIS up-conversion is demonstrated upon excitation at 980 nm, while strong green photoluminescence at 525 and 550 nm occurs upon photon absorption at 488 nm.

| S-EPMC8348420 | biostudies-literature

Formation of Thin NiGe Films by Magnetron Sputtering and Flash Lamp Annealing.

Project description:The nickel monogermanide (NiGe) phase is known for its electrical properties such as low ohmic and low contact resistance in group-IV-based electronics. In this work, thin films of nickel germanides (Ni-Ge) were formed by magnetron sputtering followed by flash lamp annealing (FLA). The formation of NiGe was investigated on three types of substrates: on amorphous (a-Ge) as well as polycrystalline Ge (poly-Ge) and on monocrystalline (100)-Ge (c-Ge) wafers. Substrate and NiGe structure characterization was performed by Raman, TEM, and XRD analyses. Hall Effect and four-point-probe measurements were used to characterize the films electrically. NiGe layers were successfully formed on different Ge substrates using 3-ms FLA. Electrical as well as XRD and TEM measurements are revealing the formation of Ni-rich hexagonal and cubic phases at lower temperatures accompanied by the formation of the low-resistivity orthorhombic NiGe phase. At higher annealing temperatures, Ni-rich phases are transforming into NiGe, as long as the supply of Ge is ensured. NiGe layer formation on a-Ge is accompanied by metal-induced crystallization and its elevated electrical resistivity compared with that of poly-Ge and c-Ge substrates. Specific resistivities for 30 nm Ni on Ge were determined to be 13.5 ??·cm for poly-Ge, 14.6 ??·cm for c-Ge, and 20.1 ??·cm for a-Ge.

| S-EPMC7221967 | biostudies-literature

Hard Chrome-Coated and Fullerene-Doped Metal Surfaces in Orthopedic Bearings.

Project description:Metal-on-metal bearings for total hip replacements have been introduced as an alternative to polyethylene in young and more active patients. These have, however, been shown to be prone to implant malpositioning and have been limited by some specific design features. In that context, coatings present an option to increase wear resistance by keeping the high fracture strength of the metal substrate. A custom-made electroplating setup was designed for the coating of CoCr substrates using (a) an industrial standard chromium electrolyte; (b) a custom-made hexavalent chromium (Cr6+) electrolyte with a reduced chromium trioxide (CrO?) content, both without solid additives and (c) with the addition of fullerene (C60) nanoparticles; and (d) a trivalent chromium (Cr3+) electrolyte with C60 addition. All coatings showed an increase in microhardness compared with the metal substrate. Trivalent coatings were thinner (10 µm) than the hexavalent coatings (23-40 µm) and resulted in increased roughness and crack density. Wear was found to be reduced for the hexavalent chromium coatings by 70-84% compared with the CoCr-CoCr reference bearing while the trivalent chromium coating even increased wear by more than 300%. The addition of fullerenes to the electrolyte did not show any further tribological effect.

| S-EPMC5744384 | biostudies-literature

First Proof-of-Principle of Inorganic Lead Halide Perovskites Deposition by Magnetron-Sputtering.

Project description:The present work reports the application of RF-magnetron sputtering technique to realize CsPbBr 3 70 nm thick films on glass substrate by means of a one-step procedure. The obtained films show highly uniform surface morphology and homogeneous thickness as evidenced by AFM and SEM investigations. XRD measurements demonstrate the presence of two phases: a dominant orthorhombic CsPbBr 3 and a subordinate CsPb 2 Br 5 . Finally, XPS data reveals surface bromine depletion respect to the stoichiometrical CsPbBr 3 composition, nevertheless photoluminescence spectroscopy results confirm the formation of a highly luminescent film. These preliminary results demonstrate that our approach could be of great relevance for easy fabrication of large area perovskite thin films. Future developments, based on this approach, may include the realization of multijunction solar cells and multicolor light emitting devices.

| S-EPMC7022632 | biostudies-literature

Synthesis and Mechanical Characterization of a CuMoTaWV High-Entropy Film by Magnetron Sputtering.

Project description:Development of high-entropy alloy (HEA) films is a promising and cost-effective way to incorporate these materials of superior properties in harsh environments. In this work, a refractory high-entropy alloy (RHEA) film of equimolar CuMoTaWV was deposited on silicon and 304 stainless-steel substrates using DC-magnetron sputtering. A sputtering target was developed by partial sintering of an equimolar powder mixture of Cu, Mo, Ta, W, and V using spark plasma sintering. The target was used to sputter a nanocrystalline RHEA film with a thickness of ?900 nm and an average grain size of 18 nm. X-ray diffraction of the film revealed a body-centered cubic solid solution with preferred orientation in the (110) directional plane. The nanocrystalline nature of the RHEA film resulted in a hardness of 19 ± 2.3 GPa and an elastic modulus of 259 ± 19.2 GPa. A high compressive strength of 10 ± 0.8 GPa was obtained in nanopillar compression due to solid solution hardening and grain boundary strengthening. The adhesion between the RHEA film and 304 stainless-steel substrates was increased on annealing. For the wear test against the E52100 alloy steel (Grade 25, 700-880 HV) at 1 N load, the RHEA film showed an average coefficient of friction (COF) and wear rate of 0.25 (RT) and 1.5 (300 °C), and 6.4 × 10-6 mm3/N m (RT) and 2.5 × 10-5 mm3/N m (300 °C), respectively. The COF was found to be 2 times lower at RT and wear rate 102 times lower at RT and 300 °C than those of 304 stainless steel. This study may lead to the processing of high-entropy alloy films for large-scale industrial applications.

| S-EPMC7304825 | biostudies-literature

Organic-Inorganic Perovskite Films and Efficient Planar Heterojunction Solar Cells by Magnetron Sputtering.

Project description:Organic-inorganic halide perovskites have been widely used in photovoltaic technologies. Despite tremendous progress in their efficiency and stability, perovskite solar cells (PSCs) are still facing the challenges of upscaling and stability for practical applications. As a mature film preparation technology, magnetron sputtering has been widely used to prepare metals, metallic oxides, and some semiconductor films, which has great application potential in the fabrication of PSCs. Here, a unique technology where high-quality perovskite films are prepared via magnetron sputtering for controllable composition, solvent-free, large-area, and massive production, is presented. This strategy transforms the perovskite materials from powder to thin films by magnetron sputtering and post-treatment (vapor-assisted treatment with methanaminium iodide gas and methylamine gas treatment), which is greatly favorable to manufacture tandem solar cells. The power conversion efficiency (PCE) of PSCs with perovskite films fabricated by magnetron sputtering is 6.14%. After optimization, high-performance perovskite films with excellent electronic properties are obtained and stable PSCs with excellent reproducibility are realized, showing a PCE of up to 15.22%. The entirely novel synthetic approach opens up a new and promising way to achieve high-throughput magnetron sputtering for large-area production in commercial applications of planar heterojunction and tandem PSCs.

| S-EPMC8596124 | biostudies-literature

Resistive Switching Characteristics of Li-Doped ZnO Thin Films Based on Magnetron Sputtering.

Project description:A kind of devices Pt/Ag/ZnO:Li/Pt/Ti with high resistive switching behaviors were prepared on a SiO2/Si substrate by using magnetron sputtering method and mask technology, composed of a bottom electrode (BE) of Pt/Ti, a resistive switching layer of ZnO:Li thin film and a top electrode (TE) of Pt/Ag. To determine the crystal lattice structure and the Li-doped concentration in the resulted ZnO thin films, X-ray diffraction (XRD) and X-ray photoelectron spectroscopy (XPS) tests were carried out. Resistive switching behaviors of the devices with different thicknesses of Li-doped ZnO thin films were studied at different set and reset voltages based on analog and digital resistive switching characteristics. At room temperature, the fabricated devices represent stable bipolar resistive switching behaviors with a low set voltage, a high switching current ratio and a long retention up to 104 s. In addition, the device can sustain an excellent endurance more than 103 cycles at an applied pulse voltage. The mechanism on how the thicknesses of the Li-doped ZnO thin films affect the resistive switching behaviors was investigated by installing conduction mechanism models. This study provides a new strategy for fabricating the resistive random access memory (ReRAM) device used in practice.

| S-EPMC6515171 | biostudies-literature

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