Jerzy Ratajski

Design, Control and in Situ Visualization of Gas Nitriding Processes

The article presents a complex system of design, in situ visualization and control of the commonly used surface treatment process: the gas nitriding process. In the computer design conception, analytical mathematical models and artificial intelligence methods were used. As a result, possibilities were obtained of the poly-optimization and poly-parametric simulations of the course of the process combined with a visualization of the value changes of the process parameters in the function of time, as well as possibilities to predict the properties of nitrided layers. For in situ visualization of the growth of the nitrided layer, computer procedures were developed which make use of the results of the correlations of direct and differential voltage and time runs of the process result sensor (magnetic sensor), with the proper layer growth stage. Computer procedures make it possible to combine, in the duration of the process, the registered voltage and time runs with the models of the process.

Modeling of Microhardness Profile in Nitriding Processes Using Artificial Neural Network

A artificial neural network was assigned to modeling of hardness profiles in the nitrided layer. In the model developed, a feed-forward neural network was applied. The designed network possesses good capacities to generalize knowledge included in experiential data. Matching the model with the training data made it possible to determine, with a good approximation, hardness profiles, which make up a set of verifying data.

Application of dilatometry with modulated temperature for thermomechanical analysis of anti-wear coating/substrate systems

Abstract Modern vacuum-plasma surface modification technologies of tools for metal and wood machining are based inter alia on the deposition of thin gradient and multilayer protection coatings with a thickness of several micrometers. Exploitation of tools are frequently carried out in complex tribological nodes, where next to mechanical loads, there are significant changes in temperature at the interface of the tool/workpiece material; hence, the knowledge of the thermomechanical stability of the coatings operating under these conditions is an important criterion used in the processes of designing of wear-resistant coating technology. In this paper, the objects of research were three types of gradient PVD coating/molybdenum substrate systems, for which time courses of amplitudes of elongation and equivalent thermal expansion coefficients of the systems were measured. Experimental measurements were made using a temperature-modulated dilatometry using concepts of dynamic load thermomechanical analysis. It was demonstrated that the developed method allows a quantitative determination of the influence of the gradient layer type on the total elongation of the substrate of the system. It was also shown that the changes of thermomechanical properties of the systems during annealing process are correlated with the time evolution of the equivalent thermal expansion coefficient. In addition, using the concepts of transition function describing the continuous change of physical and chemical parameters as a function of the spatial variables and finite element method for each of the systems, the distributions of internal thermal stresses were determined.

Investigations on the Thermo-Mechanical Properties of CrN/CrCN Gradient Coatings Using a Thermo-Dilatometric Method

The paper describes issues related to the use of dilatometric methods for the study of thermo-mechanical properties of PVD gradient coatings. Tests were conducted on three types of CrCN / CrN coatings, which differed in the nature of the change of physico-chemical parameters in the gradient transition layer, deposited on a molybdenum substrate with the use of the cathodic arc evaporation method. The scope of the experimental studies included an analysis of the changes of the thermal “extortion” of the substrate – PVD coating system during annealing processes. In parallel, for comparison purposes, a mathematical description was proposed of gradient coatings containing the transition functions of material parameters. These functions describe the changes of such parameters as the Youngs modulus, the Poissons ratio, the thermal expansion coefficient, and the density as a function of spatial variables. Using the mathematical description proposed, numerical calculations of the state of thermal stress and strain for coatings are represented, respectively, by the transition function forms (a stepped, square, and square root) were carried via FEM. Based on the experimental and computational results obtained, the comparison between the elongation of the tested samples, and the state of thermal stress and strain in the substrate-gradient coating systems analysed were all specified.

Wear and Corrosion Behavior of CrCN/CrN Coatings Deposited by Cathodic arc Evaporation on Nitrided 42CrMo4 Steel Substrates

In the paper, the results of wear and corrosion tests of the CrCN/CrN multilayer coatings, formed by cathodic arc evaporation on 42CrMo4 (AISI 4140) steel substrates are presented. The substrates were subjected to thermo-chemical treatment–nitriding with various nitriding potential. The results of nitriding were determined by XRD and the hardness profile in the samples cross-section. The morphology of thin coatings was examined with SEM. A Vickers FV-700 and Fisherscope HM2000 hardness testers enabled to investigate hardness of steel substrates and CrCN/CrN coatings respectively. A pin-on-disc wear tests were used to determine the hardness and tribological parameters of the coatings: the coefficient of the friction and wear rate. The scratch test and Rockwell test were applied to assess the adhesion of the coatings to the substrates. The corrosion properties of coating–steel substrate systems were investigated using potentiodynamic polarisation tests. Corrosion potential, corrosion current density and polarization resistance were determined. It was found that that the nitriding of steel substrates improves properties of the coating–substrate system. The nitriding 42CrMo4 steel substrate with low nitriding potential enable to obtain substrates without surface “white layer” what favours good adhesion of the coating to the substrate. The CrCN/CrN multilayer coating–steel substrate systems show good mechanical and tribological properties and corrosion resistance.

Development of Nitrided Layer during Nitriding of Steel

The present work is devoted to research the influence of micro-structural evolution of the compound zone (iron (carbo)nitrides zone) upon development of hardness profiles in diffusion zone. A different phase structure of iron (carbo)nitrides zone on steel as compared to iron, further changing with the process, may result in upsetting the quasi-equilibrium of nitrogen concentration in the iron (carbo)nitrides zone/diffusion zone interface and may as a result have impact on the kinetics of this layer’s growth. Aimed at solving this problem there was a research carried out to evaluate influence of (carbo)nitrides zone, with intentionally created diametrically different phase composition, on hardness profiles in the diffusion zone. Based on the research conducted, it was shown that the evolution of phase structure of the compound zone contributes significantly, regardless of nitrogen potential and temperature, to the formation of the diffusion zone and in particular to its effective thickness. It makes this complex picture of nitrided case development on steel even more intricated.