SBIR Phase II: Temperature-Adaptive Nano-Crystalline Combinatorial Self-Lubricating Coating

该小型企业创新研究（SBIR）第二阶段研究项目在纹理cBN/TiN上开发了一种基于温度适应性纳米颗粒的固体润滑涂层（ZnO和MoS 2及其亚稳态形式），用于硬车削和干加工应用。独特的涂层刀具刀片能够不断地将润滑剂从纹理化cBN/TiN表面上的储存器中释放出来。 目前可用的固体润滑剂涂层不提供温度适应性，不适合硬车削应用。 与磨削相比，硬车削可以为制造商节省大量成本。 然而，可实现的表面光洁度至关重要。 初步结果表明，所提出的固体润滑涂层将提高硬车削表面光洁度，并提供更大的一致性。 此外，环境和竞争成本问题也促使制造商转向干式加工。 固体润滑涂层可以通过降低刀具和工件之间界面的摩擦力来提高干加工应用中的表面光洁度并延长刀具寿命。 可商购的固体润滑剂主要以层状结构配置。 随着磨损的进行，润滑层磨损并留下硬层。 因此，所提出的提供温度适应性同时还提供连续持久润滑的新颖配置具有巨大潜力。 拟议的研究是从纳米科学和工程投资中增加工业产品价值的一个很好的例子。该项目将提供更好的理解纳米颗粒涂层的摩擦化学如何提供温度适应性并影响加工性能。 此外，它将提供关于沿颗粒和粘合剂的边界的微摩擦学沿着的见解。涂层的主要应用将是硬车削和干加工中的切削工具。 这些都是非常重要和不断增长的商业市场。 其他市场可能是旋转机械、模具和其他磨损零件。该涂层的成功开发将有助于减少使用冷却剂造成的环境废物和污染物。 在切削过程中去除的用过的切削液和受污染的金属切屑的处理变得越来越困难和昂贵。 冷却剂的成本被广泛估计为占典型零件加工成本的15%以上。 该项目将有助于促进高速加工技术的采用，这被认为是美国在面对低劳动力率国家的激烈竞争时保持其制造业基础的关键因素。

This Small Business Innovation Research (SBIR) Phase II research project develops a temperature-adaptive nanoparticles-based solid lubricant coating (ZnO and MoS2 and their metastable forms) on textured cBN/TiN for hard turning and dry machining applications. The uniquely coated tool inserts are able to constantly release the lubricants out of reservoirs on the textured cBN/TiN surface. Currently available solid lubricant coatings do not offer temperature-adaptive properties and are NOT suitable for hard turning applications. Hard turning can offer manufacturers large cost savings compared to grinding. However, the achievable surface finish is critical. The preliminary results indicate that the proposed solid lubricant coating will enhance hard turning surface finish and provide greater consistency. In addition, both environmental and competitive cost issues are causing manufacturers to migrate toward dry machining. Solid lubricant coatings can both improve surface finish and extend the tool life in dry machining applications by lowering the friction at the interface between the tool and the workpiece. Commercially available solid lubricants are primarily configured in layered structures. As wear progresses, the lubrication layer wears away and leaves the hard layer behind. Thus, the proposed novel configuration that provides temperature adaptability while also offering continuous long lasting lubrication has great potential. The proposed research is an excellent example of adding value to industrial products from the investment in nano science and engineering. The project will provide improved understanding of how the tribo-chemistry of nanoparticle coatings can offer temperature adaptive properties and affect machining performance. Also, it will provide insights regarding the micro tribology along the boundary of the particles and binder(s). The primary application of the coating will be for cutting tools in hard turning and dry machining. These are very important and growing commercial markets. Additional markets could be for rotating machinery, dies and molds, and other wear parts. The successful development of the proposed coating will help reduce environmental waste and contaminants from the usage of coolants. The disposal of both the used cutting fluid and the contaminated metal chips that were removed during the cutting process is becoming harder and more costly. The cost of the coolant has been widely estimated as contributing over 15% of a typical part.s machining costs. The project will help facilitate the adoption of high speed machining techniques, which is considered a key factor for the United States maintaining its manufacturing base in the face of strong competition from low labor rate countries.