PVD coatings and their failure behavior under extreme high contact stresses

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Physical vapor deposition (PVD) coatings can be strategically applied on relatively small stamping die inserts which are installed in the areas where severe wear may occur. This approach is most likely necessary because PVD coatings can have a much higher hardness and wear resistance than electroplated or electroless coatings and nitrided steels. Lab tests are usually used to evaluate the PVD coatings before actual production applications. Spallation is the main failure mechanism of PVD hard coatings in stamping applications, which can not be observed in lab tests conducted in operating conditions that do not correspond to actual productions. In the proposed research, pin-on-disc sliding wear tests, ball-on-plate impact fatigue tests, and extended impact fatigue tests with additional sliding motions under ultra high contact stress will be chosen as the accelerated lab tests to simulate the wear conditions of spallation failures.