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

该小型企业创新研究(SBIR)第二阶段研究项目开发了一种基于纳米颗粒的温度自适应固体润滑剂涂层(氧化锌和二硫化钼及其亚稳形式)，用于硬车削和干式机械加工。独特的涂层刀具刀片能够不断地将润滑剂从有纹理的CBN/TiN表面的储油罐中释放出来。目前，现有的固体润滑剂涂层不具有温度适应性，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是至关重要的。初步结果表明，所提出的固体润滑剂涂层将提高硬车削表面的光洁度，并提供更大的一致性。此外，环境和竞争成本问题都在促使制造商转向干式加工。在干式机械加工应用中，固体润滑剂涂层可通过降低刀具与工件之间的摩擦力来改善表面光洁度并延长刀具寿命。商业上可获得的固体润滑剂主要配置为层状结构。随着磨损的进行，润滑层会磨损，留下硬质层。因此，所提出的新型结构在提供温度适应性的同时还提供持续持久的润滑，具有巨大的潜力。这项拟议的研究是通过投资纳米科学和工程为工业产品增值的一个很好的例子。该项目将提供对纳米颗粒涂层的摩擦化学如何提供温度适应特性和影响加工性能的更好理解。此外，它还将提供关于颗粒和粘结剂边界上的微观摩擦学的见解(S)。该涂层的主要应用将是硬车削和干式加工中的刀具。这些都是非常重要且不断增长的商业市场。其他市场可能是旋转机械、模具和其他易损件。拟议涂层的成功开发将有助于减少使用冷却剂造成的环境浪费和污染。处理用过的切削液和在切割过程中去除的受污染的金属切屑都变得更加困难和昂贵。冷却液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采用高速加工技术，这被认为是美国在面临来自低劳动力比率国家的激烈竞争时保持其制造基地的关键因素。

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.