Skip to main content
SpringerLink
Log in

Amorphous Carbon Coatings for Sheet-Bulk Metal Forming Tools

  • Conference paper
  • First Online:
Sheet Bulk Metal Forming (TCRC73 2020)

Part of the book series: Lecture Notes in Production Engineering ((LNPE))

  • 853 Accesses

Abstract

Sheet-bulk metal forming processes are commonly characterized by temporally and locally varying stress conditions, likely to affect material flow during forming and therefore the geometrical accuracy of formed parts. Local modifications of friction conditions can contribute to control the flow of material and simultaneously to reduce process forces and tool wear. This chapter discusses the systematical development and evaluation of amorphous carbon coatings aiming to adapt tribological conditions and to increase wear resistance of coated forming tools. Considering requirements and boundary conditions of forming processes, especially tungsten-modified amorphous carbon coatings demonstrated their beneficial tribological-mechanical behavior in high loaded sliding contacts due to low adhesion to steel. Coating development based on design of experiments revealed wide ranges of adjustable frictional behavior and mechanical properties contributing to local tribological conditions by the application of masking techniques. The coatings proved their operational performance in application-oriented forming processes, ranging from friction tests to simulated and experimental forming operations. Multilayer strategies increased the coatings’ toughness and their resistance to wear and fatigue. These benefits, along with an additional experimentally verified sensory function for wear condition monitoring, may provide an individual and improved service life of amorphous carbon coated forming tools.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Log in via an institution
Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 219.00
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Hardcover Book
USD 279.99
Price excludes VAT (USA)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

Notes

  1. 1.

    Test parameters: ball diameter dball = 3.969 mm, load FN = 10 N, initial mean pressure pm = 1.3 GPa, sliding distance s = 1 000 m, sliding radius r = 12 mm, sliding speed v = 0.1 ms−1.

References

  1. Merklein, M., Allwood, J.M., Behrens, B.-A., Brosius, A., Hagenah, H., Kuzman, K., Mori, K., Tekkaya, A.E., Weckenmann, A.: Bulk forming of sheet metal. CIRP Ann. – Manuf. Technol. 61(2), 725–745 (2012). https://doi.org/10.1016/j.cirp.2012.05.007

    Article  Google Scholar 

  2. Fontaine, J., Donnet, C., Erdemir, A.: Fundamentals of the tribology of DLC coatings. In: Donnet, C., Erdemir, A. (eds.) Tribology of Diamond-Like Carbon Films, pp. 139–154. Springer, Boston (2008)

    Chapter  Google Scholar 

  3. Schultrich, B., Weihnacht, V.: Tribologisches Verhalten von harten und superharten Kohlenstoffschichten. Vak. Forsch. Prax. 20(1), 12–17 (2008). https://doi.org/10.1002/vipr.200800338

    Article  Google Scholar 

  4. Doege, E., Behrens, B.-A.: Handbuch Umformtechnik. Springer, Heidelberg (2016)

    Book  Google Scholar 

  5. Liu, Y., Erdemir, A., Meletis, E.I.: An investigation of the relationship between graphitization and frictional behavior of DLC coatings. Surf. Coat. Technol. 86–87, 564–568 (1996). https://doi.org/10.1016/S0257-8972(96)03057-5

    Article  Google Scholar 

  6. Scharf, T.W., Singer, I.L.: Third bodies and tribochemistry of DLC coatings. In: Donnet, C., Erdemir, A. (eds.) Tribology of Diamond-Like Carbon Films, pp. 201–236. Springer, Boston (2008)

    Chapter  Google Scholar 

  7. Sánchez-López, J.C., Fernández, A.: Doping and alloying effects on DLC coatings. In: Donnet, C., Erdemir, A. (eds.) Tribology of Diamond-Like Carbon Films, pp. 311–338. Springer, Boston (2008)

    Chapter  Google Scholar 

  8. Strondl, C., Carvalho, N.M., De Hosson, J.T.M., Van Der Kolk, G.J.: Investigation on the formation of tungsten carbide in tungsten-containing diamond like carbon coatings. Surf. Coat. Technol. 162(2–3), 288–293 (2003). https://doi.org/10.1016/S0257-8972(02)00497-8

    Article  Google Scholar 

  9. Hetzner, H., Koch, J., Tremmel, S., Wartzack, S., Merklein, M.: Improved sheet bulk metal forming processes by local adjustment of tribological properties. J. Manuf. Sci. Eng. 133(6), 061011 (2011). https://doi.org/10.1115/1.4005313

    Article  Google Scholar 

  10. Hetzner, H., Tillmann, W., Tremmel, S., Herper, J.: Tribologische Dünnschichten für die Blechmassivumformung. In: Merklein, M., Bach, F.-W., Tekkaya, A.E. (eds.) Workshop Blechmassivumformung, vol. 1, pp. 139–158. Meisenbach, Bamberg (2011)

    Google Scholar 

  11. Kersting, P., Gröbel, D., Merklein, M., Sieczkarek, P., Wernicke, S., Tekkaya, A.E., Krebs, E., Freiburg, D., Biermann, D., Weikert, T., Tremmel, S., Stangier, D., Tillmann, W., Matthias, S., Reithmeier, E., Löffler, M., Beyer, F., Willner, K.: Experimental and numerical analysis of tribological effective surfaces for forming tools in sheet-bulk metal forming. Prod. Eng. 10(1), 37–50 (2016). https://doi.org/10.1007/s11740-015-0651-6

    Article  Google Scholar 

  12. Löffler, M., Andreas, K., Engel, U., Schulte, R., Groebel, D., Krebs, E., Freiburg, D., Biermann, D., Stangier, D., Tillmann, W., Weikert, T., Wartzack, S., Tremmel, S., Lucas, H., Denkena, B., Merklein, M.: Tribological measures for controlling material flow in sheet-bulk metal forming. Prod. Eng. 10(4–5), 459–470 (2016). https://doi.org/10.1007/s11740-016-0695-2

    Article  Google Scholar 

  13. Löffler, M., Andreas, K., Engel, U., Weikert, T., Tremmel, S., Wartzack, S., Stangier, D., Tillmann, W., Merklein, M.: Surface modifications for adaption of tribological conditions in sheet-bulk metal forming processes. In: Bobzin, K., Bouzakis, K.-D., Denkena, B., et al. (eds.) THe “A” Coatings 2016: Conference Proceedings, pp. 13–20. PZH Verlag, Garbsen (2016)

    Google Scholar 

  14. Hetzner, H., Schmid, C., Tremmel, S., Durst, K., Wartzack, S.: Empirical-statistical study on the relationship between deposition parameters, process variables, deposition rate and mechanical properties of a-C:H:W coatings. Coatings 4(4), 772–795 (2014). https://doi.org/10.3390/coatings4040772

    Article  Google Scholar 

  15. Czyżniewski, A., Gulbiński, W., Radnóczi, G., Szerencsi, M., Pancielejko, M.: Microstructure and mechanical properties of W-C:H coatings deposited by pulsed reactive magnetron sputtering. Surf. Coat. Technol. 205(19), 4471–4479 (2011). https://doi.org/10.1016/j.surfcoat.2011.03.062

    Article  Google Scholar 

  16. Hetzner, H.: Systematische Entwicklung amorpher Kohlenstoffschichten unter Berücksichtigung der Anforderungen der Blechmassivumformung. Dissertation, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU) (2014)

    Google Scholar 

  17. Hetzner, H., Zhao, R., Tremmel, S., Wartzack, S.: Tribological adjustment of tungsten-modified hydrogenated amorphous carbon coatings by adaption of the deposition parameters. In: Bouzakis, K.-D., Bobzin, K., Denkena, B., Merklein, M. (eds.) Proceedings of the 10th International Conference The “A” Coatings 2013. Shaker, Aachen, pp. 39–49 (2013)

    Google Scholar 

  18. Schmid, C., Hetzner, H., Tremmel, S., Hilpert, F., Durst, K.: Tailored mechanical properties and residual stresses of a-C:H:W coatings. Adv. Mater. Res. 996, 14–21 (2014). https://doi.org/10.4028/www.scientific.net/AMR.996.14

    Article  Google Scholar 

  19. Westergård, R., Svahn, F., Wiklund, U.: Novel load-carrying layers to support low-friction PVD coatings. Surf. Coat. Technol. 176(1), 14–22 (2003). https://doi.org/10.1016/S0257-8972(02)00770-3

    Article  Google Scholar 

  20. Weber, M., Bewilogua, K., Thomsen, H., Wittorf, R.: Influence of different interlayers and bias voltage on the properties of a-C:H and a-C:H:Me coatings prepared by reactive d.c. magnetron sputtering. Surf. Coat. Technol. 201(3–4), 1576–1582 (2006). https://doi.org/10.1016/j.surfcoat.2006.02.027

    Article  Google Scholar 

  21. Strondl, C., Carvalho, N.M., De Hosson, J.T.M., Krug, T.G.: Influence of energetic ion bombardment on W-C:H coatings deposited with W and WC targets. Surf. Coat. Technol. 200(1–4), 1142–1146 (2005). https://doi.org/10.1016/j.surfcoat.2005.02.182

    Article  Google Scholar 

  22. Voevodin, A.A.: Hard DLC growth and inclusion in nanostructured wear-protective coatings. In: Donnet, C., Erdemir, A. (eds.) Tribology of Diamond-Like Carbon Films, pp. 263–281. Springer, Boston (2008)

    Chapter  Google Scholar 

  23. Hetzner, H., Schaufler, J., Tremmel, S., Durst, K., Wartzack, S.: Failure mechanisms of a hydrogenated amorphous carbon coating in load-scanning tests. Surf. Coat. Technol. 206(23), 4864–4871 (2012). https://doi.org/10.1016/j.surfcoat.2012.05.077

    Article  Google Scholar 

  24. Hetzner, H., Schaufler, J., Tremmel, S., Durst, K., Wartzack, S.: Failure mechanisms of a tungsten-modified hydrogenated amorphous carbon coating in load-scanning tests. Surf. Coat. Technol. 212, 46–54 (2012). https://doi.org/10.1016/j.surfcoat.2012.09.012

    Article  Google Scholar 

  25. Li, F., Zhang, S., Kong, J., Zhang, Y., Zhang, W.: Multilayer DLC coatings via alternating bias during magnetron sputtering. Thin Solid Films 519(15), 4910–4916 (2011). https://doi.org/10.1016/j.tsf.2011.01.052

    Article  Google Scholar 

  26. Pujada, B.R., Tichelaar, F.D., Janssen, G.C.A.M.: Hardness of and stress in tungsten carbide-diamond like carbon multilayer coatings. Surf. Coat. Technol. 203(5–7), 562–565 (2008). https://doi.org/10.1016/j.surfcoat.2008.05.051

    Article  Google Scholar 

  27. Moreno-Bárcenas, A., Alvarado-Orozco, J.M., González-Carmona, J.M., Mondragón-Rodríguez, G.C., González-Hernández, J., García-García, A.: Synergistic effect of plasma nitriding and bias voltage on the adhesion of diamond-like carbon coatings on M2 steel by PECVD. Surf. Coat. Technol. 374, 327–337 (2019). https://doi.org/10.1016/j.surfcoat.2019.06.014

    Article  Google Scholar 

  28. Weikert, T., Tremmel, S., Wartzack, S.: Gezielte Anpassung lokaler Reibungszustände unter Einsatz wolframmodifizierter amorpher Kohlenstoffschichten. Tribol. Schmierungstech. 63, 5–11 (2016)

    Google Scholar 

  29. Weikert, T., Tremmel, S., Stangier, D., Tillmann, W., Krebs, E., Biermann, D.: Tribological studies on multi-coated forming tools. J. Manuf. Process. 49, 141–152 (2020). https://doi.org/10.1016/j.jmapro.2019.11.021

    Article  Google Scholar 

  30. Weikert, T., Tremmel, S.: Dünnschichtsensoren zur Verschleißdetektion als Beitrag zur Auslegung intelligenter Werkzeuge – eine Machbarkeitsstudie. In: Merklein, M., Behrens, B.-A., Tekkaya, A.E. (eds.) 4. Workshop Blechmassivumformung: Umformtechnische Herstellung von komplexen Funktionsbauteilen mit Nebenformelementen aus Feinblechen. FAU University Press, Erlangen, pp. 133–146 (2020)

    Google Scholar 

  31. Weikert, T., Tremmel, S.: Wear detection using carbon-based sensor coatings – a novel approach. In: Proceedings of the 18th Nordic Symposium on Tribology – NORDTRIB 2018, Uppsala, 18–21 June, 2018 (2018)

    Google Scholar 

Download references

Acknowledgment

The authors greatly acknowledge the continuous support of the German Research Foundation (DFG) within the scope of the Transregional Collaborative Research Centre for sheet-bulk metal forming (TCRC 73, Subproject B4). In addition, the authors are grateful to all laboratory assistants and students who supported the realization of this work.

Author information

Authors and Affiliations

  1. Engineering Design (KTmfk), Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Martensstraße 9, 91058, Erlangen, Germany

    Tim Weikert

  2. Engineering Design and CAD, Universität Bayreuth, Universitätsstraße 30, 95447, Bayreuth, Germany

    Stephan Tremmel

Authors
  1. Tim Weikert
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Stephan Tremmel
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Stephan Tremmel .

Editor information

Editors and Affiliations

  1. Lehrstuhl für Fertigungstechnologie, Friedrich-Alexander-Universität, Erlangen, Bayern, Germany

    Marion Merklein

  2. Institut für Umformtechnik & Leichtbau, Technische Universität Dortmund, Dortmund, Nordrhein-Westfalen, Germany

    A. Erman Tekkaya

  3. Institut für Umformtechnik und Umformmaschinen, Leibniz Universität Hannover, Garbsen, Niedersachsen, Germany

    Bernd-Arno Behrens

Rights and permissions

Reprints and permissions

Copyright information

© 2021 Springer Nature Switzerland AG

About this paper

Check for updates. Verify currency and authenticity via CrossMark

Cite this paper

Weikert, T., Tremmel, S. (2021). Amorphous Carbon Coatings for Sheet-Bulk Metal Forming Tools. In: Merklein, M., Tekkaya, A.E., Behrens, BA. (eds) Sheet Bulk Metal Forming . TCRC73 2020. Lecture Notes in Production Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-61902-2_9

Download citation

  • DOI: https://doi.org/10.1007/978-3-030-61902-2_9

  • Published:

  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-030-61901-5

  • Online ISBN: 978-3-030-61902-2

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics

Search

Navigation