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Amorphous hydrogenated carbon coatings (a-C:H) are well known for their exceptional tribological properties and are established as tool coatings for numerous forming applications. However, utilized in dry forming processes of aluminium a premature failure of an a-C:H coated tool often occurs due to strong adhesive wear. In this paper the run-in behaviour of a-C:H is investigated and as a possible reason for the premature tool failure evaluated. Therefore, oscillating ball-on-disc tribometer tests and strip drawing tests, for a more realistic emulation of real forming processes, will be conducted. According to these tests, the run-in period of a-C:H coatings is characterized by a high friction value and adhesion tendency and thus is decisive for the tool performance. Based on a subsequent analysis of the coating wear, the predominating wear mechanisms during the run-in period are discussed. The intrinsic nanomater-scale a-C:H roughness is identified as a crucial factor determining the tribological properties of the run-in behaviour. By reducing the coating roughness prior to the forming process, the adhesion tendency and friction value can be reduced significantly. The results demonstrate the tribological performance of pre-treated a-C:H coatings for dry sheet metal forming of aluminium EN AW-5083.

Thin film sensor systems based on hydrogenated carbon have the advantage to combine two very important characteristics in order to be used in measurement engineering: Firstly, the sensory layer demonstrates piezoresistive behavior and secondly its good properties related to hardness and wear resistance lead in a tribologically stable system. Therefore, the thin film sensor systems can be applied into the main distribution of force within machine parts or used for universal interchangeable sensor systems, e.g. sensory washers. In this article the deposition of a self-contained thin film sensor system on a large technical component (spindle shaft) is shown. The spindle shaft with a length of 480 mm and an outer diameter of 90 mm is part of a belt driven machining spindle for planing machines in woodworking industries. In order to establish a measurement system, which allows monitoring the clamping force of the tool holder and the imbalance of the mounted tool, the thin film sensor system was directly applied to the front surface of the spindle shaft. For this application a novel self-contained thin film sensor system was developed, which consists of an alumina layer for electrical isolation, a chromium layer to establish internal sensor electrodes, a piezoresistive hydrogenated carbon layer (1 μm) and a second covering wear resistance and insulation layer (silicon and oxygen modified carbon layer). The piezoresistive sensor layer and the top layer are part of the diamond like carbon layer family (Robertson, Diam Relat Mater 12:79-84, ; Bewilogua et al. DLC based coatings for tribological applications, pp. 67-75, ; Biehl et al. Thin Solid Films 515(3):1171-1175, , Novel measurement and monitoring system for forming processes based on piezoresistive thin film systems. Springer Verlag, pp. 879-883, ). [ABSTRACT FROM AUTHOR]

Abstract: The complex processes involved in the dry friction between two bodies are not yet fully understood. Towards an improved understanding of the associated tribological phenomena, the authors combine their skills and expertise in the respective fields of tribological experimentation, modeling, and simulation, as well as topological and chemical surface analyses. The aim of this research is more accurate predictions of the tribological behavior of minimal friction material mixtures. (© 2017 Wiley‐VCH Verlag GmbH & Co. KGaA, Weinheim) [ABSTRACT FROM AUTHOR]