Method for the manufacture of an article and an article
A method for the manufacture of an article having first and second surface regions of different coefficients of friction in a treatment chamber with a rotary support for the articles and capable of simultaneously carrying out at least two PVD coating processes. The first PVD coating process is carried out with a comparatively directed vapor flux from one or more targets which can compose one or more of the elements B, Si, Ti, V, Cr, Zr, Nb, Mo, Hf, Ta and W, carbides of these elements and carbon. A second PVD coating process is carried out with a comparatively less directed or non-directed vapor flux of carbon.
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The present invention relates to a method for the manufacture of an article having a first and a second surface region of different coefficients of friction using a treatment chamber suitable for the carrying out of PVD processes.
The invention is concerned with a new concept belonging to the invention to the effect that it must be possible to provide a relatively high coefficient of friction on a first surface region and a relatively low coefficient of friction on a second surface region by means of a PVD process at a reasonable cost.
Examples for applications where such a process could be useful are, for example:
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- links of driving chains which are installed in infinitely variable drives;
- bearings which should have a high coefficient of friction on the outside so that they can be held in a housing without slipping, but which should have a lower coefficient of friction on the inside so that they can provide the journalling of a shaft or another component with extremely low wear properties, and
- fastener elements and washers for fastener elements. For example, a washer for a nut should have a higher coefficient of friction on the surface facing the component so that the washer does not turn on the component and damage the component when the nut is tightened, while the coefficient of friction for the pair washer/nut should be small so that the nut can be properly tightened, for which a relative rotary movement is required between the nut and the stationary washer.
In order to satisfy this object, the initially named method is characterized in accordance with the invention by at least two PVD coating processes being carried out at the same time in the treatment chamber, with the first PVD coating process being carried out with a comparatively directed vapor flux from one target or from a plurality of targets which can comprise one or more of the elements B, Si, Ti, V, Cr, Zr, Nb, Mo, Hf, Ta and W, carbides of the said elements and carbon and with the second PVD coating process being carried out with a comparatively less directed or non-directed vapor flux of carbon.
The invention is based on the recognition that carbides consisting of the said elements and carbon, in particular coatings with incorporated hydrogen, have a coefficient of friction which is dependent on the composition of the layer. For example, a coating B4C—C:H with 55 atomic % of boron and consequently 45 atomic % of C:H has a coefficient of friction of 0.2, whereas the same coating with 80 atomic % of boron has a coefficient of friction of 0.9.
A composition-dependent coefficient of friction can be found in all said elements, although the exact compositions required to produce clearly different coefficients of friction differ in each case. For tungsten, for example, a composition of W—C:H with 50 at % W has a high coefficient of friction, whereas with 15 at % W and a consequently higher proportion of carbon a low coefficient of friction results.
As a result of the deposition of the carbide layer from a comparatively directed vapor flux, this coating is preferably effected on the surface region which is perpendicular to and facing the vapor flux, whereas a considerably thinner coating is formed on surfaces which are not perpendicular to the vapor flux, i.e. are not facing it.
By the carbon vapor flux being comparatively less directed or non-directed, i.e. de facto forming a carbon cloud, the carbon is present at all surface regions equally with an approximately constant distribution density. As the carbon on the first surface region mixes with a larger supply of carbide molecules, a coating with relatively little carbon is effected there, whereas a high carbon concentration is achieved on the second surface region where comparatively few molecules of the carbide are deposited due to the directed properties of the vapor flux.
Thus, different carbon contents are present on the two said surface regions which result in the different coefficients of friction on these surface regions desired in accordance with the invention.
While, strictly speaking, it is not necessary to provide any movements of the articles to carry out the method in accordance with the invention, particularly when only a single article is to be coated, it is, however, advisable for reasons of process economy and for the generation of a uniform coating to arrange the object or a plurality of objects on a rotary support in a manner known per se.
The two PVD coating processes can be realized in a variety of ways.
It is possible, for example, to carry out the two PVD coating processes by using a single PVD coating apparatus. To realize this, one proceeds in accordance with claim 2 such that a metal vapor or metal and carbide ions are generated with one or more targets using a cathode sputtering process or an arc discharge vaporization process and directed onto the article as a directed vapor flux, with the cathode sputtering process or the arc discharge vaporizing process resulting in or contributing to the generation of a plasma in the treatment chamber and thereby to the. generation, from a hydrocarbon atmosphere present in the treatment chamber, of carbon ions and molecules in the form of a less directed or non-directed vapor flux, which is at least partially incorporated into the coating being formed on the article.
The carbon ions and molecules are thus generated in a plasma which is anyway present in the cathode sputtering mode or the arc discharge vaporization mode due to the operation of a cathode (target). This plasma can also be expanded by the use of selected magnetic fields in order to increase the supply of carbon ions and molecules and above all to bring it into the region of the article. The magnetic fields can also be the magnetic fields which are needed for the operation of the cathode as an imbalanced magnetron.
Another possibility of carrying out the two PVD coating processes is to use first and second PVD apparatuses in the treatment chamber, with the arrangement being able to be chosen so that at least a first PVD coating apparatus and a second PVD coating apparatus are used in the treatment chamber, with the first PVD coating apparatus generating a comparatively directed vapor flux from a target or a plurality of targets consisting of one or more of the elements B, Si, Ti, V, Cr, Zr, Nb, Mo, Hf, Ta and W, carbides of the said elements and carbon, and the second element generating a comparatively less directed or non-directed vapor flux of carbon.
To carry out the method in accordance with the invention in accordance with the first variant, the article or plurality of articles can be arranged on a rotary support and be moved through the comparatively directed vapor flux of the first PVD coating apparatus by a rotary movement of the support, with said rotary movement being either a simple rotary movement so that the article or each article has a given, at least substantially constant, effective orientation with respect to the said vapor flux, or a complex rotary movement, for example a rotary movement in which the article or each article is rotated around its own axis, with the individual rotary movements being synchronized in the case of a more complex rotary movement such that the article or each article also has a given, at least substantially constant, effective orientation with respect to the said vapor flux.
By the effective orientation of the article always being identical with respect to the directed vapor flow of the first PVD coating apparatus, the first surface region is preferably coated. By the vapor flux of carbon being less directed, it is present at all surface regions, whereby the different compositions of the first and second surface regions are created, as described above. The first PVD coating apparatus generating a comparatively directed vapor flux can be one or more of the following coating apparatuses:
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- an arc discharge vaporization device;
- a cathode sputtering device, for example in the form of a magnetron or an imbalanced magnetron;
- a linear ion source, in particular a source of this kind for the generation of carbon ions such as a plasma generating source with a heating filament.
The second PVD coating apparatus generating a comparatively less directed or non-directed vapor flux is one or more of the following coating apparatuses:
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- an ion source, in particular for the generation of carbon ions from a gaseous hydrocarbon supplied to the treatment chamber;
- a plasma source, for example with a plasma generated from a microwave source, in particular a high-power microwave source.
A second way of satisfying the object underlying the application using a method of the kind initially mentioned is characterized in that at least a first PVD coating apparatus and a second PVC coating apparatus are used in the treatment chamber, in that the article or plurality of articles is arranged on the rotary support, in that the or each article is furthermore rotatable around its own axis on the rotary support and in that the rotary movement around the or each article's own axis and the rotary movement around the axis of rotation of the support are synchronized such that the first surface region is coated preferably by the first coating apparatus and the second surface region preferably by the second coating apparatus.
In this variant of the invention, one works mainly with two directed vapor fluxes: on the one hand of metal, B and/or Si atoms or ions and carbon which result in the formation of a carbide on the article, and on the other hand of carbon, with it being possible here to generate different carbon contents, and thus also the desired different coefficients of friction, on the first and second surface regions thanks to the special synchronization of the rotary movements of the article(s).
With a carefully selected procedure, it is possible to ensure that a multi-layer coating is formed on the second surface region; said multi-layer coating being described exactly in the simultaneously filed German patent application 10005614.8 with the title “A method for the manufacture of coatings and of an article”, in which an extremely hard, wear-resistant and elastic surface with a low coefficient of friction can be generated.
The contents of this simultaneously filed application are also made part of the disclosure of the present application by way of the above reference.
Particularly preferred embodiments of the invention can be found in the further method claims.
The present invention, however, also comprises articles with corresponding coatings and defined by claims 24 to 30.
The invention is described in more detail in the following with reference to embodiments with and to the drawings, which show:
With reference to
Such a uniform distribution or a similar distribution which indeed has partially identically directed movements, but also movements of the ions and atoms in all directions, also results for other PVD coating apparatuses which are considered comparatively less directed or non-directed carbon sources for the purpose of the present invention.
With reference to
In the form shown in
Two targets 22, 24 and 26 and 28 respectively are installed in each of the chamber doors 18 and 20. The total structure in the closed state in accordance with
The reference numeral 36 indicates a feed stub for inert gas, for example argon, whereas the reference number 38 indicates a feed for a gas consisting of hydrocarbon.
In
Each article 40 to be coated in the example of
It is understood that the articles 40 are shown here merely by way of example and that the articles to be coated do not have to have any special shape. They must only have at least two difference surface regions which should be provided with coatings of different coefficients of friction and for this purpose must lie spatially apart from one another, next to one another and/or at different angles to one another.
In
The reference numeral 48 here indicates a carbon source, for example in the form of a graphite target, which is mounted on the upper wall 49 of the middle part 11 of the treatment chamber in accordance with
Carbon is thus present uniformly on all surfaces of the article 40. This results in the manner indicated above to an increased carbon content on the side areas 44 and to a lower carbon content on the surface regions 42 of the article 40. In addition to this arrangement, a hydrocarbon gas, e.g. C2H2, is fed into the treatment chamber in a known manner via the feed 38. This gas is split into carbon and hydrogen as a result of the conditions prevailing in the chamber. The carbon can also be deposited on the articles 40. It is, however, also important that the hydrogen is partially incorporated into the coatings on the surfaces 42 and 44, namely in the carbon content present there. This hydrogen helps to lower the coefficient of friction in the areas 44 with a high carbon content.
The arrangement in accordance with
It should be emphasized here, and also for the representation of
Although the carbon source 48 in the form of a graphite target is used in the examples in accordance with
It will be appreciated that a coating of the articles 40 in the embodiment in accordance with
The same reference numerals are also used in the arrangement of
The reference numerals 24 and 28 here also—in accordance with the convention used for reference numerals—indicate targets made of B4C which are operated in the arc discharge vaporization mode, as indicated by the permanent magnets 46. The reference numbers 76 here indicate carbon ion sources which are, however, here made as linear, i.e. directed, ion sources.
The embodiment of
Finally,
Although all the preceding examples deal with a coating of B4C, carbides of all the above-named elements can be considered instead of B4C. In the event of B4C and Si, the corresponding targets 22 to 28 consist preferably of the carbide itself. This can also apply to the other elements.
However, it is also possible to form the carbides in the treatment chamber. For this purpose, corresponding quantities of carbon must be made available, which is best done if some targets consist of graphite. Optionally, additional targets can be used in free regions of the treatment chamber.
In the arrangement with synchronized rotary movements, there is also the possibility of forming coatings on the side areas 44 which consist of thin, alternating layers of, for example, WC and C, with the individual layer thicknesses of the carbides being in the range between 1 and 3 nm, and is preferably approximately 2 nm, and the layer thickness of each carbon layer being in the range between approximately 1 nm and approximately 20 nm, preferably between 2 and 4 nm, with the first layer of the layer sequence preferably consisting of carbon and advantageously being somewhat thicker than the other layers, for example 500 nm.
In this embodiment, the carbon of the carbon layers is present with a comparatively high percentage of sp3 bonds, i.e. diamond-like bonds, whereby on the one hand an extremely hard layer with a low coefficient of friction can be generated, but on the other hand also a layer which is elastic and therefore eminently suitable for bearing purposes. The alternating sequence of layers of WC and C is only given by way of example here. The other above-named elements can equally be considered. If the number of sp3 bonds is put into relation with the number of sp2 bonds, then this ratio (measured with conventional measurement methods such as Raman spectroscopy) is larger than 1.
Finally, it should be pointed out that it is advantageous to deposit the coating in accordance with the invention on a bonding layer of, for example, Cr or Ti.
The deposition of this Ti or Cr layer can be realized with the same treatment chamber in accordance with the invention. It is only necessary to provide a target made of the corresponding material, with such a target being able to be provided in addition to the said targets, for example in a free region of the chamber doors which can be swung open or in any other free regions within the middle part 11.
It should also be emphasized that the different examples given here are given purely by way of example. They are in no way to be understood as a final list of all possibilities serving the realization of the invention. Instead, all apparatuses can be used which are covered by the scope of protection of the claims.
Claims
1. A method for the manufacture of an article having a first surface region and a second surface region of different coefficients of friction using a treatment chamber suitable for the carrying out of a PVD process preferably with a rotary support for the article or a plurality of such articles characterized in that at least two PVD coating processes are carried out in the treatment chamber at the same time, with the first PVD coating process being carried out with a comparatively directed vapor flux from one target or from a plurality of targets which can compose one or more of the elements B, Si, Ti, V, Cr, Zr, Nb, Mo, Hf, Ta and W, carbides of the said elements and carbon, and the second PVD coating process being carried out with a comparatively less directed or non-directed vapor flux of carbon.
2. A method in accordance with claim 1 characterized in that the two PVD coating processes are performed by using a single PVD coating apparatus such that a metal vapor or metal and carbide ions are generated with one or more targets using a cathode sputtering process or an arc discharge vaporization process and are directed to the article as a directed vapor flux, with the cathode sputtering process or the arc discharge vaporization process resulting in or contributing to the generation of a plasma in the treatment chamber and hereby to the generation from a hydrocarbon atmosphere present in the treatment chamber of carbon ions and molecules in the form of a less directed or non-directed vapor flux which are at least partially incorporated into the coating being formed on the article.
3. A method in accordance with claim 2 characterized in that magnetic fields, in particular the magnetic fields associated with an imbalanced magnetron, are used to generate an expanded plasma supplying carbon ions and molecules to the article.
4. A method in accordance with claim 1 characterized in that the two PVD coating processes are carried out in the treatment chamber using a first PVD coating apparatus and a second PVD coating apparatus.
5. A method in accordance with claim 4 characterized in that the article or a plurality of articles is arranged on a rotary support and is moved through the comparatively directed vapor flux of the first PVD coating apparatus by a rotary movement of the support, with said rotary movement being either a simple rotary movement so that the article or each article has a given, at least substantially constant, effective orientation with respect to the said vapor flux, or a complex rotary movement, for example a rotary movement in which the article or each article is rotated around its own axis, with the individual rotary movements being synchronized in the case of a more complex rotary movement such that the article or each article has a given, at least substantially constant, effective orientation with respect to the said vapor flux.
6. A method in accordance with claim 4, characterized in that the first PVD coating apparatus generating a comparatively directed vapor flux is one or more of the following coating apparatuses:
- an arc discharge vaporization device;
- a cathode sputtering device, for example in the form of a magnetron or an imbalanced magnetron;
- a linear ion source, in particular a source of this kind for the generation of carbon ions such as a plasma generating source with a heating filament.
7. A method in accordance with claim 1 characterized in that the second PVD coating apparatus generating a comparatively less directed or non-directed vapor flux is one or more of the following coating apparatuses:
- an ion source, in particular for the generation of carbon ions from a gaseous hydrocarbon supplied to the treatment chamber;
- a plasma source, for example with a plasma generated from a microwave source, in particular a high-power microwave source.
8. A method in accordance claim 1 characterized in that a homogeneous layer is formed on the first surface region and consists of a car-bide of one or more of the said elements and carbon with a relatively low carbon component, whereby a relatively high coefficient of friction is achieved, and in that a homogeneous layer is formed on the second surface region and consists of a carbide of one or more of the said elements and carbon with a relatively high carbon component, whereby a relatively low coefficient of friction is achieved.
9. A method in accordance with claim 1 characterized in that when boron is used, the coating of the first surface region contains at least substantially approximately 80 at % boron and the remainder consists of 20 at % of carbon and incorporated hydrogen as well as any contaminants, whereas the second surface region has a coating of approximately 55 at % boron and the remainder consists of 45 at % of carbon and incorporated hydrogen as well as any contaminants.
10. A method in accordance with claim 1 characterized in that when tungsten is used, the coating of the first surface region contains at least substantially approximately 50 at % tungsten and the remainder consists of 50 at % of carbon and incorporated hydrogen as well as any contaminants, whereas the second surface region has a coating of approximately 15 at % tungsten and the remainder consists of 85 at % of carbon and incorporated hydrogen as well as any contaminants.
11. A method in accordance with claim 1 characterized in that a bonding layer of, for example, Cr or Ti is formed on the said surface regions of the article or of each article prior to the generation of the respective coatings.
12. A method in accordance with claim 11 characterized in that the thickness of the bonding layer on the first surface is in the region of 0.1 μm to 1 μm and on the second surface in the region of 0.1 μm to 1 μm.
13. A method in accordance with claim 1 characterized in that the thickness of the coating on the two surface regions, including any bonding layer, is in total between 0.5 μm and 5 μm.
14. A method for the manufacture of an article having a first surface region and a second surface region of different coefficients of friction using a treatment chamber suitable for the carrying out of PVD processes and having a rotary support for the article or a plurality of such articles characterized in that at least a first PVD coating apparatus and a second PVD coating apparatus are used in the treatment chamber, in that the article or plurality of articles is arranged on the rotary support, in that the or each article is furthermore rotatable around its own axis on the rotary support and in that the rotary movement around the or each article's own axis and the rotary movement around the axis of rotation of the support are synchronized such that the first surface region is coated preferably by the first coating apparatus and the second surface region preferably by the second coating apparatus.
15. A method in accordance with claim 14 characterized in that the first PVD coating apparatus and the second PVD coating apparatus are apparatuses which each generate a comparatively directed vapor flux.
16. A method in accordance with claim 14 characterized in that the first PVD coating apparatus and/or the second PVD coating apparatus is one of the following apparatuses:
- an arc discharge vaporization device;
- a cathode sputtering device, for example in the form of a magnetron or an imbalanced magnetron;
- a linear ion source, in particular a source of this kind for the generation of carbon ions such as a plasma generating source with a heating filament.
17. A method in accordance with claim 14 characterized in that a homogeneous layer is formed on the first surface region and consists of a carbide of one or more of the said elements and carbon with a relatively low carbon component, whereby a relatively high coefficient of friction is achieved; and in that a homogeneous layer is formed on the second surface region and consists of a carbide of one or more of the said elements and carbon with a relatively high car-bon component, whereby a relatively low coefficient of friction is achieved.
18. A method in accordance with claim 14 characterized in that when boron is used, the coating of the first surface region contains at least substantially approximately 80 at % boron and the remainder consists of 20 at % of carbon and incorporated hydrogen as well as any contaminants, whereas the second surface region has a coating of approximately 55 at % boron and the remainder consists of 45 at % of carbon and incorporated hydrogen as well as any contaminants.
19. A method in accordance with claim 14 characterized in that when tungsten is used, the coating of the first surface region contains at least substantially approximately 50 at % tungsten and the remainder consists of 50 at % of carbon and incorporated hydrogen as well as any contaminants, whereas the second surface region has a coating of approximately 15 at % tungsten and the remainder consists of 85 at % of carbon and incorporated hydrogen as well as any contaminants.
20. A method in accordance with claim 14 characterized in that a bonding layer of, for example, Cr or Ti is formed on the said surface regions of the article or of each article prior to the generation of the respective coatings.
21. A method in accordance with claim 20 characterized in that the thickness of the bonding layer on the first surface is in the region of 0.1 μm to 1 μm and on the second surface in the region of 0.1 μm to 1 μm.
22. A method in accordance with claim 14 characterized in that the thickness of the coating on the first surface region, including any bonding layer, is in total between 1 μm and 5 μm and in that the thickness of the coating on the second surface region, including any bonding layer, is in total between 1 μm and 5 μm.
23. A method in accordance with claim 14 characterized in that a homogeneous layer is formed on the first surface region and consists of a carbide of one or more of the said elements and carbon with a relatively low carbon component, whereby a relatively high coefficient of friction is achieved, and in that the rotary movements of the or each article around its own axis are synchronized with the rotary movement of the support around its axis of rotation such that a multi-layer structure is created on the second surface region which comprises alternate thin layers of a carbide of one or more of the said elements and carbon, with the carbon of said alternating layers being generated by the sputtering of a target made of graphite, and in that the process is carried out such that the layer thickness of each carbon layer of the layer sequence is in the region between approximately 1 nm and approximately 20 nm, preferably between 2 and 4 nm, with the topmost layer of the layer sequence preferably consisting of carbon and advantageously being somewhat thicker than the other layers, for example 500 nm, with the layer thickness of the carbide layers being in the region between 1 and 3 nm, and is preferably approximately 2 nm, and in that the carbon of the carbon layer has predominantly sp3 bonds.
24-30. (canceled).
Type: Application
Filed: Jul 1, 2004
Publication Date: Jan 6, 2005
Applicant: Hauzer Techno Coating Europe BV (LL Venlo)
Inventors: Gerrit-Jan van der Kolk (Maatheeze), Antonius Hurkmans (Taylorsville, NC), Christian Strondl (Venlo)
Application Number: 10/884,126