Novel high damage-tolerant, wear resistant MoSi2-based nanocomposite coatings

In this study, novel MoSi2-based nanocomposite coatings were deposited on Ti-6Al-4V substrates by a two-step process involving firstly, deposition of MoSi2-based coatings, using a double cathode glow discharge process and, secondly, plasma nitridation of the as-deposited coatings. The aim of this latter step is to introduce nitrogen into the coating and promote the formation of amorphous silicon nitride. The resulting coatings were characterized by X-ray diffraction (XRD), X-ray photoelectron spectroscope (XPS), transmission electron microscopy (TEM) and scanning electron microscopy (SEM). It was found that the nanocomposite coatings were composed of nanocrystallite Mo5Si3 and MoSi2 grains embedded in an amorphous Si3N4 matrix. The mechanical properties and damage resistance of the coatings were evaluated by both Vickers indentation and nanoindentation techniques. Dry sliding wear tests were performed using a ball-on-disc type tribometer, in which the coated samples were tested against a ZrO2 ceramic ball at normal loads of 2.8 and 4.3 N under ambient conditions. Compared with the monolithic MoSi2 nanocrystalline coating, the specific wear rates of the nanocomposite coatings decreased by an order of magnitude. The specific wear rate was further improved by about 20% through the addition of Al, which was attributed to an optimum combination of mechanical properties.

► The nanocomposite coatings show an improved in both hardness and toughness. ► The soft amorphous Si3N4 phase arrests cracks, strongly reducing the crack driving force. ► The nanocomposite coatings exhibit a higher wear resistance than monolithic MoSi2.