scholarly journals Development of thin-film based sensors for temperature and tool wear monitoring during machining

2020 ◽  
Vol 87 (12) ◽  
pp. 768-776
Author(s):  
Marcel Plogmeyer ◽  
Germán González ◽  
Volker Schulze ◽  
Günter Bräuer
Keyword(s):  
Thin Film ◽  
Physical Vapor Deposition ◽  
Control Mechanisms ◽  
Insulation Layer ◽  
Sensor Layer ◽  
Thin Film Sensors ◽  
Wear Protection ◽  
Cutting Inserts ◽  
Wear Monitoring ◽  
Machining Operations

AbstractThe development of thin-film sensors for temperature and wear measurement in machining operations is presented in this work. A functional thin-film system, consisting of an Al2O3 insulation layer, a chromium sensor layer structured by photolithography and an Al2O3 wear-protection and insulation layer, is deposited by physical vapor deposition (PVD) processes onto the surface of cemented carbide cutting inserts. First specimen of the sensors are successfully fabricated and tested in laboratory experiments as well as in machining operations to demonstrate their functionality. These tool-integrated sensors can be used as an in-process monitoring device to determine the temperatures on the rake face at or close to the tool-chip contact area and to measure the progress of the flank-wear land width. The knowledge of these important process parameters opens up the possibility to develop new in-process control mechanisms in order to modify and improve the surface integrity of manufactured components. Thereby, their performance and lifetime can be enhanced.

scholarly journals Temperature measurement with thin film sensors during warm forging of steel

2021 ◽  
Author(s):  
M. Plogmeyer ◽  
J. Kruse ◽  
M. Stonis ◽  
N. Paetsch ◽  
B.-A. Behrens ◽  
...  
Keyword(s):  
Thin Film ◽  
Service Life ◽  
Tool Wear ◽  
Temperature Measurement ◽  
Surface Engineering ◽  
Dimensional Accuracy ◽  
Dlc Coatings ◽  
Thin Film Sensors ◽  
Wear Protection ◽  
Tool Service Life

AbstractWarm forged components have better surface properties and higher dimensional accuracy than hot forged components. Diamond-like-carbon (DLC) coatings can be used as wear protection coatings, which are anti-adhesive and extremely hard (up to 3500 HV), to increase tool service life. In the first funding period of the research project at the IPH – Institut für Integrierte Produktion Hannover gGmbH and the Institute for Surface Technology (IOT) of the Technical University of Braunschweig in cooperation with the Fraunhofer Institute for Surface Engineering and Thin Films (IST), the influence of different coating types and process temperatures on tool wear was investigated. The result is, that DLC coatings can reduce tool wear in some cases significantly, but that their service life is strongly dependent on the temperature. Coating-integrated temperature measurement could not be realised at that point, due to adhesion challenges. During the second funding period, the effect of multilayer DLC coatings on tool wear was investigated. Also, an additional method of the temperature measurement on the engraving surface using thin film sensors was developed in order to correlate the local process temperature and local layer wear. In this work, the development of and the results gathered by the thin film temperature sensors are presented, which enable for more accurate temperature measurements than commonly used thermocouples. Their functionality and durability under high loads were investigated and showed to be promising.

Effect of Film Thickness on Fatigue Strength of TiAl Alloy Coated with TiAlN Film at Elevated Temperature

2005 ◽  
Vol 297-300 ◽  
pp. 1446-1451 ◽  
Author(s):  
Takeshi Kasuya ◽  
Hideto Suzuki
Keyword(s):  
Thin Film ◽  
Fatigue Strength ◽  
Film Thickness ◽  
Thick Film ◽  
Physical Vapor Deposition ◽  
Tial Alloy ◽  
Testing Machine ◽  
Intermetallic Alloy ◽  
Fracture Control ◽  
The Difference

The fatigue strength of TiAl intermetallic alloy coated with TiAlN film was studied in vacuum at 1073K using a SEM-servo testing machine. In addition, three kinds of TiAlN films were given by physical vapor deposition (1, 3, and 10μ m). The fatigue strength of 3μ m was highest. Also, the fatigue strength of 1μ m was lowest. From this result, existence of optimum film thickness was suggested because the difference of fatigue strength arose in each film thickness. The justification for existence of optimum film thickness is competition of 45-degree crack and 90-degree crack. The 45-degree crack is phenomenon seen in the thin film (1μ m), and is caused by plastic deformation of TiAl substrate. The 45-degree crack is the factor of the fatigue strength fall by the side of thin film. In contrast, the 90-degree crack is phenomenon in the thick film (10μ m), and is caused as result of reaction against load to film. The 90-degree crack is the factor of the fatigue strength fall by the side of thick film. In conclusion, the optimum film thickness can perform meso fracture control, and improves fatigue strength.

scholarly journals CVD and PVD coating process modelling by using artificial neural networks

2012 ◽  
Vol 1 (1) ◽  
pp. 46 ◽  
Author(s):  
Amir Mahyar Khorasani ◽  
Mohammad Reza Solymany yazdi ◽  
Mehdi Faraji ◽  
Alex Kootsookos
Keyword(s):  
Thin Film ◽  
Vapor Deposition ◽  
Physical Vapor Deposition ◽  
Chemical Vapor ◽  
Film Coating ◽  
Deposition Process ◽  
Thin Film Coating ◽  
Mlp Neural Network ◽  
Titanium Thin Film ◽  
Pvd Coating

Thin-film coating plays a prominent role on the manufacture of many industrial devices. Coating can increase material performance due to the deposition process. Having adequate and precise model that can predict the hardness of PVD and CVD processes is so helpful for manufacturers and engineers to choose suitable parameters in order to obtain the best hardness and decreasing cost and time of industrial productions. This paper proposes the estimation of hardness of titanium thin-film layers as protective industrial tools by using multi-layer perceptron (MLP) neural network. Based on the experimental data that was obtained during the process of chemical vapor deposition (CVD) and physical vapor deposition (PVD), the modeling of the coating variables for predicting hardness of titanium thin-film layers, is performed. Then, the obtained results are experimentally verified and very accurate outcomes had been attained.

Fabrications of the Smart Thin Film Sensors on the Very Thin Oxidized Alumina of PtAl Substrate

2021 ◽  
Author(s):  
Ziyi Xie ◽  
Franklin L. Duan ◽  
Lingyi Qian ◽  
Zebin Bao
Keyword(s):  
Thin Film ◽  
Thin Film Sensors

scholarly journals A review on thin films, conducting polymers as sensor devices

2022 ◽  
Author(s):  
E.L. Veera Prabakaran ◽  
K Senthil Vadivu ◽  
B Mouli Prasanth
Keyword(s):  
Thin Film ◽  
Thin Films ◽  
Environmental Conditions ◽  
Future Research ◽  
Physical Parameters ◽  
Research Needs ◽  
Future Perspectives ◽  
Thin Film Technology ◽  
Thin Film Sensors ◽  
Sensor Devices

Abstract Thin film sensors are used to monitor environmental conditions by measuring the physical parameters. By using thin film technology, the sensors are capable of conducting precise measurements. Moreover, the measurements are stable and dependable. Furthermore, inexpensive sensor devices can be produced. In this paper, thin film technology for the design and fabrication of sensors that are used in various applications is reviewed. Further, the applications of thin film sensors in the fields of biomedical, energy harvesting, optical, and corrosion applications are also presented. From the review, the future research needs and future perspectives are identified and discussed.

scholarly journals Aspects of thin film deposition on granulates by physical vapor deposition

2016 ◽  
Vol 70 (11) ◽  
Author(s):  
Andreas Eder ◽  
Gerwin H.S. Schmid ◽  
Harald Mahr ◽  
Christoph Eisenmenger-Sittner
Keyword(s):  
Thin Film ◽  
Vapor Deposition ◽  
Physical Vapor Deposition ◽  
Thin Film Deposition ◽  
Film Deposition

Doped Thin-Film Sensors via a Sol−Gel Process for High-Acidity Determination

1997 ◽  
Vol 69 (15) ◽  
pp. 3076-3080 ◽  
Author(s):  
Leonardo R. Allain ◽  
Karn Sorasaenee ◽  
Ziling Xue
Keyword(s):  
Thin Film ◽  
Sol Gel ◽  
High Acidity ◽  
Thin Film Sensors ◽  
Sol Gel Process
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