IP Library Granted Patent US 8,039,096
Granted Patent B2
US 8,039,096 · App. 12/493,713 · Granted Oct 18, 2011

Friction- and wear-reducing coating

Assignee: Eaton Corporation
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Quick Facts
Patent No.
US 8,039,096
App. No.
12/493,713
Granted
Oct 18, 2011
Kind
B2
Abstract

A coating includes a first layer of a ceramic alloy and a second layer disposed on the first layer and including carbon. The coating has a hardness of from 10 to 20 GPa and a coefficient of friction of less than or equal to 0.12. A method of coating a substrate includes cleaning the substrate, forming the first layer on the substrate, and depositing the second layer onto the first layer to thereby coat the substrate.

Claims (32)

1. A coating comprising:

a first layer of a ceramic orthorhombic boride-based alloy represented by the general formula AlMgB 14 —X and having a thickness of from greater than 1 micron to less than or equal to 3 microns;

wherein X is present in an amount of from 0 to 70 parts by weight based on 100 parts by weight of said ceramic orthorhombic boride-based alloy and is a doping agent selected from the group of Group IV elements and borides and nitrides thereof; and

a second layer disposed on said first layer and including amorphous carbon present in a gradient concentration that increases with a distance from said first layer;

wherein the coating has a hardness of from 10 to 20 GPa;

wherein the coating has a coefficient of friction of less than or equal to 0.12.

2. The coating of claim 1 , wherein said first layer has a hardness of from 30 to 40 GPa.

3. The coating of claim 1 , wherein said second layer has a hardness of from 10 to 25 GPa.

4. The coating of claim 1 , wherein said coating does not substantially degrade at a temperature of less than or equal to 1,000° C.

5. The coating of claim 4 , wherein said coating has a wear rate of less than or equal to 2×10 −7 mm 3 /N·m as measured in accordance with ASTM G99-05.

6. A coating comprising:

a first layer of a ceramic orthorhombic based-boride alloy represented by the general formula AlMgB 14 —X and having a thickness of from 1.25 to 3 microns;

wherein X is present in an amount of from 0 to 70 parts by weight based on 100 parts by weight of said ceramic orthorhombic boride-based alloy and is a doping agent selected from the group of Group IV elements and borides and nitrides thereof; and

a second layer disposed on said first layer and including amorphous carbon present in a gradient concentration that increases with a distance from said first layer and having a thickness of from 0.1 to 1.5 microns;

wherein the coating has a hardness of from 10 to 20 GPa;

wherein the coating has a coefficient of friction of less than or equal to 0.12.

7. The coating of claim 6 , wherein said first layer has a hardness of from 30 to 40 GPa.

8. The coating of claim 7 , wherein said second layer has a hardness of from 10 to 25 GPa.

9. A method of coating a substrate, the method comprising the steps of:

cleaning the substrate;

forming a first layer of a ceramic orthorhombic boride-based alloy represented by the general formula AlMgB 14 —X and having a thickness of greater than 1 micron to less than or equal to 3 microns on the substrate;

wherein X is present in an amount of from 0 to 70 parts by weight based on 100 parts by weight of the ceramic orthorhombic boride-based alloy and is a doping agent selected from the group of Group IV elements and borides and nitrides thereof; and

depositing a second layer onto the first layer to form a coating on the substrate, wherein the second layer includes amorphous carbon present in a gradient concentration that increases with a distance from the first layer;

wherein the coating has a hardness of from 10 to 20 GPa;

wherein the coating has a coefficient of friction of less than or equal to 0.12.

10. The method of claim 9 , wherein said depositing is further defined as increasing a concentration of amorphous carbon in the second layer with a distance from the first layer so that amorphous carbon is present in the second layer in the gradient concentration.

11. The method of claim 9 , wherein said depositing is further defined as sputtering the first layer with a target material including carbon.

12. The method of claim 9 , wherein said depositing is further defined as decomposing a carbon-based gas in the presence of the first layer.

13. The method of claim 9 , wherein said cleaning is further defined as etching the substrate.

14. The method of claim 9 , wherein said forming is further defined as physical vapor depositing the first layer.

15. The method of claim 14 , wherein said physical vapor depositing is further defined as sputtering the substrate with a target material represented by the general formula AlMgB 14 —X;

wherein X is present in an amount of from 0 to 70 parts by weight based on 100 parts by weight of the ceramic orthorhombic boride-based alloy and is a doping agent selected from the group of Group IV elements and borides and nitrides thereof.

Assignments (3)
CONFIRMATORY LICENSE Recorded Nov 5, 2012
From: EATON CORP
To: ENERGY, UNITED STATES DEPARTMENT OF
Reel/Frame 029261/0744 →
CONFIRMATORY LICENSE Recorded Sep 18, 2012
From: EATON CORPORATION
To: ENERGY, UNITED STATES DEPARTMENT OF
Reel/Frame 029013/0446 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 16, 2009
From: ZHU, DONG; MILNER, ROBERT; ELMOURSI, ALAA ABDELAZIM
To: EATON CORPORATION
Reel/Frame 023382/0919 →
Continuity (2)
Provisional Application 61133491 · Jun 30, 2008
Related Publication 20100028641A1 · Feb 4, 2010