Residual Stresses and Nanoindentation Testing of Films and Coatings (eBook)

Haidou Wang, Ph. D. is a Professor and his main research interests are in surface engineering and remanufacturing. His work focuses on the characterization and evaluation of surface coatings and films, including their mechanical properties, tribological properties and lifecycle evaluation. Haidou Wang is supported by the National Natural Science Foundation for Distinguished Young Scholars. He is the Chief Scientist of the National Defense 973 Program and the Fund Manager of the Key Program of National Natural Science Foundation and major program of National Natural Science Foundation of Beijing. His contributions have been recognized with a wealth of awards. He has published eight books in Chinese and English, 160 papers indexed by SCI, and 250 papers indexed by EI. In addition, he holds three American patents, 25 Chinese patents and 23 intellectual property rights patents.Lina Zhu, Ph.D. is a Lecturer, and her main research interests are in surface engineering and tribology. Her work focuses on the characterization and evaluation of surface coatings and films, including the mechanical properties, tribological properties and wettability. Lina Zhu is supported by the National Natural Science Foundation and Natural Science Foundation of Beijing. She has published two books in Chinese, 25 papers indexed by the SCI, and 31 papers indexed by EI. In addition, she holds eleven Chinese patents. Binshi Xu is a member of the Chinese Academy of Engineering (CAE). He has been engaged in maintenance engineering, surface engineering and remanufacturing engineering for many years, and is one of the pioneers of surface engineering and remanufacturing engineering in China. Xu has carried out more than 80 projects, and has published seventeen books and more than 800 papers. In addition, he holds 20 patents. In 1996, he won the Center for Middle Eastern Studies (CMES) S&T Achievement Award; in 2004, he won the CAE’s Guanghua Engineering Award. 

Preface 5
About the Book 7
Contents 8
1 Residual Stresses of Materials 12
1.1 Definition and Classification of Residual Stresses 12
1.2 Formation Mechanism of Residual Stress 13
1.2.1 Formation Mechanism of Macroscopic Residual Stress 13
1.2.2 Formation Mechanism of Microscopic Residual Stress 14
1.3 Effect of Residual Stress on Properties of Materials 14
1.3.1 Effect of Residual Stress on Fatigue Strength 14
1.3.2 Effect of Residual Stress on Brittle Failure 15
1.3.3 Effect of Residual Stress on Stress Corrosion Cracking 16
1.3.4 Effect of Residual Stress on Machining Precision and Dimension Stability 17
1.4 Test Methods of Residual Stress 18
1.4.1 Nondestructive Testing Methods 18
1.4.1.1 X-ray Diffraction Method 18
1.4.1.2 Neutron Diffraction Method 19
1.4.1.3 Raman Spectroscopy Method 20
1.4.1.4 Ultrasonic Method 21
1.4.1.5 Magnetic Method 22
1.4.1.6 Synchrotron Radiation Method 23
1.4.2 Destructive Testing Methods 24
1.4.2.1 Hole Drilling Method 24
1.4.2.2 Stripping Method 25
1.4.2.3 Ring Core Method 25
1.4.2.4 Sectioning Method 26
1.4.2.5 Cutting Groove Method 28
References 28
2 Principle and Methods of Nanoindentation Test 31
2.1 Overview of Nanoindentation Technique 31
2.2 Measurement Principles of Hardness and Elastic Modulus 32
2.2.1 Oliver and Pharr Method (O& P Method)
2.2.2 Work-of-Indentation Method 35
2.2.3 Continuous Stiffness Measurement 37
2.3 Nanoindentation Testing Method 38
2.3.1 Indenter Types 38
2.3.2 Nanoindentation Instrumentation 40
2.4 Factors Affecting Nanoindentation Test Results 45
References 46
3 Theoretical Models for Measuring Residual Stress by Nanoindentation Method 47
3.1 Principle of Measuring Residual Stress by Nanoindentation Method 47
3.2 Effect of Residual Stress on Nanoindentation Parameters [5] 47
3.2.1 Effect of Residual Stress on Load–Depth Curves 49
3.2.2 Effect of Residual Stress on Pile-up Deformation 52
3.2.3 Effect of Residual Stress on Contact Area 57
3.2.4 Effect of Residual Stress on Mechanical Properties 58
3.3 Models for Measuring Residual Stress 59
3.3.1 Suresh Model 61
3.3.2 Lee Model 69
3.3.2.1 Lee Model I 69
3.3.2.2 Lee Model II 70
3.3.3 Xu Model 72
3.3.4 Swadener Model 73
3.3.4.1 Swadener Model I 73
3.3.4.2 Swadener Model II 74
3.4 Indentation Fracture Technique 75
References 76
4 Application of Suresh and Lee Models in the Measurement of Residual Stress of Bulk Materials 78
4.1 Measurement of Residual Stresses in Single Crystal Copper 78
4.1.1 Pile-up of Single Crystal Copper 78
4.1.2 Model Construction of the Real Contact Area 79
4.1.3 Comparison of Different Methods for Calculating Contact Area 82
4.1.4 The Real Contact Area of the Single Crystal Copper 84
4.1.5 The Real Hardness of the Single Crystal Copper 85
4.1.6 Residual Stress Calculation of the Single Crystal Copper 87
4.2 Residual Stress Determination of 1045 Steel 88
4.2.1 Experimental 88
4.2.2 Load–Depth Curves of the 1045 Steel 89
4.2.3 Pile-up Deformation of the 1045 Steel 89
4.2.4 The Real Hardness of the 1045 Steel 92
4.2.5 Calculation of Residual Stresses of the 1045 Steel 96
References 106
5 Application of Suresh and Lee Models in the Measurement of Residual Stress of Coatings 107
5.1 Residual Stresses of Fe-Based Laser Cladding Coatings 107
5.1.1 Preparation of Fe-Based Laser Cladding Coatings 107
5.1.2 Microstructures of Fe-Based Laser Cladding Coatings 109
5.1.3 Residual Stress Analysis of Fe-Based Laser Cladding Coatings 113
5.2 Residual Stress of Fe-Based Coatings Prepared by Supersonic Plasma Spraying 122
5.2.1 Preparation of Sprayed Fe-Based Coatings 122
5.2.2 Microstructure of Sprayed Fe-Based Coatings 123
5.2.3 Residual Stress Analysis of Sprayed Fe-Based Coatings 127
5.3 Residual Stress of Plasma Cladding Coatings 137
5.3.1 Preparation of Plasma Cladding Coatings 137
5.3.2 Microstructure of Plasma Cladding Coatings 138
5.3.3 Mechanical Properties of Plasma Cladding Coatings 140
5.3.4 Residual Stress Analysis of Plasma Cladding Coatings 142
5.4 Residual Stress of n-Al2O3/Ni Composite Brush Plating Coatings 146
5.4.1 Preparation of n-Al2O3/Ni Composite Brush Plating Coatings 147
5.4.2 Microstructure of n-Al2O3/Ni Composite Brush Plating Coatings 147
5.4.3 Mechanical Properties of n-Al2O3/Ni Composite Brush Plating Coatings 149
5.4.4 Residual Stress Analysis of n-Al2O3/Ni Composite Brush Plating Coatings 151
References 153
6 Application of Suresh and Lee Models in the Measurement of Residual Stress of Films 155
6.1 Residual Stress of Magnetron Sputtering Cu Films 155
6.1.1 Preparation of Magnetron Sputtering Cu Films 155
6.1.2 Microstructure of Magnetron Sputtering Cu Films 156
6.1.3 Mechanical Properties of Magnetron Sputtering Cu Films 160
6.1.4 Residual Stress Analysis of Magnetron Sputtering Cu Films 160
6.2 Residual Stress of Magnetron Sputtering Ti Films [4, 5] 164
6.2.1 Preparation and Characterization of Magnetron Sputtering Ti Films 164
6.2.2 Effects of Process Parameters on the Hardness and Elastic Modulus of Ti Films 174
6.2.3 Effect of Process Parameters on the Residual Stress of Ti Films 180
6.3 Residual Stress of TiN Films and Ti/TiN Multilayer Films [6] 186
6.3.1 Preparation and Characterization of TiN Films 186
6.3.2 Preparation and Characterization of Ti/TiN Multilayer Films 189
6.3.3 Hardness and Elastic Modulus of Ti/TiN Multilayer Films [7] 191
6.3.4 Residual Stress Analysis of TiN and Ti/TiN Multilayer Films 194
References 198
7 Application of Other Models in the Measurement of Residual Stress 199
7.1 Application of the Xu Model 199
7.2 Application of the Swadener Model 201
7.2.1 Measurement of Surface Residual Stresses in SiC Particle-Reinforced Al Matrix Composites 201
7.2.2 Measurement of Residual Stresses in Cu and Cr Films 204
7.2.2.1 Cu Films 204
7.2.2.2 Cr Films 206
7.3 Application of Indentation Fracture Method 208
7.3.1 Measurement of Residual Stresses in Three-Layer Reaction Bonded Alumina Composites 208
7.3.2 Measurement of Residual Stresses in Soda-Lime Glass 210
7.3.3 Measurement of Residual Stresses in Lithium Disilicate Glass-Ceramic 212
References 215