Surface Engineering: Science and Technology Ii

SURFACE ENGINEERING: SCIENCE AND TECHNOLOGY II

Edited by: Ashok Kumar Yip-Wah Chung John J. Moore Gary L. Doll Kyoshi Yatsui D.S. Misra SURFACE ENGINEERING: SCIENCE AND TECHNOLOGY II

Proceedings of a symposium sponsored by the Surface Engineering Committee of the Materials Processing & Manufacturing Division (MPMD) of TMS (The Minerals, Metals & Materials Society).

Held during the TMS 2002 Annual Meeting in Seattle, Washington February 17-21, 2002

Partial funding for this publication was provided for by the Seeley W. Mudd Fund

Edited by: Ashok Kumar Yip-Wah Chung John J. Moore Gary L. Doll Kyoshi Yatsui D.S. Misra

A Publication of A Publication of The Minerals, Metals & Materials Society 184 Thorn Hill Road Warrendale, Pennsylvania 15086-7528 (724) 776-9000

Visit the TMS web site at http://www.tms.org

The Minerals, Metals & Materials Society is not responsible for statements or opinions and is absolved of liability due to misuse of information contained in this publication.

Printed in the United States of America ISBN Number 0-87339-521-2 Library of Congress Number:2002100526

Authorization to photocopy items for internal or personal use, or the internal or personal use of specific clients, is granted by The Minerals, Met- als & Materials Society for users registered with the Copyright Clearance Center (CCC) Transac- tional Reporting Service, provided that the base fee of $7.00 per copy is paid directly to Copyright Clearance Center, 27 Congress Street, Salem, Massachusetts 01970. For those organizations that have been granted a photocopy license by Copyright Clearance Center, a separate system of payment has been arranged.

If you are interested in purchasing a copy of this book, or if you would like to receive the latest TMS publications catalog, please telephone 1-800-759-4867 (U.S. only) or 724-776-9000, EXT. 270. TABLE OF CONTENTS

Preface ...... ix

Nanomaterials

Modifying the Surface of Nanoparticles by Coating ...... 3 D.V. Szabó, S. Schlabach, B. Xu and D. Vollath

Formation of Photonic Nanocomposites by Surface Engineering Over Inorganic Nanoparticles ...... 15 N. Kambe

Micro To Nano-Small Research For Fuels and Combustion ...... 25 C.E. Bunker, J.R. Gord, T.R. Meyer, M.S. Brown, V.R. Katta, D.A. Zweifel, B.A. Harruff and Y-P. Sun

Formation of Gold Nanowires with MgO Surfaces ...... 35 A. Ueda, R.R. Mu, V.C. Saunders, T.C. Livingston, M.H. Wu and D.O. Henderson

Dense Deposition of Nanocomposites By a Compact YAG Laser ...... 43 M. Senna and K. Hamada

Aqueous Chemical Growth of Advanced Nanostructured Metal Oxides Thin Films ...... 51 L. Vayssieres

Purification of Aluminum Nitride Nanosized Powder Synthesized by Pulsed Wire Discharge ...... 61 C. Cho, Y. Kinemuchi, T. Suzuki, H. Suematsu, W. Jiang and K. Yatsui

Engineered Nanomaterial Hard Coatings on Metal and Polymer Substrates ...... 69 A. Singhal and G. Skandan

Synthesis of Nickel Ferrite Nanosized Powders by Pulsed Wire Discharge ...... 79 K. Ishizaka, Y. Kinemuchi, T. Suzuki, H. Suematsu, W. Jiang and K. Yatsui

Reinforced Epoxies Using Carbon Nanotubes ...... 89 R.A. Bley, D. Beascoechea and R. Niedner

v Tunable Self-Assembly of Carbon Nanotubes on Silica Surface...... 99 Z.J. Zhang, B.Q. Wei and P.M. Ajayan

Issues in Surface Engineering

Laser Surface Modification of Electronic Properties in Wide Band Gap Materials ...... 113 I.A. Salama, N.R. Quick and A. Kar

Preparation of TiFe Thin Films of Hydrogen Absorbing Alloy by Intense Pulsed Ion-Beam Evaporation...... 125 T. Saikusa, T. Suzuki, H. Suematu, W. Jiang and K. Yatsui

Surface Modification of Austenitic Stainless Steels ...... 133 H. Ocken and R. Asay

Synthesis of Functional Materials using Pulsed Power Technology ...... 143 K. Yatsui, W. Jiang, H. Suematsu, T. Suzuki, Y. Kinemuchi and S.C. Yang

Surface Modification of P/M TiC Reinforced Iron Matrix Composites ...... 153 O.N. Dogan, D.E. Alman, J.A. Hawk and P. Danielson

Functionally Graded Materials Produced with High Power Lasers...... 163 J.T. De Hosson and Y. Pei

Advances in Coating Technology

Nucleation and Growth of Cubic Boron Nitride Under Different Substrate Bias ...... 179 Q. Li, Y. Lifshitz, L.D. Marks, I. Bello and S.T. Lee

Role of Precursors on the Formation of CNX Deposited by PE-HF-CVD ...... 189 D. Dumitriu and A. Karami

Optimization of Thermoelectric Properties in Boron Carbide Thin Films Prepared by Ion-Beam Evaporation ...... 199 H. Suematsu, I. Ruiz, K. Kobayashi, M. Takeda, D. Shimbo, T. Suzuki, W. Jiang and K. Yatsui

Developing a MoSi2+ SiC Oxidation Resistance Coating for MO, a Prototype Refractory Metal ...... 207 E.C. Hixson, G.G.W. Mustoe, J.J. Moore, H.J. Kleebe, D.L. Olson and C. Suryanarayana

vi The Influence of Particle Energy Distributions on the Microstructure and Properties of Reactively Sputtered Titanium Oxide and Titanium Nitride Thin Films ...... 217 C. Muratore, J.J. Moore and J.A. Rees

Effects of Bias-Enhanced Nucleation and Growth of Diamond Films on Copper and Transition-Metal Alloy Substrates ...... 227 A. Kumar and A.K. Sikder

Epitaxial Nucleation of Diamond Polytypes on Silicon by Direct Ion Beam Deposition ...... 239 Q. Li, X.F. Duan, Y. Lifshitz, F.Y. Meng, N.G. Shang, I. Bello and S.T. Lee

Characterization of Materials

Development of Cermet Thin Films Coatings ...... 369 B. Mishra, J. Zhou and F. Kustas

Relative Nanomechanical and Raman Studies of Diamond-Like Carbon Thin Films ...... 251 J. Goldsmith, E. Sutter, J. Moore, B. Mishra and M. Crowder

Fabrication and Characterization of Mechanical Properties of Ultra- Thin Silicon Microcantilevers...... 261 P.B. Zantye, A.K. Sikder, R.K. Sharma and A. Kumar

Influence of Surface Roughness on Coercivity and Magnetic Interactions in CoCrX (X=Pt,Pd,Ta,B) Thin Film Media...... 273 M. Tarakci and S. Guruswamy

Mechanical Properties of Microstructural Evaluation of Chromium Containing Hard Coatings on Fe-Mn-Al Alloy ...... 283 J-W. Lee and J.-G. Duh

Curvature Method as a Tool to Evaluate Shape Memory Effects for TiNiCu Thin Films...... 293 Y. Fu, H. Du and S. Zhang

Observation of Surface-Related Phenomena During In-situ Nanoindentation in a Transmission Electron Microscope (TEM) ...... 305 A.M. Minor, E.T. Lilleodden, E.A. Stach and J.W. Morris

Comparison in Characteristics of Electroless Deposited and Magnetron Sputtered Ni-P-W Coatings ...... 315 F-B. Wu, Y.-Y. Tsai and J.-G. Duh

vii Oxidation/Corrosion/Nitridation/Diffusion

Factors Controlling In-Plane Cracking of Thermal Barrier Coatings ...... 327 Z. Zhang, J. Kameda, A.H. Swanson, S. Sakurai and M. Sato

The Corrosion Behavior of PVD-Grown WC-(Ti1-xAlx) N Films Multilayers in 3.5%NaCl Solution ...... 337 S.H. Ahn, J.H. Yoo, Y.S. Choi, J.G. Kim and J.G. Han

Ferritic Nitrocarburising in Fludised Bed...... 347 D.M. Fabijanic, P.D. Hodgson and G.L. Kelly

Surface Phenomena in Diffusion Limited Capillary Flow in a Reactive Porous Film ...... 357 R. Asthana

Author Index ...... 379

Subject Index ...... 381

viii PREFACE

The symposium titled “Surface Engineering: Science and Technology II” was organized by Ashok Kumar, Y. W. Chung, John J. Moore, Gary L. Doll, D. S. Misra and Kiyoshi Yatsui, and held in Seattle, Washington, during the TMS annual meeting, February 17-21, 2002. This volume consists of invited and contributed papers from national and internationals researchers represent- ing universities, federal laboratories and industries. Surface engineering covers a wide range of surface modification processes that are directed at the creation of tailor-made surface characteris- tic of materials. The objective of this symposium is to provide a multi-disciplinary discussion on surface related phenomena by which materials performance may be enhanced through engineered interface and surface modification technologies.

The objective of this symposium is to provide a forum for multi-disciplinary discussions on phenomena where materials-performance may be enhanced through engineered surfaces and inter- faces. The materials science of hard and wear-resistant coatings, including nanostructured coatings, is a scientifically challenging problem with immediate technological applications in ma- chine and machining tools, magnetic recording and others manufacturing industries. This symposium has served as a forum to review key aspects, discuss ongoing current research and speculate on future trends relating to the science, technology and applications of coatings, surface treat- ments and surface analysis for the enhanced performance of engineered components and devices. We wish to thank all the authors, particularly the invited speakers and referees, for their contribu- tions to the success of this symposium. We also acknowledge the University of South Alabama, the Northwestern University/Materials Research Center, Colorado School of Mines, The Timken Company, I. I. T. Bombay and Nagaoka University of Technology for the resources the organizers used to organize the symposium and complete this book. Special thanks are also extended to Mr. Steve Kendall from TMS for his assistance in editing this book.

Dr. Ashok Kumar Dr. Yip-Wah Chung Dept. of Mechanical Engr. & Dept. of Materials Sci.& Engr. Center for Microelectronics Research Northwestern University University of South Florida Evanston, IL 60208 Tampa, FL 33620 Tel: (847)491-3112, Fax: (847)491-7820

Dr. John J. Moore Dr. Gary L. Doll Advanced Coating & Surface Engr. Lab The Timken Company Colorado School of Mines P.O. Box 6930 Golden, CO 80401-1887 Canton, OH 44706

Dr. Kiyoshi Yatsui Dr. D. S. Misra Extreme Energy Density Research Institute Department of Physics Nagaoka University of Technology I. I. T. Bombay Nagaoka, Niigata 940-2188, Japan Powai, Mumbai 400076, India

ix AUTHOR INDEX

A I Ahn, S.H., 337 Ishizaka, K., 79 Ajayan, P.M., 99 Alman, D.E., 153 J Asay, R., 133 Jiang, W., 61, 79, 125, 143, 199 Asthana, R., 357 K B Kambe, N., 15 Beascoechea, D., 89 Kameda, J., 327 Bello, I., 179, 239 Kar, A., 113 Bley, R.A., 89 Karami, A., 189 Brown, M.S., 25 Katta, V.R., 25 Bunker, C.E., 25 Kelly, G.L., 347 Kim, J.G., 337 C Kinemuchi, Y., 61, 79, 143 Cho, C., 61 Kleebe, H.J., 207 Choi, Y.S., 337 Kobayashi, K., 199 Crowder, M., 251 Kumar, A., 227, 261

D L Danielson, P., 153 Lee, J-W., 283 De Hosson, J.T., 163 Lee, S.T., 179, 239 Dogan, O.N., 153 Li, Q., 179, 239 Du, H., 293 Lifshitz, Y., 179, 239 Duan, X.F., 239 Lilleodden, E.T., 305 Duh, J.-G., 283, 315 Livingston, T.C., 35 Dumitriu, D., 189 M F Marks, L.D., 179 Fabijanic, D.M., 347 Meng, F.Y., 239 Fu, Y., 293 Meyer, T.R., 25 Minor, A.M., 305 G Mishra, B., 251 Goldsmith, J., 251 Moore, J., 207, 217, 251 Gord, J.R., 25 Morris, J.W., 305 Guruswamy, S., 273 Mu, R.R., 35 Muratore, C., 217 H Mustoe, G.G.W., 207 Hamada, K., 43 Han, J.G., 337 N Harruff, B.A., 25 Niedner, R., 89 Hawk, J.A., 153 Henderson, D.O., 35 O Hixson, E.C, 207 Ocken, H., 133 Hodgson, P.D., 347 Olson, D.L., 207

379 P T Pei, Y., 163 Takeda, M., 199 Tarakci, M., 273 Q Tsai, Y.-Y., 315 Quick, N.R., 113 U R Ueda, A., 35 Rees, J.A., 217 Ruiz, I., 199 V Vayssieres, L., 51 S Vollath, D., 3 Saikusa, T., 125 Sakurai, S., 327 W Salama, I.A., 113 Wei, B.Q., 99 Sato, M., 327 Wu, F-B., 315 Saunders, V.C., 35 Wu, M.H., 35 Schlabach, S., 3 Senna, M., 43 X Shang, N.G., 239 Xu, B., 3 Sharma, R.K., 261 Shimbo, D., 199 Y Sikder, A.K., 227, 261 Yang, S.C., 143 Singhal, A., 67 Yatsui, K., 61, 79, 125, 143, 199 Skandan, G., 67 Yoo, J.H., 337 Stach, E.A., 305 Suematsu, H., 61, 79, 143, 199 Z Suematu, H., 125 Zantye, P.B., 261 Sun, Y-P., 25 Zhang, S., 293 Suryanarayana, C., 207 Zhang, Z., 327 Sutter, E., 251 Zhang, Z.J., 99 Suzuki, T., 61, 79, 125, 143, 199 Zweifel, D.A., 25 Swanson, A.H., 327 Szabó, D.V., 3

380 SUBJECT INDEX

A E Adhesion, 340 EIS, 339-340 Annealing ERDA, 190 Annealing Temperature, 320-321

Ni3P, 315, 319-322 F AlN Content, 61-65, 67 Fe-Mn-Al Alloy, 284, 286, 289, 292 Alumindum Nitride (AlN), 61-65, 67 Fe-Mn-Al-C Alloy, 284 Ferimagnetism, 79, 80, 86 B Fluid-Bed Reactor, 347, 347 Bia-Enhance, 227, 228, 233 Four Point Bending, 329 Bode Plot, 342 FT-IR, 189, 191, 193 Boron Carbide, 199-205 Fuels, 25 Boron Nitride, 179 G C Gallium Arsenide, 113 Carbon Nanotubes, 89, 94, 98 Galvanic Current Density, 342 Multi Walled, 91, 94 Gas Sensor, 79, 80, 84, 85 Single Walled, 90-91, 94 Gold, 35, 36, 40, 41 Capilary Flow, 357, 358, 360 CFD, 25, 27, 28, 31 H Chemical Vapor Deposition (CVD), 52, 94, Hard Coatings, 69 227-230, 240, 251 HF-CVD, 189, 190, 283 Chromizing Hydrogen Absorbing Alloy, 126 Chromization, 283-284 Pack Chromizing, 284-285, 299, 291 I

CNx Films, 189, 190 Inductance, 61-67 CoCr, 273, 274, 280, 281 Intense Pulsed Ion-Beam Evaporation, 126 Coercivity, 273, 274, 278, 280, 281 Internal Stress, 181 Combustion, 25 Ion-Beam Evaporation, 143-148, 151, 199- Composite, 153, 154, 158, 160 205 Epoxy/Nanotube, 94-98 Copper, 227 K Corrosion, 138, 139 Kaufman Ion Source, 240, 242 CPE, 344 Cracking, 163 L Crystalline, 126 Large Area High Resolution Transmission Curvature Method, 295 Electron Microscopy, 199, 200, 202 Laser, 43, 44, 49, 163-176 D D.C. –Bias, 227 M Deposited Energy, 61, 65-67 Magnetron Sputtering, 179, 180 Diamond, 239-248, 251 Mechanical Properties, 283 Diamond Films, 227-230, 233-235, 237, 238 MEMS, 25, 29, 261, 262, 306 Diffusion, 357-359, 363, 367 Metal Oxide, 51, 53, 56 Droplet, 341 MgO, 35-39, 41 Microcantilevers, 263, 264 381 Microhardness Properties Degradation, 321 Dispersion Behavior, 9, 10 Peak-Hardness, 320-321 High Frequency, 12, 13 Precipitation, 315, 316, 320-322 Magnetic, 11, 12 Microstructures, 284, 285 Suspension Behavior, 10 Microwave Plasma Process, 3-5, 12 Pulsed Wire Discharge (PWD), 61-63, 67, Synthesis, 5 79-87, 143, 144, 149-151 Molybdenum, 207, 208

MoSi2, 207, 208, 209, 211 R R.F. Sputtering N Magnetron Sputtering, 283-286 Nanocoating, 43, 49 Raman, 251-252, 257-258 Nanocomposites, 43, 44, 49, 51, 55, 58 Residual Stress, 163, 327 Nanoindentation, 76, 266, 267, 305, 306, 308, 310, 312 S Nanomaterial, 69 Scratch Test, 283-285, 291 Nanomechanical, 251-253 Critical Load, 283-285, 289-291 Nanoparticles, 3-9, 12 Shape Memory, 293, 298 Coated Nanoparticles, 5, 7-9 SiC, 163-175 Morphology, 7 Silica, 99, 104, 106, 107 Properties, 9 Silicon Carbide, 113, 207, 214 Nanosize Powder, 79-87 Sputter-Deposition, 294 Nanotubes, 99-108 Stabilized Chronium Process, 133, 134, 137 Nanowire, 35, 40, 41 Stainless Steel, 133-135 NEMS, 29 Steel, 347-355

NiFe2O4, 79-87, 149, 150 Stress, 293, 298, 299 Nitrocarburising, 347, 348 Surface Roughness, 273, 274 SWNT, 89-94, 97, 98 O Oxidation Resistant Coating, 207 T TEM, 179, 180-184, 239-241, 305, 306, P 308-312 Plasma, 217-218, 223-225 Tests Plasma Enhanced-Hot Filament CVD, 189- Flexural Stress, 95-97 198 Thermal Barrier Coatings, 163, 327 Ammonia, 189-198 Thermal Conductivity, 129 Dimethylamine, 189, 190, 192-194 Thermoelectric Properties, 199-205 Methane, 189-192 Thin Films, 51-54, 199-205, 251, 273 Precursors, 189-198 FT-IR, 189, 191, 193, 196-197 Trichloroethylene, 189, 190, 194-198 Hardness, 189, 191-197 Plasma Spray, 327, 328 TiC, 153, 154, 158, 160, 161, 163-176 Polymer, 3-5, 11, 12 TiFe (Titanium Iron), 125, 147-148 Polymerization, 93 TiNiCu Thin Films, 293, 294 Porosity, 163, 340 Titanium Nitride, 217-224 Porous Films, 357, 366 Titanium Oxide, 217-223, 225 Powder Metallurgy, 153 Transparent Coating, 72

382 V Y Via Hole, 148 YbaCuO, 145-147

W Z Wide Bandgap, 113, 123 Zero Resistance Ammeter (ZRA), 340

X X-Ray Diffraction, 128 XPS, 113, 116, 119, 120, 122

383