The aim of this project is to develop a strategy for real-time monitoring and control of physical vapour deposition processes to increase the reproducibility of vital parameters such as coating thickness, coating composition, coating adhesion and vacuum quality and thereby provide significantly enhanced quality assurance of the coatings produced. This will enable penetration of the estimated seventy five percent of the market for PVD coatings in high value manufacturing that is not currently served, supporting innovation in this important sector of the UK economy. Monitoring and control of all process stages – evacuation, substrate cleaning and coating deposition - will be, innovatively, undertaken using a single technology – optical emission spectrometry. This will be used to identify and monitor relevant emission lines associated with particular process stages to identify and signal end points, including the thickness of the coating deposited. The approach will also be applied to condition monitoring of the coating equipment to optimise maintenance schedules and system availability

This project will investigate the feasibility of creating coated FSW tools using a novel high energy physical vapour deposition (PVD) process – HiPIMS (High Power Impulse Magnetron Sputtering). Friction Stir Welding (FSW) is an innovative joining process, which uses a rotating, non-consumable tool, which is traversed along the interface of two work-pieces. The process typically provides enhanced weld quality, strength and durability together with reduced energy consumption and environmental impact when compared to conventional fusion welding processes. However, FSW tooling is an extremely demanding environment – high temperature (>700°C), high abrasion and exposure to the reactive effects of freshly exposed metal surfaces – this has limited its commercial application to low melting point alloys, principally aluminium. Through the application of HiPIMS coating, we hope to enable the welding of ‘high-temperature’ materials, such as steel and titanium for high-value industries (e.g. Aerospace & Transport).

Bluefrog Design, a design and development consultancy with particular expertise in water control products and Ionbond UK a business with patented technology in the deposition of Amorphous Diamond Like Coatings are undertaking a fesability study to establish the potential of novel materials in the production of high wear components, with particular reference to applications in the domestic and commercial water cartridge market.

No abstract available.