B4 - DLC Coatings for Forming Tools
Tribological DLC Coatings in Combination with Surface Texturing for Forming Tools to Increase Lifetime and to Improve Process Quality
Project Status: finished
Last Update: 01.10.2020
Members
In the second phase of TCRC 73, it was shown that, in sheet bulk metal forming (SBMF), tungsten-modified hydrogenated amorphous carbon coatings can affect friction between tool and workpiece. Methods of design of experiment were used to identify the impact of parameters of the coating process on the coatings’ mechanical properties and tribological behavior. The findings were used to predict and adjust the coatings’ properties. Furthermore, masking and ablation techniques were used to combine coatings with different tribological behavior on the same surface, allowing a local adaption of tribological conditions in sheet-bulk metal forming processes.
In the third phase, the coatings‘ contribution to an extension of the tool’s lifetime will be analyzed. Therefore, the coatings’ fatigue life and wear resistance will be examined and finally improved by adaption of the coatings’ architectures. Moreover, high-energetic deposition of adhesion layers and adjustment of stress in the substrate material can affect the coatings’ adhesion and wear resistance. Additional subsequent mechanical treatment will be used to reduce the roughness of coated surfaces. To ensure an individual lifetime of DLC-coated components, a carbon-based sensor coating is being developed. Research comprises the development of appropriate coating architectures, electrical bonding as well as electrical, mechanical and tribological characterization. Furthermore, a-C:H:W coatings will be used to improve die filling in sheet-bulk metal forming processes. Therefore, a-C:H:W coatings will be combined with surface modifications developed within the TCRC 73. The coatings’ wear resistance under real test conditions and the coatings’ impact on die filling of functional parts of manufactured components will be investigated for the first time.

Fig. 1: Vision of a SBMF tool, locally coated with carbon-based sensor coatings.
Working Groups
Publications
2021
- Weikert, T.; Wartzack, S.; Baloglu, M. V.; Willner, K.; Gabel, S.; Merle, B.; Pineda, F.; Walczak, M.; Marian, M.; Rosenkranz, A.; Tremmel, S.: Evaluation of the surface fatigue behavior of amorphous carbon coatings through cyclic nanoindentation. In: Surface & Coatings Technology, 407(2021), Elsevier B.V., pp. 126769
- Weikert, T.; Tremmel, S.: Amorphous Carbon Coatings for Sheet-Bulk Metal Forming Tools. In: M. Merklein, A. E. Tekkaya, B.-A. Behrens (Edt.): Sheet Bulk Metal Forming. Research Results of the TCRC73 2020. Lecture Notes in Production Engineering, (2021), Zug: Springer Nature Switzerland, pp. 192-215
2020
- Tremmel, S.; Marian, M.; Rothammer, B.; Weikert, T.; Wartzack, S.: Designing amorphous carbon coatings using numerical and experimental methods within a multi-scale approach. In: Key Engineering Materials, (2020), Trans Tech Publications, accepted
- Weikert, T.; Tremmel, S.; Stangier, D.; Tillmann, W.; Krebs, E.; Biermann, D.: Tribological Studies on Multi-Coated Forming Tools. In: Journal of Manufacturing Processes, 49(2020), pp. 141-152
- Weikert, T.; Tremmel, S.: Dünnschichtsensoren zur Verschleißdetektion als Beitrag zur Auslegung intelligenter Werkzeuge – eine Machbarkeitsstudie. In: M. Merklein, B.-A. Behrens, A. E. Tekkaya (Edt.): 4. Workshop Blechmassivumformung: Umformtechnische Herstellung von komplexen Funktionsbauteilen mit Nebenformelementen aus Feinblechen, (2020), Erlangen: FAU University Press, pp. 133-146
- Weikert, T.; Tremmel, S.: Amorphe Kohlenstoffschichten für Werkzeuge der Blechmassivumformung. In: B.-A. Behrens (Edt.): Aktuelle Entwicklungen im Bereich der Umformtechnik, (2020), Garbsen, pp. 1-2
2019
- Marian, M.; Weikert, T.; Tremmel, S.: On Friction Reduction by Surface Modifications in the TEHL Cam/Tappet‐Contact‐Experimental and Numerical Studies. In: Coatings, 9(2019)12, MDPI, pp. 1-16
- Marian, M.; Weikert, T.; Tremmel, S.: Numerical and Experimental Studies on Friction Reduction by Surface Modification in TEHL Contacts. In: Proceedings of the 74th STLE Annual Meeting & Exhibition, (2019), pp. 1-3
2018
- Weikert, T.; Tremmel, S.: Wear Detection using Carbon-Based Sensor Coatings – a novel approach. In: Proceedings of The 18th Nordic Symposium on Tribology – NORDTRIB 2018, (2018), pp. 1-2
Presentations
2020
- 05.03.2020: Weikert, T.: Amorphe Kohlenstoffschichten für Werkzeuge der Blechmassivumformung, 23. Umformtechnisches Kolloquium Hannover
2019
- 12.03.2019: Weikert, T.: Dünnschichtsensoren zur Verschleißdetektion als Beitrag zur Auslegung intelligenter Werkzeuge – eine Machbarkeitsstudie, 4. Workshop Blechmassivumformung, Garbsen
- 19.05.2019: Marian, M.: Numerical and Experimental Studies on Friction Reduction by Surface Modification in TEHL Contacts, 74th STLE Annual Meeting & Exhibition, Nashville, Tennessee
2018
- 18.06.2018: Weikert, T.: Wear Detection using Carbon-Based Sensor Coatings – a novel approach, Nordtrib 2018, Uppsala