TM-Al-O-N Coating Composition for High-Temperature Cubic Stability
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Solution Overview
Problem
Existing metal nitride coatings lack thermal stability and mechanical properties at high temperatures, particularly above 1100°C, leading to precipitation of w-AlN phase and loss of cubic phase integrity.
Innovation Solution
Incorporating controlled amounts of oxygen into transition metal aluminum nitride (TM-Al-N) coatings to form TM-Al-O-N coatings with a cubic structure, which enhances thermal stability and maintains mechanical properties by preventing w-AlN precipitation at elevated temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If oxygen is incorporated into TM-Al-N coatings to form TM-Al-O-N, then thermal stability is improved and w-AlN precipitation is prevented, but coating composition complexity increases
Solution Approach 1:
The patent applies parameter changes by controlling the oxygen concentration within a specific range (1-20 at.%) to achieve improved thermal stability while preventing w-AlN precipitation. This controlled parameter modification allows the coating to maintain cubic phase integrity at high temperatures without excessive compositional complexity
Solution Approach 2:
The patent creates a composite coating structure by incorporating oxygen into the TM-Al-N system to form TM-Al-O-N. This composite approach combines the benefits of metal nitride hardness with oxygen-induced thermal stability, resulting in a multi-element coating that prevents phase decomposition at elevated temperatures
2Stability of the object's composition
If oxygen concentration is increased to prevent w-AlN precipitation, then thermal stability improves, but coating structure complexity increases
Solution Approach 1:
The patent utilizes parameter changes by optimizing oxygen concentration within specific bounds (1-20 at.%) to achieve thermal stability enhancement while maintaining a controlled and manageable coating structure. This prevents uncontrolled phase transformations and maintains structural integrity
3Device complexity
If TM-Al-N coating is used without oxygen, then coating simplicity is maintained, but thermal stability above 1100°C deteriorates due to w-AlN phase precipitation
Solution Approach 1:
The patent applies parameter changes by introducing controlled oxygen concentrations (1-20 at.%) into the TM-Al-N system, which fundamentally alters the thermal stability characteristics. This parameter modification prevents w-AlN precipitation and extends the stable temperature range above 1100°C while maintaining reasonable compositional simplicity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The TM-Al-O-N coatings exhibit significantly improved thermal stability, retaining spinodally decomposed phases with cubic structure up to 1200°C, offering superior mechanical properties and oxidation resistance for high-temperature applications.
Implementation Method 1
a coating comprising at least one coating layer of TM-Al—O—N, exhibiting a solid solution with B1 cubic structure or spinodally decomposed phases with cubic structure
Implementation Method 2
exhibiting a solid solution with B1 cubic structure or spinodally decomposed phases with cubic structure
Implementation Method 3
the oxygen concentration in the TM-Al—O—N coating layer produces an increment of the thermal stability in comparison with a (TM1−xAlx)Nz coating layer whose element composition differs from the element composition of the (TM1−xAlx)OyNz coating layer only in that the (TM1−xAlx)Nz coating layer does not comprises oxygen, in such a manner that no precipitation of w-AlN phase is produced when the coating is exposed to temperatures higher than 1100° C.
Data Source
AI summary
Coated substrate comprising a surface coated with a coating comprising at least one coating layer of (TM1−xAlx)OyNz with (0.75−y)≤z≤(1.2−y) and 0.6>y>0, exhibiting a solid solution with B1 cubic structure, wherein x is the content of aluminum in atomic fraction if only aluminum and TM are being considered for the determination of the element composition in atomic percentage, and y is the content of oxygen in atomic fraction if only 0 and N are being considered for the determination of the element composition in atomic percentage, wherein TM is one or more transition metals and 0.05<x<0.95, wherein y correspond to a value of oxygen concentration in the TM1−xAlxOyNz coating layer that produces an increment of the thermal stability in such a manner that no precipitation of w-AlN phase is produced when the coated substrate or at least the coated surface of the coated substrate is exposed to temperatures higher than 1100° C.