Abstract
The challenges in surface engineering coupled with the modeling and simulation of corrosive-wear and mechanical properties for metallic materials were discussed in the quest for remedial approaches in order to contain these menaces that engulf the optimum performance of materials for a given application. Corrosion, wear and hardness are properties that determine the outstanding performance of any material for surface engineering applications. The aims of this research work are to carry out experimental analysis and develop a numerical model which simulates properties such as hardness and wear on material surface obtained from magnetron sputtering process due to ion-exchange formation up to the thin films solidification of titanium–carbide coated on brass and copper substrates in solid states (i.e., TiC-Br and TiC-Cu conjugates) within a unified domain. This thesis proposed both experimental and computer simulation techniques for titanium carbide (TiC) thin films materials fabricated on brass and copper metallic materials comparative results and suggestions for optimum behaviour amongst the test samples. Nevertheless, this is an experimental method to determine the wear and mechanical (i.e., hardness) behaviours that occur at the surface and interface of coating/substrate and are observed to be stringent, expensive and time consuming. Numerical simulation-based computational wear and mechanical modeling is an alternative method which is faster and cheaper than real testing and can be used in addition to testing to help improve component design and enhance wear and mechanical characteristics. Developing a finite element (FE) algorithm analysis using ANSYS R19.2 Academic workbench software that can approximately and accurately predict wear, as well as the mechanical behaviour, thereby considering surface wear damage and hardness behaviour and then verify with experimental results are the main objectives of this research study. This thesis involves the use of radio frequency magnetron sputtering (RFMS) technique to deposit TiC ceramic material onto the surface of brass and copper substrate materials using HHH-TF500 sputtering equipment. Extensive experimental tests which involve characterizations of specimens for microstructural, microhardness, corrosion and tribological analyses were investigated. The experimental tests used in this research study were done to explicitly determine the surface damage in terms of corrosion, indentation and wear which are regarded as destructive tests and on the other hand, the non-destructive tests which includes Fourier transform infrared (FTIR) spectroscope done in transmittance mode, x-ray diffraction (XRD), scanning electron microscope (SEM), optical microscope (OM) and atomic force v microscope (AFM) for microstructural analysis of the coating/substrate conjugates system. The results obtained from experimental approach are introduced into the modeling and simulation technique to validate the behaviour and performance of the individual specimen at varied process parameters. The modeling and numerical simulation analyses presented could be used in areas of cutting tools’ applications and as well as automotive manufacturing industries. However, the advent of industry 4.0 (i.e., 4th industrial revolution, 4IR), will help in predictive measures acquired from modeling and numerical simulation results obtained from different experiments which could be embedded into the production line to perform bulk manufacturing at fewer human activities.
Ph.D. (Mechanical Engineering)