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Microstructural Assessment of Molybdenum Disulfide Coatings Using Nanoindentation Hardness.

Tomas F Babuska1, Alexander Mings1, Steven R Larson1

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Physical vapor deposition (PVD) molybdenum disulfide (MoS2) coatings offer superior performance. Nanoindentation hardness reliably predicts MoS2 coating properties and wear rate, enabling process optimization for aerospace and defense.

Keywords:
MoS2PVDcrystallinitydensityfrictionhardnessnanoindentationwear

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Area of Science:

  • Materials Science
  • Tribology
  • Thin Film Deposition

Background:

  • Molybdenum disulfide (MoS2) coatings are critical for aerospace and defense due to low friction and high wear resistance.
  • Traditional MoS2 coatings (burnished, resin-bonded) face consistency issues, while Physical Vapor Deposition (PVD) offers better control but higher costs and adoption hesitancy.
  • Variability in PVD MoS2 properties stems from complex process-structure-property relationships.

Purpose of the Study:

  • To elucidate the process-structure-property relationships in PVD MoS2 coatings.
  • To develop performance-based metrics for assessing microstructural changes and accelerating PVD process development.
  • To establish reliable methods for identifying high-performance PVD MoS2 coatings.

Main Methods:

  • Characterization of microstructure, mechanical, and tribological properties of 61 distinct PVD pure MoS2 coatings.
  • Development of performance-based metrics, focusing on hardness and modulus, to correlate with microstructural features (density, orientation, crystallinity).
  • Utilizing nanoindentation to infer coating performance (wear rate) and properties (density, texture, stoichiometry).

Main Results:

  • Established correlations between nanoindentation hardness and key coating properties, including density, crystalline texture, and stoichiometry.
  • Demonstrated that nanoindentation hardness can effectively predict tribological performance (wear rate).
  • Identified that PVD MoS2 coatings near theoretical density exhibit superior tribological performance.

Conclusions:

  • Nanoindentation hardness serves as a reliable, performance-based metric for evaluating PVD MoS2 coatings.
  • Understanding and controlling PVD process parameters to achieve near-theoretical density is key to optimizing tribological performance.
  • This work provides a pathway for accelerated development and optimization of PVD MoS2 coatings for demanding applications.