coatings Article High-Temperature Corrosion of AlCrSiN Film in Ar-1%SO2 Gas Poonam Yadav 1 , Dong Bok Lee 1, *, Yue Lin 2 , Shihong Zhang 2 and Sik Chol Kwon 3 1 2 3 * School of Advanced Materials Science & Engineering, Sungkyunkwan University, Suwon 16419, Korea; [email protected] School of Materials Science & Engineering, Anhui University of Technology, Maanshan 243002, China; [email protected] (Y.L.); [email protected] (S.Z.) Department of Advanced Materials Engineering, Chungbuk National University, Cheongju 28644, Korea; [email protected] Correspondence: [email protected]; Tel.: +82-31-290-7355 Academic Editors: Niteen Jadhav and Andrew J. Vreugdenhil Received: 26 December 2016; Accepted: 9 March 2017; Published: 13 March 2017 Abstract: AlCrSiN film with a composition of 29.1Al-17.1Cr-2.1Si-51.7N in at. % was deposited on a steel substrate by cathodic arc ion plating at a thickness of 1.8 µm. It consisted of nanocrystalline hcp-AlN and fcc-CrN, where a small amount of Si was dissolved. Corrosion tests were carried out at 800 ◦ C for 5–200 h in Ar-1%SO2 gas. The major corrosion reaction was oxidation owing to the high oxygen affinity of Al and Cr in the film. The formed oxide scale consisted primarily of (Al,Cr)2 O3 , within which Fe, Si, and S were dissolved. Even after corrosion for 200 h, the thickness of the scale was about 0.7–1.2 µm, indicating that the film had good corrosion resistance in the SO2 -containing atmosphere. Keywords: AlCrSiN film; oxidation; sulfidation; SO2 gas corrosion 1. Introduction Aluminum nitride films have good oxidation resistance due to the formation of Al2 O3 scale [1]. Their properties can be enhanced by alloying with the transition metal Cr. AlCrN films have been applied on dies, molds, and cutting tools [2] for their high hardness [3], thermal stability [4], good resistance to wear [5], and oxidation [6–9]. AlCrN films were oxidized to Al2 O3 and Cr2 O3 [6], or (Cr,Al)2 O3 [9], which suppressed oxygen diffusion. The addition of Si to the AlCrN films refines the grain [10,11], decreases crystallinity [11], increases hardness [12,13], and improves the resistance to wear [10] and oxidation [13–15]. AlCrSiN films have been deposited on cemented carbides [11,13,16], Si [11,12,15], and steel [10–12,17] by cathodic arc evaporation [11,16,17], cathodic arc ion plating [10], and magnetron sputtering [13,15]. The high-temperature oxidation of AlCrSiN films in air results in the formation of thin, dense oxide layers consisting primarily of Cr2 O3 [17], (Cr2 O3 , Al2 O3 ) [14], and (Cr2 O3 , Cr2 O5 , Al2 O3 ) [13]. However, the corrosion behavior of AlCrSiN films in various corrosive environments needs be investigated for broad applications. In this study, the high-temperature corrosion of AlCrSiN film in a SO2 -containing atmosphere was performed, with an emphasis on TEM/EDS analyses. Resistance to sulfur-containing atmospheres is vital for utilizing AlCrSiN as the protective coating in petrochemical plants, coal-gasification units, turbines, and heat exchangers. Sulfur in SO2 can induce serious corrosion by forming non-protective, highly non-stoichiometric sulfide scales [18]. In this study, corrosion tests were carried out on AlCrSiN film at 800 ◦ C for 5–200 h in Ar-1%SO2 gas. The microstructure, corrosion products, and corrosion mechanism of the AlCrSiN film are discussed. Coatings 2017, 7, 44; doi:10.3390/coatings7030044 www.mdpi.com/journal/coatings Coatings 2017, 7, 44 2 of 6 2. Experimental Section Coatings 2017, 7, 44 2 of 6 AlCrSiN film was deposited on a steel substrate (AISI M2 high speed steel; Fe-6W-5Mo-4Cr-2V 2. Experimental Section in wt %) by cathodic arc ion plating using Cr and Al88 Si12 cathodes. It was deposited for 5 h at a ◦ C, a(AISI AlCrSiN film on a steel substrate high speed steel;V,Fe-6W-5Mo-4Cr-2V nitrogen pressure of 1was Pa, deposited a temperature of 400 bias M2 voltage of −150 an arc current of 55 A, in wt %) by cathodic arc ion plating using Cr and Al 88Si12 cathodes. It was deposited for 5 h at a and a cathode-to-substrate distance of 7 cm. The rotation speed of the sample holder was 3 rpm, nitrogen pressure of 1 Pa, a temperature of 400 °C, a bias voltage of −150 V, an arc current of 55 A, and an AlCrN interlayer was deposited between the film and the substrate for 20 min. The coated and a cathode-to-substrate distance of 7 cm. The rotation speed of the sample holder was 3 rpm, and samples were corroded at 800 ◦ C for 5–200 h in the flowing Ar-1%SO gas inside the quartz reaction an AlCrN interlayer was deposited between the film and the substrate for2 20 min. The coated samples tube, which was heated inside tube furnace. Following corrosion, the coated samples were inspected were corroded at 800 °C fora 5–200 h in the flowing Ar-1%SO 2 gas inside the quartz reaction tube, using which a scanning electron microscope (SEM), Auger electron spectrometer (AES), X-ray photoelectron was heated inside a tube furnace. Following corrosion, the coated samples were inspected spectrometer (XPS), and transmission microscope operated at 200 keV) equipped with using a scanning electron microscopeelectron (SEM), Auger electron (TEM spectrometer (AES), X-ray photoelectron spectrometer (XPS), and transmission electron at 200 keV) equipped with an energy dispersive spectrometer (EDS with 5microscope nm spot (TEM size). operated The TEM samples were prepared by an energy dispersive spectrometer (EDS with 5 nm spot size). The TEM samples were prepared by milling using a focused ion beam system after carbon coating. milling using a focused ion beam system after carbon coating. 3. Results and Discussion 3. Results and Discussion Figure 1 shows the TEM/SAED/EDS results of the as-deposited AlCrSiN film, the composition Figure 1 shows the TEM/SAED/EDS results of the as-deposited AlCrSiN film, the composition of which was 29.1Al-17.1Cr-2.1Si-51.7N in at.in%at.according to the probe microanalysis (EPMA). of which was 29.1Al-17.1Cr-2.1Si-51.7N % according to electron the electron probe microanalysis The AlCrSiN film was 1.8 µm thick, single-layered (Figure 1a), and consisted of nanocrystalline (EPMA). The AlCrSiN film was 1.8 μm thick, single-layered (Figure 1a), and consisted hcp-AlN of and fcc-CrN (Figurehcp-AlN 1b). It is known that the crystal CrAlN changes from B1-fcc to nanocrystalline and fcc-CrN (Figure 1b). It is structure known thatofthe crystalfilms structure of CrAlN films fromAlN B1-fcc to B4-hcp above AlNat.concentration of 65–75 at. %of [6], the addition Si B4-hcpchanges above the concentration of the 65–75 % [6], and the addition Siand to CrAlN filmsoffacilitates to CrAlNof films facilitates hcp-AlN [16]. Inofthis study,seemed the nucleation of hcp-AlN by Si. the formation hcp-AlN [16].the In formation this study,ofthe nucleation hcp-AlN to be accelerated seemed to beAlN-rich accelerated by was Si. Inbrighter Figure 1c, the the AlN-rich area was In Figure 1c, the area than CrN-rich areabrighter becausethan Al the hasCrN-rich a lower area scattering because Al has a lower scattering factor than Cr. Si dissolved rather uniformly in the film, as shown factor than Cr. Si dissolved rather uniformly in the film, as shown in Figure 1d. Here, the presence of in Figure 1d. Here, the presence of nitrogen in the film was ignored, because TEM/EDS could not nitrogen in the film wasthe ignored, because TEM/EDS could not accurately quantify the light element. accurately quantify light element. (a) carbon coating (b) CrN(222) AlN(101) Film CrN(220) AlN(103) CrN(200) 0.5 μm (c) B 200 nm Concentration (at.%) substrate (d) 60 Al 40 Cr 20 Si 0 0 300 100 200 Distance (nm) 400 Figure 1. As-deposited AlCrSiN film. (a) TEM cross-sectional image; (b) selected area electron Figure 1. As-deposited AlCrSiN film. (a) TEM cross-sectional image; (b) selected area electron diffraction (SAED) pattern of the film; (c) enlarged TEM image of the film; (d) EDS concentration diffraction (SAED) pattern of the film; (c) enlarged TEM image of the film; (d) EDS concentration profiles along A-B shown in (c). profiles along A-B shown in (c). Gold was deposited on the AlCrSiN film using a sputter, and corroded at 800 °C for 5 h in order ◦ C for to understand the corrosion of the AlCrSiN film atand the corroded early corrosion stage. In Figure 2, Gold was deposited on themechanism AlCrSiN film using a sputter, at 800 5 h in order to the highest point of Au indicates the original film surface. During corrosion, nitrogen diffused understand the corrosion mechanism of the AlCrSiN film at the early corrosion stage. In Figure 2, the outwardly from the film, while oxygen and sulfur diffused inwardly. Oxygen diffused dominantly highest point of Au indicates the original film surface. During corrosion, nitrogen diffused outwardly and deeply, while sulfur was present only at the outermost surface. The ingress of sulfur through from the film,oxides whilecould oxygen and sulfur diffused inwardly. Oxygen diffused compact be limited, because the solubility of sulfur in most oxides dominantly is very limitedand [19].deeply, while sulfur was present only at the outermost surface. The ingress of sulfur through compact oxides could be limited, because the solubility of sulfur in most oxides is very limited [19]. It is worth noting that oxides are thermodynamically more stable than the corresponding sulfides. Since Al is more active Coatings 2017, 2017, 7, 7, 44 44 Coatings Coatings 2017, 7, 44 33 of of 66 3 of 6 It is worth noting that oxides are thermodynamically more stable than the corresponding sulfides. than Al predominantly underneath the Au film.stable Silicon was and non-uniformly Since Al is oxidized more than Cr, oxidized predominantly underneath the Au film. Silicon was It isCr, worth notingactive that oxides areAl thermodynamically more than theweakly corresponding sulfides. present in the film. weakly present inoxidized the film. predominantly underneath the Au film. Silicon was Since and Al isnon-uniformly more active than Cr, Al weakly and non-uniformly present in the film. ◦ C for Figure 2. 2. AES depth profiles the AlCrSiN film after corrosion at800 800 5h in Ar-1%SO 2 gas. Figure 2. AES depth profiles ofof the AlCrSiN film after corrosion atat 800 5for h5 in Ar-1%SO The Figure AES depth profiles of the AlCrSiN film after corrosion °C°Cfor h in Ar-1%SO 2 gas. 2 gas. The penetration rate is 19 nm/min for the reference SiO 2 . penetration rate israte 19 nm/min for the SiO2SiO . 2. The penetration is 19 nm/min forreference the reference Figure of the AlCrSiN AlCrSiNfilm filmafter aftercorrosion corrosionatat 800 °C 10 The h. The Figure33 3shows showsthe theTEM/EDS TEM/EDS results results of of the 800 forfor ◦10 Figure shows the TEM/EDS results the AlCrSiN film after corrosion at°C800 C h. for 10 h. scale was 0.20.2μm reflecting the corrosion resistanceofofthe the AlCrSiN film (Figure 3a). Oxide scale was μmthick, thick, reflecting thegood good corrosion resistance film (Figure Oxide The scale was 0.2 µm thick, reflecting the good corrosion resistanceAlCrSiN of the AlCrSiN film3a). (Figure 3a). whiskers protruded (Figure3b). 3b).According Accordingtotothe theTEM/EDS TEM/EDS spot analysis, whiskers protrudedover overangular angularoxide oxide grains grains (Figure spot analysis, Oxide whiskers protruded over angular oxide grains (Figure 3b). According to the TEM/EDS spot scaleconsisted consistedofof(Al,Cr) (Al,Cr)2O 2O33 grains grains with dissolved Chromia and α- αthethe scale dissolved Fe Feand andSiSiions ions(Figure (Figure3c). 3c). Chromia and analysis, the scale consisted of (Al,Cr)2 O3 grains with dissolved Fe and Si ions (Figure 3c). Chromia and 3 are misciblebecause becausethey theyhave havethe the same corundum ofof Si Si shown in Figure AlAl 2O23O are miscible corundumstructure. structure.The Theamount amount shown in Figure α-Al2 O3 are miscible because they have the same corundum structure. The amount of Si shown in inaccurate,because becausethe thespurious spurious Si Si signal can owing to to thethe 3c 3c is is inaccurate, can come come out outfrom fromthe theEDS EDSdetector detector owing Figure 3c is inaccurate, because the spurious Si signal can come out from the EDS detector owing to the internal fluorescence. Iron diffused outward from the substrate through the nanocrystalline film internal fluorescence. Iron diffused outward from the substrate through the nanocrystalline film internal fluorescence. Iron diffused outward from the substrateSince through the nanocrystalline film toward toward thesurface surfaceaccording accordingto tothe the concentration concentration gradient. preferentially toward the gradient. Sinceoxidation oxidationoccurred occurred preferentially theowing surface according to the concentration gradient. Since oxidation occurred preferentially owing to the thermodynamicstability stability of of the the oxides, oxides, sulfur 3c.3c. The XPS analysis, owing toto the thermodynamic sulfurwas wasabsent absentininFigure Figure The XPS analysis, thehowever, thermodynamic stability ofatthe oxides, sulfur was absent in Figure 3c. The XPS analysis, however, identified 2.6 at. %S the surface of the (Al,Cr) 2O3 scale. Such a discrepancy in the chemical however, identified 2.6 at. %S at the surface of the (Al,Cr)2O3 scale. Such a discrepancy in the chemical identified 2.6 at.of%S the surface ofthe thesurface (Al,Cr)2was O3 scale. Suchto a discrepancy the chemicalofcomposition composition theatoxide scale at attributed the differentindetectability XPS and composition of the oxide scale at the surface was attributed to the different detectability of XPS and of TEM-EDS. the oxide scale at the surface was attributed to the different detectability of XPS and TEM-EDS. TEM-EDS. Figure 3. AlCrSiN film after corrosion at 800 °C for 10 h in Ar-1%SO2 gas. (a) TEM cross-sectional Figure 3. AlCrSiN film after corrosion at 800 ◦ C for 10 h in Ar-1%SO2 gas. (a) TEM cross-sectional image, (b) enlarged image of rectangular area shown in (a), (c) EDS concentration profiles along the image, enlargedfilm image of corrosion rectangular shown in h (a), EDS concentration profiles along the Figure (b) 3. AlCrSiN after at area 800 °C for 10 in(c) Ar-1%SO 2 gas. (a) TEM cross-sectional spots 1–14. spots image,1–14. (b) enlarged image of rectangular area shown in (a), (c) EDS concentration profiles along the spots 1–14. Coatings 2017, 2017, 7, 7, 44 44 Coatings of 66 44 of Figure 4 shows the TEM/EDS results of the AlCrSiN film after corrosion at 800 °C for 50 h. The ◦ C for 50 h. 4 shows the TEM/EDS results of the the slowly AlCrSiN film after corrosion at 8004a). scaleFigure was still thin because of the formation growing oxide scale (Figure Spots 1–3 The scale was still thin because of the formation of the slowly growing oxide scale (Figure 4a). Spots 1–3 and 4–9 corresponded to the (Fe, Si, S)-dissolved (Al,Cr)2O3 scale and the S-free, (Fe, O)-dissolved and 4–9 corresponded to the (Fe, Si, S)-dissolved (Al,Cr) scale and the S-free, (Fe, O)-dissolved AlCrSiN film, respectively (Figure 4b). Nitrogen was around the oxide scale. The 2 O3absent AlCrSiN film, respectively (Figure4b4b). was absent around the of oxide The concentrations concentrations shown in Figure are,Nitrogen however, suspicious, because the scale. difficulty in quantifying shown in Figure are,Si. however, suspicious, of the difficulty in quantifying nitrogen, nitrogen, oxygen,4band Nonetheless, sulfurbecause was detected at the outer part of the scale. The oxygen, inward and Si. Nonetheless, sulfur was at the outer The inward diffusion ofamount oxygen diffusion of oxygen through thedetected nanocrystalline filmpart led of tothe thescale. dissolution of rather a large through theinnanocrystalline film led to theshown dissolution of rather a large of oxygen the film. of oxygen the film. The oxide grains in Figure 4a were tensamount of nanometers inindiameter. The oxide grains shown in such Figure nanometers in diameter. Dissolution foreign Dissolution of foreign ions as 4a Fe were and Sitens canoffacilitate the rapid establishment of the of protective ions such Fe and Si can facilitate the rapid establishment of the (Al,Cr) (Al,Cr) 2O3 as scale by increasing the defect concentration through the protective doping effect. The 2 Oprotruded 3 scale by increasing the defect through the effect. diffusion The protruded oxides at spots 1 and oxides at spots 1 and concentration 2 were evidently formed bydoping the outward of Cr, Al, Fe, and Si. Hence, 2it were evidently formed byproceeded the outward diffusion ofinward Cr, Al, transport Fe, and Si. is seen that the is seen that the corrosion not only by the of Hence, oxygen it (see Figure 2) but corrosion proceeded only by inward transport oxygen (see Figure 2) Figures but also 3byand the4). outward also by the outward not diffusion ofthe cations from the filmofand the substrate (see At the diffusion of of cations from the the substrate Figures 3 and 4). Atthat the outer part oftothe scale, outer part the scale, Cr film was and frequently richer(see than Al, suggesting Cr tended diffuse Cr was frequently richer outwardly faster than Al.than Al, suggesting that Cr tended to diffuse outwardly faster than Al. Figure 4. 4. AlCrSiN after corrosion corrosion at at 800 800 ◦°C for 50 50 h. h. (a) (a) TEM TEM cross-sectional cross-sectional image; image; (b) (b) EDS EDS Figure AlCrSiN film film after C for concentration profiles profiles along along the the spots spots 1–10. 1–10. concentration The SEM/TEM/EDS results of the AlCrSiN film at the later stage of corrosion are shown in The SEM/TEM/EDS results of the AlCrSiN film at the later stage of corrosion are shown in Figure 5. The surface of the scale was covered with angled, round, and rod-shaped oxide grains Figure 5. The surface of the scale was covered with angled, round, and rod-shaped oxide grains (Figure 5a). Spots 1–4 shown in Figure 5b show a rod-shaped (Al,Cr)2O3 grain dissolved with Fe, Si, (Figure 5a). Spots 1–4 shown in Figure 5b show a rod-shaped (Al,Cr)2 O3 grain dissolved with Fe, and S (Figure 5c). Al, Cr, Fe, and Si clearly diffused outwards to spots 1–4. The ratio of Al/Cr in the Si, and S (Figure 5c). Al, Cr, Fe, and Si clearly diffused outwards to spots 1–4. The ratio of Al/Cr oxide scale fluctuated depending on the location, as shown in Figure 5c. For example, spots 1–4 are in the oxide scale fluctuated depending on the location, as shown in Figure 5c. For example, spots Al-rich, while spots 5 and 6 are Cr-rich. More frequently, Cr-rich oxide scale formed on the Al-rich 1–4 are Al-rich, while spots 5 and 6 are Cr-rich. More frequently, Cr-rich oxide scale formed on the oxide scale. Spot 7 indicates that the (Al,Cr)2O3 oxide contained some Si, S, and N. At spot 8, the Al-rich oxide scale. Spot 7 indicates that the (Al,Cr)2 O3 oxide contained some Si, S, and N. At spot 8, nitride film began to oxidize. Spots 9–14 corresponded to the (Fe, O, S)-dissolved AlCrSiN film. the nitride film began to oxidize. Spots 9–14 corresponded to the (Fe, O, S)-dissolved AlCrSiN film. Coatings 2017, 7, 44 Coatings 2017, 7, 44 5 of 6 5 of 6 Figure 5. corrosion at at 800 800 ◦°C for 200 200 h h in in Ar-1%SO Ar-1%SO22 gas. Figure 5. AlCrSiN AlCrSiN film film after after corrosion C for gas. (a) (a) SEM SEM top top view; view; (b) (b) TEM TEM cross-sectional image; (c) EDS concentration profiles along the spots 1–14. cross-sectional image; (c) EDS concentration profiles along the spots 1–14. 4. Conclusions 4. Conclusions The AlCrSiN AlCrSiN film was single-layered, single-layered, and nanocrystalline hcp-AlN The film was and consisted consisted of of nanocrystalline hcp-AlN and and fcc-CrN, fcc-CrN, which had a small amount of dissolved Si. Its corrosion behavior was studied at 800 °C for 5–200 h ◦ which had a small amount of dissolved Si. Its corrosion behavior was studied at 800 C for 5–200 h in in Ar-1% SO 2 gas. At the early corrosion stage, Al oxidized preferentially at the surface. As the Ar-1% SO2 gas. At the early corrosion stage, Al oxidized preferentially at the surface. As the corrosion corrosion proceeded, the competitive and to the formation (Al,Cr) 2O3 grains proceeded, the competitive oxidationoxidation of Al andof CrAl led to Cr theled formation of (Al,Cr)of2 O 3 grains with or with or without dissolved ions Fe,S.Si, and S. TheO(Al,Cr) 2O3 scale effectively protected the film. The without dissolved ions of Fe, Si, of and The (Al,Cr) 2 3 scale effectively protected the film. The corrosion corrosion proceeded not only by the inward transport of oxygen sulfur, but outward also by the outward proceeded not only by the inward transport of oxygen and sulfur, and but also by the diffusion of diffusion of Al, Cr, Si, and N from the film as well as Fe from the substrate. Compared to sulfur, Al, Cr, Si, and N from the film as well as Fe from the substrate. Compared to sulfur, oxygen diffused oxygen diffused dominantly andfilm. deeply the of film. of the with scaleangled, was covered dominantly and deeply into the The into surface the The scalesurface was covered round,with and angled, round, and rod-shaped oxide grains. rod-shaped oxide grains. Acknowledgments: This work was supported under the framework of the international cooperation program Acknowledgments: This work wasFoundation supported under the(2016K2A9A1A01952060). framework of the international cooperation program managed by the National Research of Korea managed by the National Research Foundation of Korea (2016K2A9A1A01952060). Author Contributions: Contributions: Yue YueLin, Lin,Shihong ShihongZhang Zhangand andSik Sik Chol Kwon synthesized coatings by cathodic arc Author Chol Kwon synthesized thethe coatings by cathodic arc ion ion plating. 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