SBIR-STTR Award

A novel coating technology is proposed for increased wear and improved life and reliability of commutator bars in electrical sliding devices found in manned and unmanned underwater vehicles. Diamond-Like Nanocomposite (DLN) coatings represent a family Of thiWrfilms that bxhibit unique combinations of technologically interesting properties including high adhesion to virtually any substrate (including metals, crystalline and glass dielectrics, plastics), excellent chemical and diffusion, barrier properties 4;,good hardnew-high elasticity and flexibility high wear resistance, very high thermal-shock resistance, extremely low friction coefficient, controllable electric properties, and good thermal stability. Substrate size is limited only by chamber size currently a substrate of maxim= size 800 mm can be coated), and both interior and exterior surfaces can be coated. Also, the few-micron thick films can be continuously graded in composition and hence properties tailored from the interface to the bulk. Phase I work will be devoted to a demonstration of lftbbscoatings and performance on actual commutator bars in DC motors. Motor performance till be compared before and after coating, using several tests including efficiency, maximum power, horse power, temperature rises and torque. Property measurements will include hardness, electrical conductivity and wear resistance Phase II work would involve improved coating designs and implementation of hardware modifications.

A new class of thin film materials, diamond-like nanocomposites (DLN), has developed. These materials have properties that make them excellent candidates for coating sliding electrical contacts. In the recently completed Phase I program, the unique properties of the coatings were demonstrated. In the Phase II program, we propose to coat coupons and motor parts. Coating motor parts is expected to result in significantly higher motor performance and lower maintenance. A series of coating depositions will be performed to optimize the desposition parameters for the specific substrate materials. We propose to study tribological properties of the coatings in collaboration with Oak Ridge National Lab. Coatings will also be tested through simulations and in actual motors. We will work with MET, a motor manufacturer, who will supply motor parts and test the performance of motors containing DLN coated components.

Benefits:
High performance motors, wear-resistant electrical contacts, ultra-capacitors, ink-jet heads as well as other applications requiring high wear-resistance.

Keywords:
diamond like wear DLN nanocomposite motors