PVD aluminyum kaplama prosesi buharlaşma fazı ve tungsten filament tel geometri optimizasyonu
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2022
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info:eu-repo/semantics/openAccess
Özet
PVD alüminyum kaplama prosesi otomotiv aydınlatma sektöründe yaygın olarak kullanılmaktadır. Diğer kaplama proseslerine göre ekonomik ve çevre dostu olduğu için endüstride kullanımı daha da yaygınlaşmaktadır. PVD alüminyum kaplama prosesinde, proses tasarımı ve ürün geometrisi nihai ürün kalitesini direkt olarak etkilemektedir. Alüminyum kaplama kalınlığının ürünün optik gereksinimlerini karşılaması, sürdürülebilir ve homojen kalınlıkta olması prosesin en önemli çıktısı ve başlıca kriteridir. Bu çalışmanın amacı, endüstriyel boyutlardaki PVD kaplama makinesinde üretilen ürünün, kaplama kalınlığını arttıracak seri üretim koşullarına uygun proses koşullarının optimizasyon çalışması ile belirlenmesidir. Optimizasyon çalışmalarında, Taguchi L27 deneysel tasarım metodu kullanılarak, parçanın çember içerisindeki iki boyutlu konumunun, buharlaşma kaynağı olarak kullanılan tungsten filament geometrisinin, alüminyum tel kütlesinin ve makine ön ısıtma parametrelerinin, alüminyum kaplama kalınlığına olan etkisi incelenmiştir. Çalışmalar endüstriyel ölçekteki PVD kaplama makinesinde gerçekleştirilmiş ve optimum çalışma şartlar belirlenmiştir. MİNİTAB® sonuçlarının değerlendirilmesinde Taguchi'nin "en büyük daha iyi" değerlendirme kriterleri kullanılmıştır. Altlık parça üzerindeki kaplama kalınlığını en çok etkileyen faktörler, tungsten filamentin buharlaşma kaynağına olan uzaklığı ve elektrota göre konumu olarak bulunmuştur. Filamentin elektrota göre orta kısımlarda bulunması ve buhar kaynağına yakın konumlandırılması, kaplama kalınlığının artmasına ve standart sapmanın azalmasına sebep olmaktadır. Bu durum ürünün sürdürülebilirliği ve alümiyum kaplama homojenitesini arttırmaktadır. Alüminyum kütlesinin sürekli artışı kaplama kalinlığında sürekli artışa neden olmamak ile birlikte deneylerde kullanılan tungsten filament tiplerinde dezavantaj yaratmaktadır. Alüminyum kaplama kalınlığını en az etkileyen faktör ise filament geometrisidir. Kullanılan filament tiplerine göre en iyi sonucu basket tipi tungsten filament vermektedir. Fakat çalışmada kullanılan diğer tungsten tipleri, sarmal ve deve tipi arasında bariz farklılıklar yoktur, her biri seri üretim koşullarında yarattığı diğer avantajlar nedeni ile seçilebilir. Taguchi deneysel tasarım çalışmasına ek olarak, PVD makinesinin üç farklı ön ısıtma parametresi incelenmiş ve deneysel tasarım doğrulama deneyleri yapılmıştır. Ön ısıtma gelirilimin buharlaşma gerilimine yakın olması (7kV), alüminyumun sıvı fazda daha fazla sürede kalmasına ve çember zeminine damlamasına neden olmaktadır. Bu durum kaplama kalınlığını olumsuz etkilemektedir. Elde edilen sonuçlar doğrultusunda kaplama kalınlığını arttıracak proses koşulları belirlenmiştir. Bu proses koşulları gelecek projelerde yer alacak ürün ve proses tasarımlarına ait girdileri oluşturacaktır.
The PVD aluminum coating process is widely used in the automotive industry. It is becoming more widespread due to its economical and enviromental advantages compared to its alternatives. Product geometry and process design, in particular, have a direct impact on end-product quality. The most important out-puts of the process are the achievement of optical requierements, sustainable production and homogenity of the aluminium thickness. The purpose of this research is to describe the process conditions that directly affect the coating thickness under serial production settings while taking into account the industrial scale of the PVD aluminum coating equipment. For the optimization studies, Taguchi L27 experimental design method was used to determine the effects of the position of the part in two dimension, the distance between the substrat and vapour source, tungsten filament geometry, mass of the aluminum wire and machine pre-heating paramaters. The results were evaluated based on the aluminium coating thickness of the substrate. These studies were performed by using the industrial scale of PVD coating machine and optimized process conditions were determined. Taguchi's " the larger is better" evaluation criteria was chosen for the evaluation of the MİNİTAB® results. The most effective factors on the coating thickness of the substrate were determined as the subsrate position relative to the electrode and distance between the substrate and evaporation source. Increasing the closeness of the part to the source and using the middle position of the electrode caused the increase of the avarage coating thickness of the part and decrease the standart deviation of the coating. In this regard, sustainability and homogenity of the part were also improved. Contrary to expectation, steady increasement of the aluminum usage mass did not affect the coating thickness linearly or positively. However, disadvantages of aluminum mass for the tungsten filament types which were used in the studies were observed. The less effective factor on aluminum coating thickness is the type of the tungsten filament. Although basket type tungsten filament showed better perfomance compared to the others, camel and spiral type, all of them can be used in serial production by considering the advantages and disadvantages in total. In addition to the Taguchi experimental design studies, 3 different pre-heating parameters were also investigated and the verification studies of the experimental design were performed. It is the fact that when the pre- heating voltage is close to the evaporation voltage (7kV), aluminium wire stays in liquid phase more than usual and starts to drop on to the chamber ground. Thus, the coating thickness and sustaniability can be affected negatively. In conclusion, process conditions to increase the coating thickness have been determined in this study. These process conditions are expected to provide key inputs for the future product and process developments.
The PVD aluminum coating process is widely used in the automotive industry. It is becoming more widespread due to its economical and enviromental advantages compared to its alternatives. Product geometry and process design, in particular, have a direct impact on end-product quality. The most important out-puts of the process are the achievement of optical requierements, sustainable production and homogenity of the aluminium thickness. The purpose of this research is to describe the process conditions that directly affect the coating thickness under serial production settings while taking into account the industrial scale of the PVD aluminum coating equipment. For the optimization studies, Taguchi L27 experimental design method was used to determine the effects of the position of the part in two dimension, the distance between the substrat and vapour source, tungsten filament geometry, mass of the aluminum wire and machine pre-heating paramaters. The results were evaluated based on the aluminium coating thickness of the substrate. These studies were performed by using the industrial scale of PVD coating machine and optimized process conditions were determined. Taguchi's " the larger is better" evaluation criteria was chosen for the evaluation of the MİNİTAB® results. The most effective factors on the coating thickness of the substrate were determined as the subsrate position relative to the electrode and distance between the substrate and evaporation source. Increasing the closeness of the part to the source and using the middle position of the electrode caused the increase of the avarage coating thickness of the part and decrease the standart deviation of the coating. In this regard, sustainability and homogenity of the part were also improved. Contrary to expectation, steady increasement of the aluminum usage mass did not affect the coating thickness linearly or positively. However, disadvantages of aluminum mass for the tungsten filament types which were used in the studies were observed. The less effective factor on aluminum coating thickness is the type of the tungsten filament. Although basket type tungsten filament showed better perfomance compared to the others, camel and spiral type, all of them can be used in serial production by considering the advantages and disadvantages in total. In addition to the Taguchi experimental design studies, 3 different pre-heating parameters were also investigated and the verification studies of the experimental design were performed. It is the fact that when the pre- heating voltage is close to the evaporation voltage (7kV), aluminium wire stays in liquid phase more than usual and starts to drop on to the chamber ground. Thus, the coating thickness and sustaniability can be affected negatively. In conclusion, process conditions to increase the coating thickness have been determined in this study. These process conditions are expected to provide key inputs for the future product and process developments.
Açıklama
Anahtar Kelimeler
PVD kaplama, fiziksel buhar biriktirme, taguchi metodu, alüminyum kaplama, metalizasyon, PVD coating, physical vapor deposition, taguchi method, aluminium coating, metallization
