Conventional thermal spraying processes are almost exclusively carried out in an air atmosphere, resulting in the oxidation of the particle surfaces and interfaces within the coating and between the substrate and coating. Furthermore, the initial process of surface activation conventionally takes place in an air atmosphere, preventing an oxide-free interfacial transition. Consequently, the application of spraying materials with high oxygen affinity represents a major challenge. To overcome these issues, the present study utilized silane-doped inert gases to create an environment in which the oxygen concentration was equivalent to the residual oxygen content in an extreme high vacuum. By transferring the corundum blasting and coating process (wire arc spraying) to this environment, materials with a high oxygen affinity can be applied without oxidation occurring. For industrial use, this is an interesting prospect, e.g., for repair coatings, as the homogeneity of the composite is improved by a non-oxidized coating. Using the example of arc-sprayed copper coatings, the microstructure and mechanical properties of the coatings were analysed. The results showed that the oxide-free, wire arc sprayed copper coatings exhibited an improved wetting behaviour resulting in a significant reduction of the coating porosity. Moreover, the improved wetting behaviour and led to an increase in the bonding rate and apparent Young’s modulus. Contrary to expectations, the residual stresses decrease although relaxation mechanisms should be inhibited, and possible reasons for this are discussed in the paper.

Engineering in vacuum or under a protective atmosphere permits the production of materials, wherever the absence of oxygen is an essential demand for a successful processing. However, very few studies have provided quantitative evidence of the effect of oxidized surfaces to tribological properties. In the current study on 99.99% pure copper, it is revealed that tribo-oxidation and the resulting increased abrasive wear can be suppressed by processing in an extreme high vacuum (XHV) adequate environment. The XHV adequate atmosphere was realized by using a silane-doped shielding gas (1.5 vol% SiH₄ in argon). To analyse the influence of the ambient atmosphere on the tribological and mechanical properties, a ball—disk tribometer and a nanoindenter were used in air, argon, and silane-doped argon atmosphere for temperatures up to 800 °C. Resistance measurements of the resulting coatings were carried out. To characterize the microstructures and the chemical compositions of the samples, the scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD) were used. The investigations have revealed a formation of η-Cu₃Si in silane-doped atmosphere at 300 °C, as well as various intermediate stages of copper silicides. At temperatures above 300 °C, the formation of γ-Cu₅Si were detected. The formation was linked to an increase in hardness from 1.95 to 5.44 GPa, while the Young’s modulus increased by 46% to 178 GPa, with the significant reduction of the wear volume by a factor of 4.5 and the suppression of further oxidation and susceptibility of chemical wear. In addition, the relevant diffusion processes were identified using molecular dynamics (MD) simulations.

Wear and the resulting temperature has a significant influence on the frictional contact behavior of two surfaces in contact. In order to establish accurate wear prediction models, it is essential to measure the temperature at the point of action. This work shows the approach for manufacturing a component-inherent temperature sensor on a ceramic sphere via laser structuring in order to measure friction-induced temperature changes precisely at the point of action during tribologically relevant ball-on-disc tests. Within this paper, different sensor layouts are tested and the sensor fabrication and high temperature contacting via laser direct structuring on ceramics is revealed in detail. A TCR of $2440\pm 123\ \text{ppm}/^{\circ}\mathrm{C}$ could be achieved after an annealing process for the layout with the smallest line width. Measurements of the wear resistance of the Al 2 O 3 layer showed, that the sensors life span enables a sliding distance of at least 1,000 mm. During the tribological testing, friction induced temperature changes as well as short-term temperature peaks were measured.

The production processes of the metalworking industry are usually carried out in the presence of oxygen. Par ticularly due to surface oxidation on tools and parts during production under normal atmosphere, high wear is observed in tribological systems. The focus of these investigations is the question to what extent the ambient atmosphere has an influence on the tribological system. For this purpose, the identification and characterization of wear mechanisms in an oxygen-free atmosphere is of high relevance. To analyse the influence of the ambi ent atmosphere on the tribological properties of titanium, ball-on-disc investigations are carried out on a univer sal tribometer (UMT) in an air, argon and silane-anodized atmosphere. By suppressing the oxidation under ex clusion of oxygen, a reduction of the tribochemical wear could be shown, which is accompanied by a reduction of the wear volume by a Factor of 4.5. However, due to the adhesion of both friction partners, which already occurs at low temperatures, caused by the omission of the friction-reducing cover layers, the friction coefficient increased. In addition, novel alloy formations at the interfaces were detected and analysed.