Ceramics have a number of applications as coating material due to their high hardness, wear and corrosion resistance, and the ability to withstand high temperatures. Critical to the success of these materials is the effective heat transfer through a material to allow for heat diffusion or effective cooling, which is often limited by the low thermal conductivity of many ceramic materials. To meet the challenge of improving the thermal conductivity of ceramics without lowering their performance envelope, carbon nanotubes were selected to improve the mechanical properties and thermal dispersion ability due to its excellent mechanical properties and high thermal conductivity in axial direction. However, the enhancements are far lower than expectation resulting from limited carbon nanotube content in ceramic matrix composites and the lack of alignment. These problems can be overcome if ceramic coatings are reinforced by carbon nanotubes with good dispersion and alignment. In this study, the well-dispersed and aligned carbon nanotubes preforms were achieved in the form of vertically aligned carbon nanotubes (VACNTs) and Buckypaper. Polymer derived ceramic (PDC) was selected as the matrix to fabricate carbon nanotube reinforced ceramic nanocomposites through resin curing and pyrolysis. The SEM images indicates the alignment of carbon nanotubes in the PDC nanocomposites. The mechanical and thermal properties of the PDC nanocomposites were characterized through Vickers hardness measurement and Thermogravimetric Analysis. The ideal anisotropic properties of nanocomposites were confirmed by estimating the electrical conductivity in two orthogonal directions.

Novel electrodeposition strategies have been developed for the fabrication of thick adherent zirconia ceramic and composite coatings for biomedical applications. The new method is based on the electrophoretic deposition (EPD) of polyelectrolyte additives combined with the cathodic precipitation of zirconia. The method enables the room- temperature electrosynthesis of crystalline zirconia nanoparticles in the polymer matrix. Adherent crack-free coatings up to several microns thick were obtained. The deposits were studied by thermogravimetric and differential thermal analysis, X-ray diffraction analysis, scanning and transmission electron microscopy, and atomic force microscopy. Obtained results pave the way for electrodeposition of other ceramic-polymer composites. Novel advanced nanocomposite coatings based on bioceramic hydroxyapatite (HA) have been developed for the surface modification of orthopaedic and dental implant metals. HA nanoparticles prepared by a chemical precipitation method were used for the fabrication of novel HA-chitosan nanocomposite coatings. The use of chitosan enables room-temperature fabrication of the composite coatings. The problems related to the sintering of HA can be avoided. A new electrodeposition strategy, based on the EPD of HA nanoparticles and electrochemical deposition of chitosan macromolecules, has been developed. The method enabled the formation of dense, adherent and uniform coatings of various thicknesses in the range of up to 60μm. Bioactive composite coatings containing 40.9-89.8 wt% HA were obtained. The deposit composition and microstructure can be tailored by varying the chitosan and HA concentrations in the deposition bath. A mathematical model describing the formation of the HA-chitosan composite deposit has been developed. X-ray studies revealed preferred orientation of HA nanoparticles in the nanocomposites. Obtained coatings provide corrosion protection of the substrates and can be utilized for the fabrication of advanced biomedical implants. For further functionalization of the HA-chitosan composite coating, Ag and CaSi03 have been incorporated into the coating. Novel HA-Ag-chitosan and HA-CaSiO3-chitosan nanocomposite coatings have been deposited as monolayers, laminates, and coatings of graded composition. The obtained results can be used for the development of biocompatible antimicrobial coatings with controlled Ag+ release rate, and nanocomposite coatings with enhanced bioactivity. / Thesis / Doctor of Philosophy (PhD)

<p> New electrophoretic deposition methods for the fabrication of advanced organic-inorganic composite coatings on metallic substrates for biomedical applications have been developed. In the proposed methods, chitosan was used as a matrix for the fabrication of multilayer and functional graded chitosan- hydroxyapatite (HA) coatings. The HA particles showed preferred orientation of c-axis parallel to the layer surface, which is similar to the bone structure. Electrochemical studies showed that the obtained coatings provided corrosion protection of the metallic substrates, such as stainless steel and Nitinol.</p> <p> The feasibility of co-deposition of chitosan and heparin has been demonstrated. Composite chitosan-heparin layers were used for the surface modification of chitosan-HA coatings. Obtained results paved the way for the electrophoretic fabrication of novel coatings for biomedical implants with improved blood compatibility.</p> <p> The feasibility of co-deposition of hyaluronic acid and HA has also been demonstrated. The co-deposition of hyaluronic acid and HA resulted in the fabrication of novel nanocomposite films by electrodeposition. The chemical composition, microstructure, corrosion protection, and other functional properties of the nanocomposites have been investigated. Co-deposition of hyaluronic acid and multiwalled carbon nanotubes has been studied by TGA/DT A and SEM studies.</p> <p> The feasibility of deposition of novel composites based on alginic acid has been demonstrated. New electrochemical strategies were used for the fabrication of alginic acid-HA, alginic acid-heparin and alginic acid -hyaluronic acid nanocomposites. The composition of these nanocomposite coatings can be varied by variation in bath composition for EPD.</p> <p> The electrochemical mechanisms for the fabrication of all these advanced organic-inorganic composite coatings have been developed.</p> / Thesis / Master of Applied Science (MASc)

<p>Razvijene su TiAlN/TiSiN i CrAlN/TiSiN nanoslojne prevlake u kojima je napravljen spoj nanoslojnog i nanokompozitnog dizajna. Akcenat je stavljen na proizvodnju prevlaka visoke tvrdoće i visoke otpornosti na lom. Proučavane su i jednoslojne TiAlN, nanokompozitne TiSiN i višeslojne TiAlN/TiSiN prevlake kako bi se utvrdilo kako dizajn utiče na osobine prevlaka. Sve prevlake pripremane su sa jednim, dva i tri stepena rotacije. Pokazano je da dizajn i vid rotacije značajno utiču na mikrostrukturu i teksturu prevlaka, a time na njihove mehaničke osobine, otpornost na lom, adheziju između prevlake i podloge, topografiju površine i tribološko ponašanje. Nanoslojne i nanokompozitne prevlake odlikuju se kompaktnom nanokristalnom mikrostrukturom, dok jednoslojne TiAlN prevlake imaju stubastu strukturu sa kristalnim zrnima veće veličine. Pri prelasku sa jednog na više stepeni rotacije mikrostruktura prevlaka postaje kompaktnija sa kristalnim zrnima manje veličine i manjom poroznošću. U skladu sa tim, najmanju hrapavost, najveću tvrdoću, najveću otpornost na lom i najveću otpornost na habanje imaju nanoslojne i nanokompozitne prevlake pripremane sa dva i tri stepena rotacije.</p> / <p>With the aim to develop hard coatings characterized by both, high hardness<br />and high resistance to cracking, synergy between nanolayered and<br />nanocomposite design was made and nanolayered TiAlN/TiSiN and<br />CrAlN/TiSiN coatings were produced. Monolayer TiAlN, nanocomposite<br />TiSiN and multilayer TiAlN/TiSiN were also studied in order to find the<br />relation between the coating design and their properties. All coatings were<br />deposited with 1-fold, 2-fold and 3-fold rotation. It is shown that coating<br />design and type of rotation have great influence on coating microstructure<br />and texture, and in this way on their mechanical properties, resistance to<br />cracking, adhesion between coating and substrate, surface topography and<br />tribological behavior. Nanolayered and nanocomposite coatings are<br />characterized by compact nanocrystalline microstructure, while monolayer<br />TiAlN coatings have columnar structure with larger crystalline grains. By<br />increasing the number of rotational degrees from 1-fold to 3-fold size of<br />crystalline grains decreases and microstructure becomes more dense.<br />Therefore, nanolayered and nanocomposite coatings deposited with 2-fold<br />and 3-fold rotation are characterized by the highest hardness, highest<br />resistance to cracking, highest wear resistance and the smoothest surface<br />topography.</p>

Anodisation is a surface treatment process, commonly used to form a protective oxide coating on the surface of metals like aluminium. Anodised coatings, being grown out of the base metal have excellent interface strength but are porous and brittle. Porosity of the coating reduces the hardness and the brittle nature of the oxide induces cracking. In practice, the pores are typically filled with organic dye and sealed. Under certain controlled electrochemical conditions, anodisation results in a highly ordered hexagonal porous structure in pure aluminium. In this work, we explore the possibility of using this ordered porous alumina to form a novel metal nanocomposite as a tribological coating. By optimizing the nonporous structure and tuning the electrodeposition process, we uniformly filled the ordered pores with copper. We have measured the hardness of the resulting ordered and aligned nanocomposite. We explore the possibility of using this composite coating for tribological applications by carrying out some preliminary reciprocating wear test. Ordered porous alumina layer is formed by a two-step anodisation process. By optimizing the anodisation conditions, we control the thickness of the coating and the pore size. The interface of the porous structure and aluminium substrate is defined by a non-conducting dense barrier oxide layer. However, to deposit metal into the pores, a conducting path should be established through the barrier layer. One possibility is to etch out the bottom of the pores at the cost of the interface strength and losing out on the main advantage of anodised coatings. To be able to fill metal without this sacrifice, we utilised the dendritic structure in the barrier layer formed by a step-wise reduction of voltage towards the end of anodisation process. Optimisation of this dendritic structure led to uniform deposition of metal into pores, achieved by pulsed electrodeposition. In pulse lectrodeposition, a positive pulse is applied to remove accumulated charge near to the bottom of pores, followed by a negative pulse to deposit metal and a delay to allow diffusion of ions. By optimising the pulse shape and duration, we have achieved uniform growth of metal into pores. Further, monitoring the deposition current helped us to identify and control different phases of growth of the nanowire. The properties of the porous alumina and the nanocomposite were measured by nanoindentation. The deformation characteristics were obtained by observing the indents in a FE-SEM. We find that dendritic modification of interface has very little effect on the hardness of the porous alumina layer. We also found that the porous alumina deformed either by compaction or by forming circumferential and radial cracks. When copper is filled in the nano pores, the hardness increased by 50% and no circumferential cracks were found up to the load of 10 mN for a film thickness of about 1 µm. Coefficient of friction of the coating reciprocated against steel in dry condition is found to be around 0.4. Minimal wear was observed from the SEM images of wear track. In summary, a novel nanocomposite coating with ordered porous alumina as matrix embedded with aligned metal nano rods has been developed. This was achieved by optimally modifying the barrier layer without sacrificing the interfacial strength. Uniform coating has been achieved over an area of 10 mm x 10 mm. The coating is found to have high hardness and high wear resistance.

Metalorganic Chemical Vapour Deposition (MOCVD) is a versatile technique for the deposition of thin films of oxide materials as it offers advantages, such as deposition over large surface area, conformal coverage, selective area deposition, and a high degree of compositional control. The MOCVD process uses metalorganic (MO) complexes, such as β-diketonate and alkoxide-based complexes, as precursors. These complexes are stable and moderately volatile. Because of the direct bond between metal and oxygen, MO complexes are natural precursors for oxide coatings. As the process involves chemical reactions taking place on the substrate surface, growth of thin films by MOCVD depends on various parameters such as the chemical nature and concentration of precursors, reaction pressure, reaction temperature, and the nature of the substrate. Such a large parameter space of the CVD process, when combined with the dynamics (thermodynamics and fluid dynamics) and kinetics, makes it rather complex. This complexity allows one to make thin films of metastable phases, including amorphous materials. One of the important findings of the work is that MOCVD process is capable of making composite coatings of carbonaceous metal oxide. Manganese is multivalent and forms various stable oxides, such as MnO, Mn2O3, Mn3O4 and MnO2. There are various potential applications of manganese oxides. MnO2 is a very well studied material for its electrochemical applications in dry cells, lithium-ion batteries, and in supercapacitors. Hence, it becomes pertinent to explore the properties of thin films of manganese oxides prepared by MOCVD for various electrochemical and other applications. The thesis work is divided into two parts. Part 1 describes the synthesis of manganese complexes, their characterization, and their application to the CVD of coatings, especially those of carbonaceous MnO. Part 2 is devoted to a detailed study of electrochemical aspects of the carbonaceous MnO coatings, followed by a report on their unusual transport properties. Chapter 1 begins with a brief introduction to thin film deposition processes. In particular, the CVD process is described with reference to various parameters such as carrier gas flow, pressure, temperature and most importantly, the CVD precursor. The chapter ends with a description of the scope of the work undertaken for the present thesis. Chapter 2 deals with “Synthesis and Characterization of MO complexes”. It begins with a description of the classification of CVD precursors with the description of MO complexes such as β-diketonates, which are generally subliming crystalline solids. Manganese β-diketonate complexes are discussed in detail. Due to the multivalent nature of Mn, there are two possible complexes namely Mn(acac)2(H2O)2 and Mn(acac)3. These complexes have been synthesised and characterized (confirmed) by various techniques, such as elemental analysis (CHN), X-ray diffraction (XRD), FTIR spectroscopy, and mass spectroscopy. Thermal analysis of the complexes shows that they are suitable as MOCVD precursors. We have used Mn(acac)2(H2O)2 as a precursor in the present work. Metalorganic complexes, where metal ion is directly bonded with both nitrogen and oxygen, can be potential candidates for the precursor for oxynitrides coatings. We have therefore studied solid crystalline anthranilate complexes of various metal ions, such as Mn2+, Co2+, Cu2+ and Zn2+ and confirmed their formation. Thermal analysis shows that anthranilate complexes are fairly volatile below 250oC and decompose below 500oC. These complexes were pyrolysed in open air and in sealed tube at different temperatures, and the resulting powder product examined by XRD, SEM, EDAX and FTIR. This preliminary study shows that anthranilate complexes yield different oxides of Mn, Co and Cu under different pyrolysis conditions, with very interesting morphological features. Pyrolysis of Zn(aa)2 in a sealed tube leads to the formation of a nanocomposite of carbon and zinc oxide (wuerzite), rich in carbon, with potential for applications in catalysis. On the other hand, the pyrolysis of Zn(aa)2 in air at the same temperature leads to leads to crystalline, nanostructured zinc oxide (wuerzite). However, no attempt has been made to use these anthranilates as CVD precursors. Chapter 3 deals with “MOCVD of Manganese Oxides and their Characterization”. It begins with a brief review of various manganese oxides and their properties. This is followed by description of the CVD reactor used for the present work, together with the conditions employed for the deposition of MnOx films. Depositions have been carried out on different substrates such as SS-316, ceramic alumina and Si (111), while varying various deposition parameters, viz., substrate, reactor pressure, carrier gas (argon) flow rate, and the duration of deposition. Significantly, depositions are divided into two categories: one, carried out in argon ambient, in the absence of a supply of oxygen (or any other oxidant) and the second one, under oxygen flow, using argon as carrier gas. The films deposited in the absence of oxygen flow are thick, black in colour, and electrically conducting, indicating the presence of carbon. The growth rate follows a typical thermal pattern, with activation energy of ~ 1.7 eV. Detailed characterization by XRD, TEM/ED, Raman, FTIR and XPS (X-ray photoelectron spectroscopy) shows that these films are composed of MnO in a carbon-rich amorphous matrix. High-resolution SEM (fig. 1) reveals a fractal pattern of cauliflower morphology, comprising very fine particles (4 – 10 nm), characteristic of very large specific surface area of the film, which is confirmed by volumetric BET measurement (~2000 m2/g). We conclude that growth in argon ambient leads to a homogenous nanocomposite film of hydrated MnO in carbon-rich matrix. Thus, our study reveals that MOCVD is a novel one-step chemical method to produce homogenous composite thin films, wherein all components of the nanocomposite film emerge from the same chemical precursor. Carbon incorporation is generally avoided by empirical process design, as it is viewed as an impurity. The potential advantages of carbon incorporation are thus not examined and the composite nature of carbonaceous films not recognized in the literature. Carbonaceous nanocomposite film can be significant as an electrode in supercapacitors, as discussed in part 2 of the thesis. Chapter 3 describes films deposited under oxygen flow, which are no longer black and are highly resistive, indicating the absence of carbon in the film, as confirmed by Raman spectroscopy. XRD, FTIR and Raman spectroscopy reveal that the films obtained under oxygen flow are more crystalline than the ones obtained in the absence of oxygen flow, and that the films are generally nanocrystalline composites of two manganese oxides, such as MnO and Mn3O4. Given the context of the carbonaceous MnO films described above, chapter 4 begins with a review of electrochemical capacitors (also called supercapacitors or ultracapacitors), which are emerging as important energy storage devices. Until now, in the Mn-O system, hydrated MnO2 has been well-studied as an electrode material due to its low cost and environmental compatibility, but the low electrical conductivity of MnO2, together with irreversible redox reactions, reduces its performance. In electrochemical capacitor applications, metal-oxide/carbon composites are finding importance. Chapter 4 deals with “MnO/C Nanocomposite Coatings as Electrodes for Electrochemical Capacitor”. In this chapter, we have examined the novel EM, i.e., the hydrated MnO/C nanocomposite coating prepared by the MOCVD process on a conducting substrate (current collector) such as SS-316 as an electrode. Electrochemical measurements have been carried out for both the 3-electrode assembly (for basic aqueous electrolyte) and 2-electrode assembly (for gel polymer electrolyte) using cyclic voltammetry (CV), AC impedance and charge-discharge techniques. The studies lead to a maximum specific capacitance of 230 – 270 F/g at 1 mA/cm2 discharge current density for the MnO/C nanocomposite coating grown at 680oC. The Bode plot shows a maximum phase angle of around 74 – 82o, indicating capacitive behaviour. The MnO/C nanocomposite film shows a very small time constant (0.5 – 3 msec), which is good for high frequency applications. The pulse power figure of merit is found to be 650 – 2000 W/g. Capacitance determined for a large number of charge-discharge cycles (~20000), and at large current densities (50 mA/cm2) show promising results. The energy density (5 - 32 Wh/kg) and power density (2 – 4 kW/kg) estimated from charge-discharge data at 1 mA/cm2 shows the potential of the nanocomposite MnO/C as electrode for superior capacitor devices. Gel polymer electrolytes (GPE) offer the advantage of large electrochemical potential window due to its structural and chemical stability. Studies have been carried out to show that the MnO/C nanocomposite film is compatible with gel polymer electrolytes based on poly(methyl methacrylate) (PMMA) and poly(acrylonitrile) (PAN) with salts of magnesium triflate and magnesium perchlorate, respectively) and plasticizers (ethylene carbonate (EC) + propylene carbonate (PC)), in a 2-electrode assembly. Chapter 5 deals with “Magnetoconductance in MnO/C Nanocomposite Coatings on Alumina”. Amorphous systems, such as MnO/C composites wherein carbon is amorphous and MnO is nearly so, are highly symmetric condensed phases, which do not possess long range translational or orientational order. Disorder in the system creates Anderson localized states just above the valence band, which lead to reduced electrical conductivity. Amorphous systems show either a small negative magnetoresistance (~ 5%) or a small positive magnetoconductance (~ 7%) at very low temperatures (~ 10 K). As such, the transport properties of the MnO/C nanocomposite film have been investigated, and are reported in chapter 5. Transport and magnetotransport measurements have been made on the MnO/C nanocomposite film grown on alumina. It is found that the MnO/C nanocomposite coating exhibits a giant negative MR (22.3%) at a temperature as high as 100 K, which is unusual because pure MnO is anti-ferromagnetic and does not ordinarily show any magnetoresistance (MR), while amorphous carbon is known to show a small MR at very low temperatures (~7 K), due to weak-localization. The present results mean that a mechanism other than weak-localization plays a role in this nanocomposite material. Further study of this material is called for, which can perhaps lead to giant magnetoresistance (GMR) at room temperature in a metal-oxide/carbon nanocomposite. A summary of the work and an outlook for further research are given in the concluding chapter 6.