Selective oxidation-induced strengthening of Zr/Nb nanoscale multilayers

The paper presents a new approach, based on controlled oxidation of nanoscale metallic multilayers, to produce strong and hard oxide/metal nanocomposite coatings with high strength and good thermal stability. The approach is demonstrated by performing long term annealing on sputtered Zr/Nb nanoscale metallic multilayers and investigating the evolution of their microstructure and mechanical properties by combining analytical transmission electron microscopy, nano-mechanical tests and finite element models. As-deposited multilayers were annealed at 350 C in air for times ranging between 1 - 336 hours. The elastic modulus increased by approx. 20% and the hardness by approx. 42% after 15 hours of annealing. Longer annealing times did not lead to changes in hardness, although the elastic modulus increased up to 35% after 336 hrs. The hcp Zr layers were rapidly transformed into monoclinic ZrO2 (in the first 15 hours), while the Nb layers were progressively oxidised, from top surface down towards the substrate, to form an amorphous oxide phase at a much lower rate. The sequential oxidation of Zr and Nb layers was key for the oxidation to take place without rupture of the multi-layered structure and without coating spallation, as the plastic deformation of the metallic Nb layers allowed for the partial relieve of the residual stresses developed as a result of the volumetric expansion of the Zr layers upon oxidation. Moreover, the development of residual stresses induced further changes in mechanical properties in relation to the annealing time, as revealed by finite element simulations.