Effects of Deposition Parameters on the Microstructural Evolution and Mechanical Properties of TiN Coatings on 7075-T6 Aluminum Alloy

Abstract

The 7075-T6 aluminum alloy exhibits excellent specific strength due to the presence of precipitated η′ phase, but its surface mechanical performance under demanding conditions is often limited. In this study, a horizontal cylindrical magnetron sputtering system was used to deposit TiN coatings on the surface of 7075-T6 aluminum alloy to enhance its surface mechanical properties and structural performance. The effects of deposition temperature, substrate bias voltage, and N2/Ar flow ratio on the microstructure, surface morphology, phase composition, hardness, and residual stress of the coatings were systematically investigated. The results showed that at 80 °C, enhanced lateral atomic diffusion promoted the transformation of the coating growth mode from coarse columnar crystals to dense quasi-layered structures. The surface roughness decreased from 0.193 μm at room temperature to 0.077 μm, the (111) preferred orientation significantly increased, the hardness reached 383 HV, and the compressive stress was −2.8 GPa. However, when the temperature was raised to 120 °C, grain coarsening and TiN/7075Al interface thermal mismatch stress dominated, and the hardness decreased by approximately 19.3%. At −80 V bias, the atomic impact effect produced by ion bombardment made the coating densified optimally, with the lowest surface roughness of 0.068 μm, a hardness of 377 HV, and a compressive stress of −3.1 GPa; at −150 V, excessive bombardment led to severe re-sputtering and lattice distortion, resulting in a compressive stress of −6.8 GPa and a hardness of 351 HV. When N2/Ar = 10/25, the reaction sputtering kinetics and chemical thermodynamic conditions reached the optimal balance, achieving the highest diffraction peak signal-to-noise ratio and the narrowest full width at half maximum. These results reveal the temperature-dependent competitive relationship between thermally activated coating densification and thermal mismatch-induced structural degradation, providing insights into the optimization of TiN coating deposition parameters on aluminum alloys.