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PTFE/Pyrrolidone-2 showed similar reduced modulus trends with a constant value region of 3.7 GPa from 2 μm to 2.6 μm contact depth. This trend is observed in the hardness measurements as well for both coatings, as seen in Figure 4.8(b). The slight increase in modulus and hardness at shallow contact depths is likely an artifact resulting from surface roughness, tip variation, and stage vibration (Hay, 2009), which are significant at shallow depths. Note that according to the ISO 14577, to avoid the influence of surface roughness on the extracted thin film properties, the surface roughness of the tested sample should be lower than 5 % of the indentation depth at which results are required. However, from past experience we have found that even in the presence of higher roughness since the indenter tip geometry is typically small and the slopes of the roughness are large, reliable measurements could be performed beyond the 5 % (Pergande et al., 2004). Clearly having such soft coatings on a much harder substrate (cast iron) results in substrate effects at contact depths as low as 10 % of the coating thickness. This is because the plastic zone induced by the indenter propagates deeper into the coating, and at some critical contact depth (where the plateau region ends), the plastic zone reaches the coating/substrate interface (Ohmura et al., 2001). The critical contact depths, where substrate effects become significant are 2.6 μm for PTFE/Pyrrolidone-2 and 1.5 μm for Resin/PTFE/MoS2, which are clearly observed in the log-log inset in Figure 4.8(a). These critical contact depths correspond to 11 % and 8 % of their coating thickness, respectively, and are lower than what was reported by Tayebi et al. (2004) in the case of a thin (less than 1 μm) gold film on a hard substrate. They showed that substrate effects were seen when the contact depth was 20 % of the coating thickness. In the present study that uses softer polymeric coatings, the substrate 64PDF Image | TRIBOLOGY OF POLYMERIC COATINGS FOR AGGRESSIVE BEARING APPLICATIONS
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