Low friction ceramic coatings using dry aerosol deposition
Innovative thin ceramic coatings applied via dry aerosol deposition (DAD) provide ultralow friction and high wear resistance for razor blades. The scalable process uses alumina and alumino-silicate, achieving high adhesion and durability without heat.
Overview
Dry aerosol deposition (DAD) presents a groundbreaking method for applying ultrafine-grained ceramic coatings to razor blades, offering significant reductions in friction and enhanced wear resistance. This scalable, high throughput kinetic spray process operates without the need for heat, allowing for the application of thin (~0.5 micron) coatings with excellent adhesion to substrates like stainless steel. By utilizing materials such as alumina and alumino-silicate, the process achieves high hardness and bio-inertness while maintaining cost-efficiency. The addition of MoSi2 as a solid lubricant can further lower friction, offering a revolutionary solution for the razor blade industry.
Technical specifications
- DAD Process: High throughput, scalable, no-heat process ensuring full densification and adhesion.
- Materials Used: Alumina (Al2O3) for high hardness and bio-inertness; alumino-silicate (AlSi) for cost-effective solutions; MoSi2 for enhanced lubrication.
- Film Characteristics: Thin films (~0.5 to 0.75 microns), ultrafine-grained, conditioned to nano-metric smoothness.
- Application Method: Capable of depositing on various substrates including high polish stainless steel.
- Performance: Offers ultralow friction coefficient and high wear resistance; resistant to reaction with tissue.
Technology readiness level
The current development stage of this technology is at Technology Readiness Level 3. Initial process development and material characterization have been conducted. Future phases include micromechanical measurement, tribological testing, and product sample provision for field trials.
About New Mexico Institute of Mining and Technology
New Mexico Tech is a STEM-focused public research university in Socorro with an applied, field-scale research profile. Its Energetic Materials Research and Testing Center runs expansive test ranges adjacent to campus for research, evaluation, and training. The Petroleum Recovery Research Center and the New Mexico Bureau of Geology and Mineral Resources provide industry-facing labs, data, and services, while a co-op program links employers to student talent. Research is supported by competitive federal funding from agencies such as the National Science Foundation, Department of Energy, and Department of Defense. An Office of Innovation Commercialization and a university research park support IP, licensing, and startup formation.
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