On the significance of the H/E ratio in wear control: a nanocomposite coating approach to optimised tribological behaviour

Microstructural design of hard coatings

Supertough wear-resistant coatings with ‘chameleon’ surface adaptation

Diamond-like carbon (DLC) films combine several excellent properties like high hardness, low friction coefficients and chemical inertness. The DLC coating material can be further classified in two main groups, the hydrogenated amorphous carbon (a-C:H, ta-C:H) and the hydrogen free amorphous carbon (a-C, ta-C). By adding other elements like metals (a-C:H:Me) or non-metal elements like silicon, oxygen, fluorine or others (a-C:H:X), several modifications of the properties can be adjusted according to application requirements. First reports on hard amorphous carbon films were published in the 1950s and about 20 years later there began worldwide intensive research activities on DLC. In the following years the number of publications increased continuously and the importance for industrial applications became more and more evident. Several deposition techniques were applied to prepare a-C:H, ta-C, metal containing a-C:H:Me and non-metal containing a-C:H:X coatings. In parallel the structure and deposition mechanisms of DLC coatings were extensively studied. An essential obstacle for a broad industrial application was the high compressive stress level in a-C:H films causing delamination and limiting the film thicknesses. With metal based intermediate layer systems most adhesion problems could be solved satisfactorily and thus from the mid-1990s the pre-conditions for a broad application especially in the automotive industry were given. With modified a-C:H:X and a-C:X coatings a considerable friction reduction or surface energy adjustments could be achieved.

History of diamond-like carbon films — From first experiments to worldwide applications

A critical review of the pulsed laser deposition (PLD) of amorphous diamond-like carbon (DLC) films is presented. A short review of the PLD process is followed by a review of various experimental configurations for DLC deposition and a discussion of the influence of process parameters on the composition and energy of ablated carbon plumes. Particular emphasis is given to the relationship between plume properties and film structure and mechanical characteristics. For the first time, a cumulative influence of the laser power density (fluence) and wavelength on the formation and properties of DLC films is shown. The influence of bias, additional auxiliary energy, substrate temperature, and the presence of hydrogen is also discussed. A fluence-wavelength region for DLC formation is proposed and correlated with the kinetic energy of ablated carbon species. It is shown that lower fluences are required to produce DLC films when shorter-wavelength lasers are used. The latest available results on applications of PLD DLC films as protective coatings for reducing friction and wear are also discussed. Methods are proposed to improve film adhesion to steel substrates, so that DLC films can be used in highly loaded friction contacts. Finally, process improvements that are necessary to permit scaling up PLD for growing DLC films are outlined.

Preparation of amorphous diamond-like carbon by pulsed laser deposition: a critical review

The reactive d.c.-magnetron sputter technique in conventional and unbalanced modes was used to prepare tungsten-containing hydrodcarbon (W-C:H) coatings which have low friction coefficients and high wear resistances. Reproducible deposition processes stable over a long time without poisoning could be realized using a plasma emission monitor (PEM) control unit. From investgigation of light emission spectra of the magnetron discharge the intensive tungsten line at 401 nm was selected as most suitable for process control. The dependences of characteristic process parameters such as target voltage, optical emission intensity or deposition rate on the reactive gas flow were quite different from those known for the reactive sputter deposition of TiN or other nitrides and oxides. For both tungsten and WC targets the PEM intensity decreased monotonically with increasing acetylene flow. However, the deposition rates on substrates with floating potential increased. An additional r.f. excitation of the substrate electrode caused only slight changes in rate and metal content in the coatings. It can be concluded that the sputter process is dominant for W-C:H growth. The contribution of direct plasma polymetrization at the substrate is small. From-X-ray diffraction investigations it was concluded that the W-C:H coatings contain microcrystallites of the metastable cubic tungsten carbide WC1 − x. The Vickers hardness and Young's modulus depend on the atomic ratio of tungsten to carbon.

H. Dimigen

Papers

Preparation of W-C:H coatings by reactive magnetron sputtering