Tribological Performance of Diamond and Diamondlike Carbon Films at Elevated Temperatures

In this study, the authors investigated the tribological performance of diamond and diamondlike carbon (DLC) films as a function of temperature. Both films were deposited on silicon carbide (SiC) by microwave plasma chemical vapor deposition and ion-beam deposition processes. Tribological tests were performed on a reciprocating wear machine in open air (20 to 30% relative humidity) and under a 10 N load using SiC pins. For the test conditions explored, the steady-state friction coefficients of test pairs without a diamond or DLC film were 0.7 to 0.9 and the average wear rates of pins were 10^?5 to 10^?7 mm³/N·m, depending on ambient temperature. DLC films reduced the steady-slate friction coefficients of the test pairs by factors of three to five and the wear rates of pins by two to three orders of magnitude. Low friction coefficients were also obtained with the diamond films, but wear rates of the counterface pins were high due to the very abrasive nature of these films. The wear of SiC disks coated with either diamond or DLC films was virtually unmeasurable while the wear of uncoated disks was substantial. Test results showed that the DLC films could afford low friction up to about 300° C. At higher temperatures, the DLC films graphitized and were removed from the surface. The diamond films could withstand much higher tempera-lures, but their tribological behavior degraded. Raman spectroscopy and scanning electron microscopy were used to elucidate the friction and wear mechanisms of both films at high temperatures.     

Amorphous hydrogenated carbon films for tribological applications II. Films deposited on aluminium alloys and steel

This paper describes the methods for the deposition of AHC films on aluminium alloys (2024, 7075 and an additional Al-Si alloy) and AISI 4340 steel. Both unmodified and silicon modified AHC films were deposited. AHC films could be deposited on aluminium alloys without any interlayer. The deposition of AHC films on steel required an interlayer which could be aluminium, silicon or chromium. Thin films (1–2 μm) deposited on aluminium alloys and steel influenced durability of films and friction coefficients in contact with steel. These were believed to be due to plastic deformation of substrates. Deposition of a thicker coating system (interlayer + AHC) reduced friction coefficients and also improved film durability. The durability of films deposited on steel substrates was evaluated under both unlubricated and lubricated conditions for 5.5 million cycles under 4.4 N load and up to 2.5 m/s sliding speed. Although there was wear, the films survived 5.5 million test cycles under unlubricated sliding, but in the presence of two lubricants, the film wear was very small and could not be measured. It was observed that the wear of the steel counterface in contact with silicon-containing AHC films could be higher than that against an uncoated steel in the presence of certain lubricants.     

Tribochemical interactions of Si-doped DLC film against steel in sliding contact

This study concerns the effects of tribochemical interactions at the interface of Si-DLC (silicon-doped diamond-like carbon) film and steel ball in sliding contact on tribological properties of the film. The Si-DLC film was over-coated on pure DLC coating by radio frequency plasma-assisted chemical vapor deposition (r.f. PACVD) with different Si concentration. Friction tests against steel ball using a reciprocating type tribotester were performed in ambient environment. X-Ray photoelectron spectroscopy (XPS) and auger electron spectroscopy (AES) were used to study the chemical characteristics and elemental composition of the films and mating balls after tests. Results showed a darkgray film consisting of carbon, oxygen and silicon on the worn steel ball surface with different thickness. On the contrary, such film was not observed on the surface of the ball slid against pure DLC coating. The oxidation of Si-DLC surface and steel ball was also found at particular regions of contact area. This demonstrates that tribochemical interactions occurred at the contact area of Si-DLC and steel ball during sliding to form a tribofilm (so called transfer film) on the ball specimen. While the pure DLC coating exhibited high coefficient of friction (∼0.06), the Si-DLC film showed a significant lower coefficient of friction (∼0.022) with the presence of tribofilm on mating ball surface. However, the Si-DLC film possesses a very high wear rate in comparison with the pure DLC. It was found that the tribochemical interactions strongly affected tribological properties of the Si-DLC film in sliding against steel.     

Is Ultra-Low Friction Needed to Prevent Wear of Diamond-Like Carbon (DLC)? An Alcohol Vapor Lubrication Study for Stainless Steel/DLC Interface

The effects of n-pentanol vapor on friction and wear of hydrogenated diamond-like carbon (DLC) films during sliding against a 440C stainless steel (SS) ball were investigated with a reciprocating pin-on-disc tribometer. Under dry sliding conditions, the friction coefficient is initially high (>0.2) for a so-called run-in period and then gradually subsequently decreases to an ultra-low value (<0.025). During the run-in period, a carbon transfer film is formed on the SS ball side, which seems to be the key for the ultra-low friction behavior. In n-pentanol vapor environments, the friction coefficient remained nearly constant at ~0.15 throughout the entire test cycles without any noticeable run-in period. Although the friction coefficient is high, there is no visible wear on rubbing surfaces when examined by optical microscopy, and the transfer film forming tendency on the SS ball side was much reduced. In humid environments, the wear prevention effect is not observed and transfer films do form on the ball side. These results imply that the n-pentanol layer adsorbed on DLC film from the vapor phase provides a molecularly thin lubrication layer which can prevent the substrate from wear.     

Amorphous hydrogenated carbon films for tribological applications I. Development of moisture insensitive films having reduced compressive stress

Although earlier investigations on the tribological behaviour of amcrphous hydrogenated carbon (AHC) films in sliding contact with steel showed encouraging results, four open issues were identified. They were: (a) dependence of friction and wear on humidity (i.e., the friction coefficient and the wear increased with humidity), (b) limitations on film thickness (i.e., films greater than 2 μm thick delaminated due to large compressive stress), (c) deposition of films on substrates other than silicon and (d) lubricant compatibility (i.e., formation of lubricant-derived antiwear films on AHC film surfaces). Steps were taken to address some of these open issues by incorporating silicon in AHC films. Friction and wear tests were conducted on AHC films containing various amounts of silicon. Incorporation of silicon in AHC films rendered the friction coefficients and the wear of a steel counterface insensitive to moisture. Silicon incorporation in AHC films also significantly reduced compressive stress. This allowed deposition of 10 μm thick films. These effects were achieved without any compromise with the friction coefficient and the film wear if the amount of silicon in the film was kept within a certain concentration range. In addition, silicon-containing AHC films were thermally more stable than silicon-free films. Experiments conducted with two lubricants resulted in significantly lower wear of the silicon-free AHC films than that obtained for unlubricated sliding. Similar friction coefficients were obtained for AHC film/steel and steel/steel combinations in lubricated sliding.     

Comparison of the fretting wear of 100Cr6/100Cr6, Si3N4/Si3N4 and Si3N4/100Cr6 contacts in lubricated and dry conditions

The fretting wear behaviour of bearing steel against bearing steel, silicon nitride against silicon nitride, and silicon nitride against bearing steel, was investigated under lubricated and dry conditions. Amplitudes in the intermediate 5 to 50 μm range, and test durations from 10 to 360 min, were studied. Light microscopy, scanning electron microscopy (SEM), transmission electron microscopy (TEM) and energy dispersive X-ray spectroscopy (EDS) were employed to determine the detailed nature of the friction and wear processes. In the silicon nitride against silicon nitride contact, brittle fracture of Si₃N₄ grains, and tribochemical reaction creating an amorphous layer on the mechanically damaged surface, were found. The main mechanism of fretting wear in the case of bearing steel against bearing steel contact was delamination. In the silicon nitride against bearing steel contact, chemical reactions predominated.     

Performance results of MEMS coated with a conformal DLC

A MEMS electrostatic lateral output motor has been successfully coated with a diamond like carbon (DLC) coating to protect against wear. Experiments were performed to characterize coating chemistry and performance. Friction results from accelerated screening tests using a miniature, lightly loaded ball on flat tribometer showed that the DLC coating maintained low friction longer compared to uncoated silicon. DLC on DLC experiments showed the lowest friction, and those that were run in 30% RH showed a much longer lifetime than ones run in dry air. Uniformity of DLC coverage on MEMS was verified by Auger electron spectroscopy (AES), microRaman spectroscopy, scanning electron microscopy (SEM), transmission electron microscopy (TEM) and energy dispersive X-ray spectroscopy (EDS). Micrographs revealed that there is about a 3:1 ratio of DLC coating for a line of sight deposition region to a non line of sight deposition region. DLC coated MEMS outperformed uncoated MEMS by 16X in air and 300X in vacuum, albeit performance in vacuum was lower than in air. A very clear difference in wear debris was seen between devices run in air and in vacuum. Cylindrical rolls were dominant in the devices that were run in air and platelets were dominant on devices run in vacuum. Ultimately, the DLC coating was found to greatly improve performance over uncoated MEMS.     

箔片空气轴承表面钛掺杂DLC膜的制备与表征

采用中频非平衡磁控溅射方法在箔片空气轴承的主轴材料40Cr钢、支承元件铍青铜箔片及硅片上制备了钛掺杂的DLC膜,并对膜的结构、摩擦磨损性能、结合强度以及内应力等进行了表征.结果表明:所制备的DLC膜含有较多的sp2键,与基体结合力强,两种轴承材料上沉积DLC膜之间的摩擦配副的减摩抗磨效果较好,摩擦因数在0.06～0.0...     

TiNi表面磁控溅射DLC薄膜的纳米压痕与摩擦性能

采用室温磁控溅射技术在TiNi合金表面制备出DLC/SiC(类金刚石/碳化硅)双层薄膜(SiC为中间层),采用拉曼光谱仪、纳米压痕仪和球-盘式摩擦磨损仪研究DLC薄膜的结构、纳米压痕和摩擦性能.结果表明:制备的DLC/SiC薄膜石墨含量高、纳米硬度(5.493 GPa)低、弹性模量(62.2447 GPa)低.在以氮化硅球(半径为2mm)为对摩件,4.9N载荷、室温、Kokubo人体模拟体液润滑下,该DLC/SiC薄膜具有低且稳定的摩擦因数,其平均值约为0.094.     

负偏压对DLC薄膜结构和摩擦学性能的影响

采用离子束溅射沉积镀膜法制备了DLC薄膜,研究了偏压对薄膜性能的影响。通过原子力显微镜(AFM)和拉曼光谱对DLC薄膜的表面形貌以及内部结构进行了分析表征。并用UTM-2摩擦磨损仪对其摩擦学性能进行了测试。结果表明,利用离子束溅射沉积制备的DLC薄膜具有良好的减摩抗磨性能。随着偏压的增加薄膜的摩擦因数先减小后增加,在-150 V偏压时,薄膜的摩擦学性能最好。     

Fretting wear and fracture behaviors of Cr-doped and non-doped DLC films deposited on Ti–6al–4V alloy by unbalanced magnetron sputtering

Cr-doped and non-doped diamond-like carbon (DLC) films were deposited on a Ti–6Al–4V alloy substrate using an unbalanced magnetron sputtering (UBMS). Fretting wear behavior of the specimens was investigated using a ball-on-disk fretting tester. The fracture phenomenon of the DLC films was determined as the number of fretting cycles to reach a high value of the friction coefficient. The results showed that the Cr-doped and non-doped DLC films exhibited a lower friction coefficient and wear rate compared to that of the uncoated specimen. However, the Cr-doped DLC film fractured only in a few cycles, while the non-doped DLC film fractured after fretting cycles of about 200,000. A fracture mechanism of the Cr-doped and non-doped DLC films was reported in this study.     

Molecular dynamics simulations of atomic-scale tribology between amorphous DLC and Si-DLC films

Silicon-doped diamond-like carbon (Si-DLC) films possess the potential to improve wear performance of DLC films in humid atmospheres and at higher temperatures. But many experimental results of Si-DLC films show that their structures and tribological properties changed greatly with silicon content. Therefore, molecular dynamics (MD) simulations were used to study the sliding friction process between DLC and Si-DLC films on un-lubricated boundary condition. The results show that a part of sp² bonding of the Si-DLC films is converted into sp³ bonding with the addition of silicon atoms, and the sp³/sp² ratio increases with the increase in silicon content. A transfer film between the DLC and Si-DLC films is formed and the friction force changes with the silicon content. Moreover, the simulations have showed that the silicon addition promotes the bonding of interfilms being formed.     

Friction and Wear of Various DLC Films in Water and Air Environments

Three types of diamond-like carbon (DLC) films, pure DLC, F-containing DLC, and a Si-containing DLC film, were deposited on a WC–Co substrate by a plasma-enhanced CVD technique. Friction and wear properties were determined using a ball-on-plate type reciprocating friction tester in water, comparing the water results to those in ambient air. The friction coefficient of DLC and F–DLC films in water was considerably lower than that in air. With Si–DLC, the friction was almost the same level in both water and air, and was less than 0.1. The specific wear rate of films in water was much smaller than that in air and varied around the low level of 10^–8 mm³/Nm in water, The mating ball wear was also less than 10^–8 mm³/Nm. With DLC and F–DLC films, the transferred amount of material on the friction surface of a mating ball was larger in a water environment than that in air. With a Si–DLC film, the difference in the transferred amount when exposed to either the water or air environment was negligible.     

离子束增强沉积薄膜的摩擦磨损行为与结构分析

采用离子束增强沉积（IBED）技术在不锈钢1Cr18Ni9Ti衬底表面生长氮化钛薄膜以及氮离子注入,进行了干滑动摩擦磨损试验与组织结构电镜分析,表明增强沉积膜较离子注入具有更高耐磨性能。     

Tribological studies of coated pistons sliding against cylinder liners under laboratory test conditions

The presence of coatings and surface topography play an important role in the tribological performance of sliding components. Depending on the coating used, it is possible to reduce friction and/or reduce wear. However, although there may be low friction and wear‐resistant coatings suitable for use in pistons, some coatings may hinder the tribological performance by changing the lubrication regime or by preventing additives from their intended function through chemical mechanisms. In this work, piston skirt segments extracted from a commercial aluminium alloy piston were coated with a diamond‐like carbon (DLC) coating, a graphite–resin coating or a nickel–polytetrafluoroethylene (Ni–PTFE) coating and were tribologically tested using a reciprocating laboratory test rig against commercial grey cast iron liner segments. The tribological tests used commercial synthetic motor oil at a temperature of 120 °C with a 20 mm stroke length at a reciprocating frequency of 2 Hz. Results showed that the graphite–resin coating, although it may serve as a good break‐in coating, wears rapidly. The Ni–PTFE coating showed friction reduction, whereas the DLC coating wore off quickly due to its small thickness. Furthermore, the higher hardness of the DLC coating relative to the cast iron liner surface led to pronounced changes on the liner counterface by polishing. In contrast with the uncoated piston skirt segments, all of the coatings prevented the formation of a visible tribochemical film on the cast iron surface. Copyright © 2012 John Wiley & Sons, Ltd.     

Effect of Water Swelling on the Tribological Properties of PMMA Spin-Cast Film and Brush in Aqueous Environment

Due to their light weight, low corrosion and good tribological properties, polymer films have been widely studied in dry condition as well as recently in aqueous environment. Though the presence of water can further reduce the friction, it promotes the wear rate of the polymer films. As a remedy to decrease the wear rate of polymer films under aqueous condition, in this study, we used PMMA brush which is chemically anchored to a substrate and compared its friction and wear properties with those of conventional PMMA spin-cast film. Ellipsometry, contact angle measurements and atomic force microscopy are used to study the surface properties, e.g., wear mechanisms and wear depths of PMMA films. Under different sliding speeds and applied loads, PMMA brush showed lower friction than PMMA spin-cast film in aqueous. Moreover, it was shown that the swelling of water molecules is a dominant factor in determining the wear durability of PMMA films in which PMMA brush showed better wear performance than PMMA spin-cast film.     

Tribochemical effects on the friction and wear behaviors of diamond-like carbon film under high relative humidity condition

Friction and wear behaviors of diamond-like carbon (DLC) film in humid N₂ (RH-100%) sliding against different counterpart ball (Si₃N₄ ball, Al₂O₃ ball and steel ball) were investigated. It was found that the friction and wear behaviors of DLC film were dependent on the friction-induced tribochemical interactions in the presence of the DLC film, water molecules and counterpart balls. When sliding against Si₃N₄ ball, a tribochemical film that mainly consisted of silica gel was formed on the worn surface due to the oxidation and hydrolysis of the Si₃N₄ ball, and resulted in the lowest friction coefficient and wear rate of the DLC film. The degradation of the DLC film catalyzed by Al₂O₃ ball caused the highest wear rate of DLC film when sliding against Al₂O₃ ball, while the tribochemical reactions between DLC film and steel ball led to the highest friction coefficient when sliding against steel ball.     

Influence of counterbody material on wear of ta-C coatings under fretting conditions at elevated temperatures

The high temperature tribological performance of tetrahedral amorphous carbon coatings has been analyzed at elevated temperatures up to 250 °C in air against three different counterbody materials—steel 100Cr6, α-alumina and silicon nitride. The results show that the counterbody material influences the friction and wear behavior and therefore coating life time strongly. This effect is well known for these coatings at room temperature under dry environmental conditions, equivalent to conditions above 100 °C when water molecules desorb from the surface. However, the sharp difference in tribological performance between silicon nitride on the one hand and alumina and steel on the other hand cannot be understood in this context. Analyzing the friction behavior during the running-in phase, it is evident that only alumina and steel form a stable interface with constant low friction and relatively low wear rates. Silicon nitride forms an unstable interface with fluctuating COF and relatively high wear rates due to its own inherent tendency to tribo-oxidation.     

沉积温度对脉冲真空弧源沉积类金刚石薄膜性能的影响

利用脉冲真空弧源沉积技术在Cr17Ni14Cu4不锈钢和Si(100)基体上制备了类金刚石(DLC)薄膜,研究了基体沉积温度对DLC薄膜的性能和结构的影响。研究表明,随着沉积温度由100 ℃提高到400 ℃,DLC薄膜中sp3 键质量分数减少,sp2键质量分数增多,薄膜复合硬度逐渐降低。当DLC薄膜沉积温度达到400 ℃时,薄膜中C原子主要以sp2键形式存在,与沉积温度为100 ℃时制备的DLC薄膜相比,薄膜复合硬度降低50%。DLC薄膜具有优异的耐磨性,摩擦因数低,随着沉积温度由100 ℃提高到400 ℃,Cr17Ni14Cu4不锈钢表面沉积的DLC薄膜耐磨性降低。沉积温度为100 ℃时,Cr17Ni14Cu4不锈钢表面沉积的DLC薄膜后,耐磨性大幅度提高。DLC薄膜与不锈钢基体结合牢固。     

Compatibility of DLC coatings with formulated oils

In the present study, the tribological performance and compatibility of hydrogenated amorphous carbon coating (a-C:H) and metal-doped diamond-like carbon (DLC) coating (Me-C:H) with formulated oils under the boundary lubrication regime was investigated. The investigation employed ball-on-flat contact geometry in reciprocating sliding motion and six formulated oils (manual gearbox oil, automatic gearbox oil, hydraulic oil, compressor oil, and normal and high performance motor oil), with pure poly-alpha-olefin (PAO) oil used as a reference. In addition, DLC coatings behavior in diesel and gasoline fuel was evaluated.Compared with the uncoated steel surfaces a-C:H coatings give improved wear resistance in base PAO as well as in fully formulated oils and fuels. On the other hand, W-doped DLC coatings show the lowest steady-state friction under boundary lubrication, especially when using oils with high additive contents.