Optimization of diamond-like carbon coatings for mechanical and tribological applications. Review
Diamond-like carbon (DLC) coatings are used to improve the quality of industrial products due to a wide range of exceptional physical, mechanical and tribological properties. Problems that limit the scope of application of hard non-hydrogenated DLC coatings with properties closest to those of diamon...
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Національний науковий центр «Харківський фізико-технічний інститут» НАН України
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Reshetnyak, E.N. Luchaninov, A.A. Strel’nitskij, V.E. 2023-12-10T12:44:23Z 2023-12-10T12:44:23Z 2023 Optimization of diamond-like carbon coatings for mechanical and tribological applications. Review / E.N. Reshetnyak, A.A. Luchaninov, V.E. Strel’nitskij // Problems of Atomic Science and Technology. — 2023. — № 2. — С. 74-93. — Бібліогр.: 117 назв. — англ. 1562-6016 DOI: https://doi.org/10.46813/2023-144-074 https://nasplib.isofts.kiev.ua/handle/123456789/196090 621.793:679.826 Diamond-like carbon (DLC) coatings are used to improve the quality of industrial products due to a wide range of exceptional physical, mechanical and tribological properties. Problems that limit the scope of application of hard non-hydrogenated DLC coatings with properties closest to those of diamond are considered. The scientific literature is reviewed devoted to improving the characteristics of DLC-based wear-resistant coatings. The approaches currently used to reduce internal compressive stresses, improve adhesion to the substrate, and increase the strength of coatings are analyzed. Aspects of optimization of deposition parameters, doping, constructing the gradient and multilayer structure are considered. Based on the generalization of the results of the reviewed publications, a conclusion is made about the advantages of using coatings with a multilayer structure. A promising design undoped multilayer DLC coatings with high protective properties is discussed. Алмазоподібні вуглецеві покриття використовуються для підвищення якості промислових виробів завдяки широкому спектру виняткових фізичних, механічних і трибологічних властивостей. Розглянуто проблеми, що обмежують сферу застосування твердих негідрогенізованих алмазоподібних покриттів із властивостями, які найбільш близькі до алмазу. Проведено огляд наукової літератури, що присвячена покращенню характеристик зносостійких покриттів на основі алмазоподібного вуглецю. Проаналізовано сучасні підходи до зниження внутрішніх напружень стиску, покращення адгезії до основи та підвищення міцності покриттів. Розглянуто аспекти оптимізації параметрів осадження, легування, побудови градієнтної та багатошарової структури. На основі узагальнення результатів розглянутих публікацій зроблено висновок про переваги використання покриттів із багатошаровою структурою. Розглядається перспективна конструкція нелегованих багатошарових DLC-покриттів з високими захисними властивостями. en Національний науковий центр «Харківський фізико-технічний інститут» НАН України Problems of Atomic Science and Technology Physics of radiation and ion-plasma technologies Optimization of diamond-like carbon coatings for mechanical and tribological applications. Review Оптимізація алмазоподібних вуглецевих покриттів для механічних та трибологічних застосувань. Огляд Article published earlier |
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Digital Library of Periodicals of National Academy of Sciences of Ukraine |
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| title |
Optimization of diamond-like carbon coatings for mechanical and tribological applications. Review |
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Optimization of diamond-like carbon coatings for mechanical and tribological applications. Review Reshetnyak, E.N. Luchaninov, A.A. Strel’nitskij, V.E. Physics of radiation and ion-plasma technologies |
| title_short |
Optimization of diamond-like carbon coatings for mechanical and tribological applications. Review |
| title_full |
Optimization of diamond-like carbon coatings for mechanical and tribological applications. Review |
| title_fullStr |
Optimization of diamond-like carbon coatings for mechanical and tribological applications. Review |
| title_full_unstemmed |
Optimization of diamond-like carbon coatings for mechanical and tribological applications. Review |
| title_sort |
optimization of diamond-like carbon coatings for mechanical and tribological applications. review |
| author |
Reshetnyak, E.N. Luchaninov, A.A. Strel’nitskij, V.E. |
| author_facet |
Reshetnyak, E.N. Luchaninov, A.A. Strel’nitskij, V.E. |
| topic |
Physics of radiation and ion-plasma technologies |
| topic_facet |
Physics of radiation and ion-plasma technologies |
| publishDate |
2023 |
| language |
English |
| container_title |
Problems of Atomic Science and Technology |
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Національний науковий центр «Харківський фізико-технічний інститут» НАН України |
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Article |
| title_alt |
Оптимізація алмазоподібних вуглецевих покриттів для механічних та трибологічних застосувань. Огляд |
| description |
Diamond-like carbon (DLC) coatings are used to improve the quality of industrial products due to a wide range of exceptional physical, mechanical and tribological properties. Problems that limit the scope of application of hard non-hydrogenated DLC coatings with properties closest to those of diamond are considered. The scientific literature is reviewed devoted to improving the characteristics of DLC-based wear-resistant coatings. The approaches currently used to reduce internal compressive stresses, improve adhesion to the substrate, and increase the strength of coatings are analyzed. Aspects of optimization of deposition parameters, doping, constructing the gradient and multilayer structure are considered. Based on the generalization of the results of the reviewed publications, a conclusion is made about the advantages of using coatings with a multilayer structure. A promising design undoped multilayer DLC coatings with high protective properties is discussed.
Алмазоподібні вуглецеві покриття використовуються для підвищення якості промислових виробів завдяки широкому спектру виняткових фізичних, механічних і трибологічних властивостей. Розглянуто проблеми, що обмежують сферу застосування твердих негідрогенізованих алмазоподібних покриттів із властивостями, які найбільш близькі до алмазу. Проведено огляд наукової літератури, що присвячена покращенню характеристик зносостійких покриттів на основі алмазоподібного вуглецю. Проаналізовано сучасні підходи до зниження внутрішніх напружень стиску, покращення адгезії до основи та підвищення міцності покриттів. Розглянуто аспекти оптимізації параметрів осадження, легування, побудови градієнтної та багатошарової структури. На основі узагальнення результатів розглянутих публікацій зроблено висновок про переваги використання покриттів із багатошаровою структурою. Розглядається перспективна конструкція нелегованих багатошарових DLC-покриттів з високими захисними властивостями.
|
| issn |
1562-6016 |
| url |
https://nasplib.isofts.kiev.ua/handle/123456789/196090 |
| citation_txt |
Optimization of diamond-like carbon coatings for mechanical and tribological applications. Review / E.N. Reshetnyak, A.A. Luchaninov, V.E. Strel’nitskij // Problems of Atomic Science and Technology. — 2023. — № 2. — С. 74-93. — Бібліогр.: 117 назв. — англ. |
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74 ISSN 1562-6016. Problems of Atomic Science and Technology. 2023. №2(144)
SECTION 3
PHYSICS OF RADIATION AND ION-PLASMA TECHNOLOGIES
https://doi.org/10.46813/2023-144-074
UDC 621.793:679.826
OPTIMIZATION OF DIAMOND-LIKE CARBON COATINGS FOR
MECHANICAL AND TRIBOLOGICAL APPLICATIONS. REVIEW
E.N. Reshetnyak, A.A. Luchaninov, V.E. Strel’nitskij
National Science Center “Kharkov Institute of Physics and Technology”, Kharkiv, Ukraine
E-mail: reshetnyak@kipt.kharkov.ua
Diamond-like carbon (DLC) coatings are used to improve the quality of industrial products due to a wide range
of exceptional physical, mechanical and tribological properties. Problems that limit the scope of application of hard
non-hydrogenated DLC coatings with properties closest to those of diamond are considered. The scientific literature
is reviewed devoted to improving the characteristics of DLC-based wear-resistant coatings. The approaches
currently used to reduce internal compressive stresses, improve adhesion to the substrate, and increase the strength
of coatings are analyzed. Aspects of optimization of deposition parameters, doping, constructing the gradient and
multilayer structure are considered. Based on the generalization of the results of the reviewed publications, a
conclusion is made about the advantages of using coatings with a multilayer structure. A promising design undoped
multilayer DLC coatings with high protective properties is discussed.
INTRODUCTION
Among the various types of diamond-like carbon
(DLC), an attractive material for protective and
functional coatings is tetrahedral amorphous carbon (ta-
C), which exhibits unique physical and mechanical
properties similar to diamond. High hardness, excellent
wear resistance, low coefficient of friction, corrosion
resistance, biocompatibility make such coatings an
indispensable material for various applications in
metalworking, mechanical engineering, aerospace
industry, medicine, micromechanics and other fields.
The continuous increase in requirements for the
properties of materials used in increasingly harsh
conditions, such as high loads and temperatures,
requires the development of new types of coatings with
improved characteristics.
One of the important restraining factors on the way
to expand the areas of use DLC is the problem of
insufficient adhesion of thick (≥0.5 μm) coatings. The
low adhesion of hard coatings is associated with a high
level of internal mechanical stresses, which do not allow
to build up their thickness more than a few hundred
nanometers, which is too small for many technical
needs. In addition, hard surfaces may be too brittle to
provide sufficient strength. Currently, various methods
have been developed that allow obtaining thick DLC-
based coatings with an optimal combination of
hardness, strength, wear resistance and tribological
characteristics: application of transitional and gradient
layers; alloying of coating material; formation of
nanoscale multilayer and composite structures.
This review presents the results of research on ways
to improve the performance of mainly undoped DLC
coatings for mechanical and tribological applications at
high loads. In the presented material, attention is mainly
focused on information about the synthesis and
properties of coatings based on DLC, which are
obtained by methods of magnetron sputtering and
vacuum-arc deposition.
1. CURRENT TRENDS IN THE CREATION
OF HARD WEAR-RESISTANT COATINGS
An important problem of modern materials science
is obtaining materials with increased strength
characteristics, that is, high ability to resist destruction
and irreversible change of shape under the action of
external loads. Most materials work under conditions of
wear, cavitation, cyclic loads, corrosion at cryogenic or
high temperatures, in which the maximum loads occur
in the surface layers, where the main stress
concentrators are located. The condition and properties
of the surface layer largely determine the operational
characteristics of the products as a whole. Therefore,
applying protective, strengthening and wear-resistant
coatings to cutting tools, parts, technological equipment
units, machine-building and instrument-building
products is an effective way to improve their physical
and mechanical characteristics, performance and service
life. Protective coatings with a thickness of several to
tens of microns are widely used in various industries.
The most common among hard materials for them are
ceramics based on nitrides, carbides, borides, oxides,
silicides of transition metals, as well as DLC.
Traditional methods of applying such coatings are
varieties of Chemical Vapor Deposition (CVD) and
Physical Vapor Deposition (PVD) [1–3].
Every year, the requirements for protective
properties become stricter, which requires the search for
new types of coatings and the improvement of their
application methods. In traditional ceramic systems, the
most common approach to the creation of new hard
coatings in the last decade is related to reduction of
crystal grain sizes and formation of nanocomposites and
nanolayered structures. Among nanostructured coatings
for surface strengthening, considerable attention is paid
to multicomponent coatings, which combine compounds
with metallic and covalent types of bonds. A
nanocomposite structure can consist of nanocrystalline
ISSN 1562-6016. Problems of Atomic Science and Technology. 2023. №2(144) 75
(nc-) grains of hard nitrides, carbides, borides or
silicides of transition metals surrounded by an
amorphous matrix (a typical and well-studied
representative is the nc-TiN/Si3N4 coating). The limited
solubility of components in such systems makes it
possible to form coatings under non-equilibrium
deposition conditions that not only possess increased
hardness, but also demonstrate high temporal and
thermal stability of structure and properties [4–7].
Another trend in the development of new protective
coatings is attempts to combine the best properties of
various systems by further increasing the number of
components. It should be noted that amorphous carbon
is also used for the synthesis of numerous hard coatings,
including as a component of multicomponent
nanocomposite and nanolayered structures. The research
results indicate the possibility of obtaining multi-
component protective coatings with radically improved
functional properties due to the formation of a
nanostructured state.
Usually, to characterize the material's ability to resist
wear, the value of hardness (H) is involved, and to
characterize the resistance to elastic deformations
without destruction, the value of Young's modulus (E)
should be taken into account. As a rule, materials with
high hardness and rigidity possess high wear resistance.
Diamond, whose properties are due to an electronic
structure that ensures strong covalent interatomic
bonding, is a prime example, with its highest known
hardness and exceptional wear resistance [8, 9]. Many
researchers have been trying to obtain nanostructured
coatings with maximum hardness for a number of years,
however, it has now become especially clear that high-
quality wear-resistant coatings require a combination of
strength, hardness and the ability to recover. Hardness
and elasticity are of equal importance for increasing
wear resistance, especially in complex processes
associated with shock loading and erosion. An
important feature of hard coatings is that materials with
high hardness can significantly differ in values of the
modulus of elasticity [4, 7, 10]. The development of
nanoindentation devices and techniques currently allows
for fairly accurate measurement of these characteristics
even for thin coatings, minimizing the effect of the
substrate on the results [11–13]. The combination of
high hardness and low modulus of elasticity is
considered optimal [4, 10].
Recently, the H/E plasticity index has been
considered as a quantitative characteristic of the
mechanical properties of nanostructured coatings. The
H/E ratio is used to characterize the material's resistance
to elastic fracture deformation (resistance to brittle
fracture). It is believed that the higher the H/E ratio, the
better the strength and wear resistance of the coating.
Coarse-crystalline materials are characterized by values
of H/E<0.04. For nanostructured coatings, the H/E
values are in the range of 0.06…0.1, which indicates
their better stability. A hard coating with a low modulus
buckles under load and then recovers, instead of
fracturing [4, 10].
In this sense, DLC coatings exhibit unique
characteristics. Differences in the DLC structure of
different types lead to a significant difference in
hardness and modulus of elasticity [14–20]. The
plasticity index H/E for DLC is extremely high
(0.08…0.21) compared to steels and ceramics. This
means that DLC possess a relatively high deformation
tolerance. The variety of values can be seen in Table. In
more detail, the types of DLC coatings will be
considered in section 2.1.
Another factor important for high wear resistance of
coatings is the coefficient of friction. A low coefficient
of friction can effectively reduce the contact
temperature during dry sliding and thus has a huge
potential to reduce the thermal load on the coating and
substrate material. In addition, components with such a
coating ensure high energy efficiency by reducing
frictional losses.
Classification of DLC coatings and their characteristics [14–17]
DLC coating Graphite Diamond
Type of coating a-C a-C:H ta-C ta-C:H – –
Method of deposition PVD
CVD,
PVD + CVD
PVD
PVD, CVD,
PVD + CVD
– –
Deposition temperature, C RT–200 RT–500 RT–300 RT–500 – –
sp
3
, % 5…50 10…60 50…90 40…70 0 100
Hydrogen, at.% <5% 5…60 <5% 5…50 0 0
Density, g/cm
3
1.4…2.2 1.2…2.0 2.5…3.2 2.0…2.6 2.267 3.515
Hardness H, GPa 9…25 5…25 25…90 9…60 0.2…2 100
Young's modulus E, GPa 100...400 100...300 200...900 120...300 10 1000
H/E 0.08...0.1 0.1...0.16 0.1...0.2 0.16...0.21 – –
Coefficient of friction
(low humidity <5%)
0.3...0.8 0.003...0.3 0.4...0.8 0.08...0.2 0.01 0.1
Coefficient of friction
(high humidity >5%)
0.1...0.2 0.02...0.5 0.08...0.12 – – –
Coefficient of friction (in water) 0.04...0.1 0.01...0.7 0.03...0.07 – – –
Wear resistance relative to steel
(low humidity)
C B÷A A B–A – –
Corrosion resistance x–C B B–A C–B – –
A – Excellent; B – Good; C – Somewhat poor; x – Poor.
76 ISSN 1562-6016. Problems of Atomic Science and Technology. 2023. №2(144)
Much effort has been devoted to the development of
protective layers with a low coefficient of friction
capable of acting as solid lubricants in order to replace
the commonly used expensive and dangerous cooling
lubricants, or in conditions where the use of lubricants is
not possible. The application of coatings is especially
important for high-speed and dry cutting, processing of
non-ferrous metals, hard materials and wood, as well as
in friction pairs operating at high loads [21, 22].
In Fig. 1. the classification of various hard coatings
according to their hardness and friction characteristics is
given, from which it follows that most carbon films are
able to provide not only high hardness, but also low
friction. In particular, DLC films appear to provide the
widest range of hardness and friction values, while
some of the more recently developed nanocomposite
coatings (based on ceramics) are ultrahard but unable to
provide lubrication or low friction [23].
Fig. 1. A schematic representation of hardness and
coefficients of friction (COF) of carbon-based and other
hard coatings [23]
Thus, amorphous carbon remains a relevant material
for creating wear-resistant coatings, as it allows to adapt
them to a wide range of applications, including in heavy
and difficult operating conditions. Hard DLC coatings
are suitable for improving the performance of many
types of products. However, achieving this
improvement requires choosing the appropriate type of
carbon coating and optimizing its characteristics.
2. STRUCTURE, SYNTHESIS
AND MECHANICAL PROPERTIES
OF DLC COATINGS
2.1. STRUCTURE AND CLASSIFICATION
Carbon is a unique material due to the variety of
allotropic modifications, which are characterized by
different types and spatial orientation of chemical bonds
(sp
3
, sp
2
, sp
1
types of hybridization). In addition to the
well-known crystalline diamond (sp
3
), graphite (sp
2
),
and carbine (sp
1
), there are also various amorphous
forms with a predominant amount of one or another
type of hybridization [8, 9, 14, 15]. In graphite, carbon
atoms have hybridization of the sр
2
type, in which three
of the four valence electrons are involved. This type of
hybridization leads to trigonal coordination of atoms,
which form a flat hexagonal grid with strong covalent
bonds – a graphene sheet. The electrons of the carbon
atoms that remained unhybridized connect the graphene
sheets together. Thus, graphite crystals consist of
graphene layers connected only by weak van der Waals
bonds. Graphite is a soft material. The layered structure
is the reason for its ability to wear layer by layer. Weak
interlayer connections can be destroyed by small
external mechanical forces, so graphite is often used as
a dry lubricant for friction units [8, 9].
Unlike graphite, for a wear-resistant coating,
diamond has more desirable mechanical properties, such
as high values of atomic density, hardness and Young's
modulus. This is due to the four covalent bonds that
connect each carbon atom to its nearest neighbor,
forming a tetrahedral coordination that has high bond
energy in all directions. The tetrahedral environment of
carbon atoms in diamond is arranged due to
hybridization of the sр
3
type, in which all four valence
electrons are involved [8, 9].
DLC is a collective term for a wide range of
amorphous carbon coatings, including those containing
bonded hydrogen (hydrogenated). The term “diamond-
like” emphasizes a set of properties similar to diamond
and, at the same time, implies the lack of order of
crystalline diamond [14, 15]. According to the two-
phase model, films of amorphous carbon consist of two
phases embedded in each other. The first phase is
diamond-like, having sp
3
-hybridization of carbon atoms.
The second phase is graphite-like, consisting of
fragments of graphite planes and distorted fragments
like fullerenes. The last phase is characterized by sp
2
-
hybridization of carbon. The characteristic size of the
clusters of each of the phases is several nanometers
[24, 25].
Hydrogenated DLCs are formed during deposition in
a hydrogen-enriched atmosphere. A hydrogen atom has
only one valence electron and preferentially binds to sp
2
sites, turning them into sp
3
sites. The limitation is that
hydrogen can only bond to one carbon atom, unlike
carbon, which can bond to four other atoms in this
hybridization. As a result, the structure of hydrogenated
DLC will have fewer strong carbon bonds than if the
structure were free of hydrogen [14–16].
Thus, due to the two-phase structure, DLC combines
the properties of diamond and graphite, while
hydrogenated areas do not contribute to diamond-like
properties. The sp
3
/sp
2
-bond ratio and hydrogen content
are key parameters that determine the physical
characteristics of coatings. The ternary phase diagram of
amorphous carbon is shown in Fig. 2 [15]. This
classification is an updated version of the one
summarized by J. Robertson [14]. It shows how
hydrogen-free and hydrogenated DLCs are formed,
depending on the amount of sp
2
, sp
3
, and hydrogen.
Fig. 2. Ternary phase diagram of carbon materials
as a function of hybridization type and
hydrogen content [15]
ISSN 1562-6016. Problems of Atomic Science and Technology. 2023. №2(144) 77
The forms of amorphous carbon with a graphitic
structure, such as carbon black, coal, glassy carbon, and
graphitic films of amorphous carbon are placed in the
lower left corner of the diagram. The area of
carbohydrate polymers frames the right lower corner. At
the zone near the corner, the coating is not formed.
Different technological methods of deposition make it
possible to form the coatings of amorphous carbon with
a different amount of sp
3
-bonds, as well as the coatings
of hydrogenated amorphous carbon, placed in the
middle of the phase diagram. In order to distinguish
amorphous carbon with a large number of sp
3
-bonds
from amorphous carbon with a large number of sp
2
-
bonds, the designations ta-C (tetrahedral amorphous
carbon) and a-C (amorphous carbon) were introduced,
respectively. Variations of the plasma chemical gas
phase deposition method allow obtaining hydrogenated
amorphous carbon both with a low content of sp
3
-bonds
(a-C:H) and with a large content of sp
3
-bonds (ta-C:H).
However, the name a-C and a-C:H is often used for
amorphous carbon in general, without specifying the
amount sp
3
.
Introduction of hydrogen into the coating makes it
possible to vary widely the optical, electrical, and
mechanical properties of amorphous carbon films. In
addition, doping with other chemical elements also
leads to changes in existing properties or even to
appearance of new ones. All this leads to a great variety
of existing options. The classification of DLC coatings
is shown in Fig. 3. All coatings are divided into three
large groups according to their chemical composition:
unalloyed, alloyed and hybrid.
In undoped DLCs, the carbon atoms are bonded to
hydrogen or another carbon atom, and the structure
contains no other elements. Unalloyed coatings can be
divided into subclasses based on hydrogen content:
hydrogenated and hydrogen-free. Further division of
each of these subclasses is based on the content of
tetrahedral sp
3
-bonds: amorphous DLC (a-C:H, a-C)
and tetrahedral amorphous DLC (ta-C:H, ta-C). In
doped DLCs, metal or non-metal atoms can be added to
the coating. With coatings alloyed with metals,
chromium, titanium, molybdenum or tungsten are
usually used. As for non-metals, nitrogen, silicon or
fluorine are used. By hybrid, we mean DLC coating
with a combination of alloyed and non-alloyed layers
[26, 27].
Fig. 3. General classification of types of DLC coatings [26, 27]
2.2. METHODS OF DEPOSITION
AND MECHANISM OF FORMATION
A wide range of CVD and PVD thin film deposition
methods are suitable for obtaining DLC coatings [14].
Some are suitable for laboratory research, while others
are better for industrial production. Plasma Enhanced
Chemical Vapor Deposition (PECVD) [28] is mainly
used to deposit hydrogenated DLCs. In the PECVD
process, the coating on the substrate is formed during
chemical reactions activated by an electric discharge in
the environment of hydrocarbons (acetylene, methane,
benzene, and others). A significant advantage of the
method is the possibility of depositing a-C:H on fairly
large areas and on objects of complex shape. Filtered
vacuum-arc deposition (FC?VAD) [29], magnetron
sputtering (MS) [30], and to a large extent pulsed laser
deposition (PLD) [31] can be attributed to the most
common methods of deposition of hydrogen-free DLC
coatings In these methods of physical deposition, a
graphite cathode (target) is used as a source of carbon
particles.
Different DLC deposition methods share three
important characteristics: (i) plasma is used as a source
of active substances, (ii) the substrate is usually at room
temperature (at least there is no need to maintain a high
temperature of the substrate during the process, as in
classical CVD processes), (iii) energetic particles (ions
and/or neutrals) participate in the deposition process
[32]. The latter is due to the fact that the formation of
sp
3
-bonds is effective in the field of thermodynamic
stability of diamond (high pressure and temperature),
which is ensured due to radiation-stimulated processes
associated with ion bombardment of the growth surface
of the coating [33, 34]. C
+
ion energies of about 100 eV
are required to achieve the highest sp
3
/sp
2
ratio.
Initially, the main factor increasing the sp
3
content was
considered to be the preferential sputtering of sp
2
sites
during DLC film growth [35]. Later, they discovered the
formation of DLC under the surface of the film. The so-
called subplantation model considers the progressive
densification of DLC in the subsurface layer, which is
associated with the formation of sp
3
metastable regions
due to the penetration of energetic ions [36, 37].
Incoming neutrals and low-energy ions do not penetrate
the surface of the coating, but form an outer layer
saturated with sp
2
. Thus, the properties of the
78 ISSN 1562-6016. Problems of Atomic Science and Technology. 2023. №2(144)
synthesized diamond-like material are primarily
determined by the ion energy, which is controlled by a
negative bias potential on the substrate. The higher the
degree of ionization of carbon plasma, the greater is the
part of carbon ions with increased energy that are
deposited on the substrate and form a coating with the
maximum content of sp
3
-bonds. In this regard, the use
of filtered cathode vacuum-arc plasma, the degree of
ionization of which is almost 100%, is one of the most
common industrial methods of deposition of hydrogen-
free ta-C thin films, which have the best characteristics
[29, 38]. In addition to being able to generate a stream
of highly ionized carbon plasma efficiently enough, the
vacuum-arc method has advantages over other methods
in terms of the deposition rate of ta-C condensate, its
adhesion to the substrate, and hardness. The use of
modern high-performance plasma filters allows you to
avoid the problem of the presence of coarse defects in
the form of graphite macroparticles, products of
graphite cathode erosion in the arc discharge process, in
vacuum-arc coatings. The principle of operation of the
filters is based on the separation of charged (ions,
electrons) and neutral (droplets, macroparticles, atoms)
components of the plasma generated by the cathode in
the plasma-optical system [39].
The method of MS is free from the problem of
macroparticles, however, the degree of ionization of the
carbon flow is much lower than that of vacuum-arc
plasma, even when using high-power impulse
magnetron sputtering (HIPIMS) [40]. In addition,
during MS, bombardment of the surface of the growing
carbon film with inert working gas ions, which not only
affect the sp
3
content, but can also be implanted into the
film [41, 42], which worsens its characteristics, has a
significant impact.
Magnetoelectric filters are the most radical means of
eliminating the droplet fraction in vacuum-arc coatings,
but the higher the desired degree of purification, the
smaller the output ion current of the filter, and therefore
the lower the deposition rate. At the same time, in many
practical cases, there is no need for ultrapurification of
plasma. Creating conditions that limit the size of the
macroparticles in the plasma flow may be sufficient to
make the film suitable for practical use. For example, in
wear-resistant anti-friction coatings on the working
parts of friction surfaces and tools, the presence of
particles with a size of no more than 1 μm is quite
acceptable. In this regard, alternative methods of
limiting the size of macroparticles are of considerable
practical interest, which, although they do not provide
ideal plasma cleaning, but are simpler and cheaper
compared to methods that require the use of filters. One
of the ways to reduce the emission of macroparticles of
increased size is to reduce the time the cathode spot
stays in one place, which is achieved in a pulsed arc [43,
44]. The DC vacuum arc method with superimposed
high current pulses also gives good results [45, 46].
The mechanism that contributes to the formation of
sp
3
-bonds is related to the shallow implantation of low-
energy carbon ions (25…500 eV) [14]. Fig. 4 shows the
dependence of the sp
3
fraction on the ion energy for
ta-C. With increasing ion energy, the sp
3
content first
sharply increases, reaching a maximum in the range of
100…140 eV, and then gradually decreases [47]. Such a
course of dependence was qualitatively explained in
terms of the balance between implantation and
relaxation, which is described by the model of thermal
peaks. The same model is used to describe the formation
of compressive stresses in coatings [48…50]. Ion
bombardment is a non-equilibrium process that is not
identical to conventional heating, because the kinetic
energy of the bombarding ions is transferred to a local
region and is accompanied by excessively fast cooling
at a rate of about 10
13
…10
14
K/s. Near the trajectory of
the ion in the substance, a region of high thermal energy
density is formed, a thermal peak, that exists for a short
period of time (~ 10
-13
…10
-12
s). This provides
conditions for atomic rearrangement in the superheated
collision zone, resulting in changes in the structure and
internal stresses in the coatings. Estimates show that
with instantaneous heating to 3000…4000 K, the
pressure in the zone can reach 10 GPa, which exceeds
the static pressure required for diamond synthesis. It is
the presence of high compressive stresses that makes it
energetically advantageous to rearrange sp
2
-bonds into
sp
3
, which leads to the formation of dense ta-C. When
the average energy of the ions increases above 100 eV,
in the thermal peaks conditions arise capable of
ensuring the relaxation of the compacted region to a
more stable sp
2
state, which determines the non-
monotonic dependence of the content of the sp
3
fraction
on the energy of the ions. Similarly, the hardness,
density and level of residual compressive stresses in the
coatings change, as there is a linear correlation between
these parameters and the sp
3
fraction [14].
Fig. 4. Dependence of the sp
3
fraction on energy of
carbon ions for DLC films [47]
2.3. MECHANICAL PROPERTIES
A feature of the properties of diamond-like coating
is a strong dependence on the deposition method and
conditions. As an illustration, Table shows the typical
mechanical characteristics of different categories of
DLC coatings summarized according to the data of
review works [14–17], as well as data for diamond and
graphite. Characteristic values of the percentage of sp
3
-
bonded carbon, hydrogen content, approximate density,
hardness and Young's modulus, coefficients of friction
in wet and dry atmospheres, the degree of wear
resistance relative to steel and corrosion resistance are
shown for the coatings. Hydrogen-free ta-C coatings
have properties closest to diamond. At the content of
sp
3
-bonds of 80…90%, the coatings possess density
close to that of diamond, 3.1…3.2 g/cm
3
, and their
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hardness can reach 90 GPa. They are characterized by
high resistance to corrosion and wear. The coefficient of
friction of such coatings at humidity >5% is in the range
of 0.08…0.12, however, in dry conditions it increases
several times [15, 17]. Hydrogenated coatings are softer
and less dense, and their advantage is lower values of
friction coefficients compared to hydrogen-free ones, in
particular in vacuum, dry air and inert gases [16].
The frictional behavior of DLC is controlled by a
number of factors, both internal (composition, structure,
roughness, configuration of carbon atoms) and external
(environment, sliding speed, type of movement, applied
load, counterbody material). J. Fontaine and others [51]
consider coating friction as a result of a combination of
adhesion, abrasive and shear mechanisms. The strongest
adhesive interactions for DLC coatings result from the
covalent bonds that form between the contacting
surfaces. The abrasive contribution is caused by the
mechanical interaction of surface irregularities. The
shear component of friction is associated with the
formation of an interphase transfer layer during sliding.
A transition layer with low shear strength is responsible
for low friction coefficients. Each of these mechanisms
is sensitive to the hydrogen content in the coating, and
depending on the test conditions becomes decisive.
DLC differs from graphite, which is used as a solid
lubricant, by the mechanism of displacement during
friction. Because DLC is amorphous, it cannot undergo
the same type of volumetric shear as graphite, whose
lubricity is provided by the shear deformation of the slip
planes. Instead of shear planes, DLC films shear across
the interface between the opposing surface material and
the coating. Under the effect of friction in DLC
graphitization occurs in the contact zone, localized in
so-called hot spots with a high contact temperature,
which leads to low friction due to the formation of a
thin tribolayer [16].
The increase in the coefficient of friction in a
vacuum or dry environment for hydrogen-free coatings
is due to the increase in the contribution of the adhesion
mechanism. Absence of hydrogen in the structure makes
it impossible to passivate the surface of the coating,
which is characteristic of hydrogenated coatings. In the
event that hydrogen is present in the structure or in the
external environment, hydrogen atoms bind to carbon
atoms in the film, which limits the number of areas
where covalent bonds can be formed between the
contacting surfaces, that is, adhesion between the
mating surface and the tested sample is low. This leads
to very low values of the coefficient of friction.
However, the further expansion of the areas of practical
use of hydrogenated coatings is mainly hindered by
their relatively low hardness (not more than 40 GPa)
and low thermal stability (not higher than 400 C). The
transformation of DLC to its more stable graphite
structure can begin at a temperature of about 250 C,
which leads to a decrease in the hardness of the coating.
The formation of graphite is facilitated by the loss of
hydrogen, which is responsible for the stabilization of
sp
3
-bonds [16].
As for protective and wear-resistant coating,
structural stability, hardness and wear resistance may be
more important factors than a low coefficient of friction.
High wear resistance is ensured both by the formation
of nano-sized tribolayers on the contacted surfaces,
which dampen external stresses, prevent degradation of
the base material and provide a minimum coefficient of
friction, and by increasing the stability and hardness of
the surface layer itself [16]. Such requirements under
significant loads in mechanical and tribological
applications are best met by solid hydrogen-free ta-C
coatings, especially in active environments or in
lubrication conditions.
Let us consider in more detail the influence of
deposition parameters on the characteristics of ta-C
coatings. For the synthesis of films with properties close
to diamond, it is necessary to maximize the sp
3
content,
which is a function of the bias potential and substrate
temperature. Many works show that the accelerating
potential of the substrate is the most important factor
that determines the sp
3
/sp
2
ratio, as well as the
mechanical, electrical, and optical properties of ta-C
films [14, 52–65]. Fig. 5,a shows the dependences of the
sp
3
content and compressive stresses of ta-C films on
the substrate potential obtained in [65]. The coatings
were deposited by the FCVAD method at room
temperature using an S-shaped magnetic filter. With
increase in the potential from 20 to 350 V, the sp
3
content varied non-monotonically from 84 to 88%, and
the stress level from 6 to 11 GPa. The curves with
maxima near 90 V have a general appearance similar to
the dependence of the sp
3
content on the ion energy
shown in Fig. 4.
a
b
Fig. 5. Dependence of the sp
3
content and compressive
stresses of the ta-C coatings obtained by the FVAD
method as a function of the substrate bias potential (a)
and temperature (b) of the substrate [57, 65]
80 ISSN 1562-6016. Problems of Atomic Science and Technology. 2023. №2(144)
Indeed, vacuum-arc carbon plasma contains mainly
singly charged ions with the most likely energy of about
25 eV, which are then accelerated to the substrate
surface in the field of a bias potential. However, it
should be taken into account that the use of filters leads
to a change in the characteristics of the plasma flows
from which coating is formed on the substrate, in
particular, to a shift in the energy distribution function
of ions [38, 39]. That is why the value of the substrate
potential corresponding to the maximum content of sp
3
-
hybridized bonds and their quantity are parameters that
have certain values not only for each deposition method,
but also depend on the features of the equipment, in
particular, they differ for different filtration systems.
Similar non-monotonic dependences on the substrate
potential were obtained when using curvilinear filters of
different designs [54–59], however, the positions of the
maxima were slightly different. The maximum sp
3
content could be achieved at DC potential values from
50 to 200 V, depending on the features of the
equipment. The authors of [53] did not observe the
maximum, as it was outside the scope of the research –
the sp
3
content monotonically decreased from 60 to 36%
when the potential increased from 50 to 350 V. For
DLC magnetron films, the effect of the potential is not
so significant, which is quite expected. In work [30], for
the MS method, different sp
3
/sp
2
ratios were obtained by
changing the bias potential from 175 to 300 V. As the
potential increased, the sp
3
/sp
2
ratio increased in the
range from 0.74 to 0.98, which corresponds to an
increase in the sp
3
content from 40 to 50%.
As already mentioned, there is another important
factor affecting the sp
3
content – growth temperature. It
is known that it is necessary to ensure a deposition
temperature below 120 С in order to obtain energy
dependences with a maximum like in Fig. 5,a [66].
Fig. 5,b shows the sp
3
content and residual stress level
for carbon FCVAD coatings as a function of substrate
temperature during deposition at certain ion energy. It
can be seen that when a certain temperature is reached
in the coating, the diamond-like bonds suddenly
disappear and the stresses decrease. The transition
temperature in these experiments is about 140 C with
an average energy of carbon ions of 130 eV, and 200 C
for ions with a lower energy of 90 eV [57]. However,
the effective ion energy and substrate temperature are
often not precisely known. In addition, when choosing
the optimal deposition parameters, the effect on the
temperature of the deposition rate, ion current, and the
angle of incidence of the flow should be taken into
account [66, 67]. Thus, the optimum ion energy for
maximum sp
3
content discussed above is often not
directly applicable to industrial coating equipment,
especially when using rotary part mounting systems. In
addition, the optimal sets of deposition parameters must
be adapted not only to obtain the highest sp
3
content and
corresponding hardness, but also to achieve other
desired coating properties (adhesion, stress, coefficient
of friction, etc.) that are determined by the geometry of
the products and their application.
Unfortunately, the correlation between sp
3
content
and other mechanical characteristics of coatings is not
unambiguous. The hardest coatings are the most
stressed, which can negatively affect their adhesion to
the substrate [14]. In addition, the sp
3
content can affect
the coating roughness, another surface property that is
related to the coefficient of friction and determines the
suitability of DLC for tribological applications. It is
known that when using highly ionized carbon plasma,
the increase in ion energy significantly contributes to
the preferential removal of protruding areas due to
sputtering, which makes it possible to achieve values of
rms surface roughness at the level of 0.05 nm, i.e.,
almost atomic smoothness of the surface [68].
Sometimes coatings containing more diamond-like
bonds show an optimal set of properties. Thus, in [52],
an electromagnetic filter of the “blind” type was used to
obtain DLC coatings by the FCVAD method. It is
shown that the dependence of the content of the sp
3
fraction with an increase in the DC potential from 25 to
200 V has a maximum. The highest content of sp
3
-
bonds, about 63%, was measured in the coating
deposited at a substrate bias potential of 100 V, which
also possess maximum hardness and Young's Modulus
of 50 and 371 GPa, respectively, in combination with
minimal surface roughness. In addition, the coating
synthesized at this bias potential had excellent adhesion-
complete peeling of the film occurred at a load of 41 N.
On the contrary, in [30] the authors who deposited films
by MS method showed that with an increase in the
sp
3
/sp
2
ratio from 0.74 to 0.98, the adhesion worsened
and the critical load decreased from 31 to 18 N. As the
sp
3
content increased, the coefficient of friction varied
depending on the material of the counterbody due to
various mechanisms. In contact with Si3N4, the friction
coefficient increased from 0.12 to 0.16 due to the
reduction of the effect of the graphite tribolayer on the
friction boundary, and in contact with the Ti6Al4V
alloy it decreased from 0.32 to 0.13 due to the inhibition
of the formation of hard abrasive oxides. However, the
wear rate of the DLC films in both cases showed a
linearly decreasing correlation with the bias potential on
the substrate and not with the sp
3
/sp
2
ratio.
As a rule, the analysis of literature data makes it
possible to make a fairly reliable comparison of DLC
films created by different methods only by some
mechanical characteristics, which are determined using
the same standardized methods. These include the stress
level in DLC coatings, which is usually measured by the
degree of curvature of a thin silicon substrate, and the
calculations are based on Stoney's formula [69]. With
the advent and development of nanoindentation
methods, it is quite correct to compare the hardness and
Young's modulus of coatings, which are determined
based on the Oliver and Pharr method [11].
As for brittleness, fragility of DLC films, one of the
methods of their assessment consists in visual
observations of the appearance of the coating surface
around the place of indentation of a Rockwell spherical
indenter or a Vickers or Berkovich pyramid. This
method is only partially standardized, that is, it allows
only a relative comparison of coatings. Adhesion of
hard coatings is measured by scratch testers [70]. In a
standard surface scratch test, a spherical Rockwell
indenter with a radius of 200 μm is drawn along the
surface under a load of 0…100 N, which gradually
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increases [71]. The measure of adhesion is the value of
the critical load Lc, from which the peeling of the
coating within the limits of the scratch track and the
destruction of its edges begins. Currently, microscratch
testers are also used, in which the Rockwell indenter
radius is 25…100 μm, and the load is from units of mN
to 30 N, and nanoscratch testers, in which the indenter
radius is 1…25 μm, and the load is from 10 μN to
several mN [72]. Such a wide range of testing
conditions makes it difficult to compare the adhesion of
DLC coatings [73], given the dependence of the Lc
measurement results on the indenter tip radius [74].
The coefficient of friction and the rate of wear are
determined by the results of tests on friction machines
of various types, while in fact it is difficult to find at
least two publications by independent authors in which
the kinematic parameters of the tests, the material of the
counter-body and its geometric parameters completely
match. In addition, the results of studies of mechanical
characteristics are significantly influenced by the
thickness of the coatings, as well as the type and method
of preparation of the surface of the substrate before their
application. The only thing that can be relied on more or
less precisely is the comparison of the measurement
results within each specific study, which allows to
determine the general trends in the change of the
deposition parameters, which can ensure the
improvement of the mechanical properties of the
coatings.
3. PROBLEMS OF USING sp
3
-RICH DLC
COATINGS AND GENERAL WAYS TO
SOLVE THEM
Thin hard DLC coatings have a wide range of
applications in industry. In the automotive industry,
DLC is used due to its excellent tribological properties
that reduce wear and friction losses [23, 27, 29, 75–77].
The high wear resistance of DLC coatings opens up
wide possibilities for their use in the production of
measuring instruments, templates, tips of active control,
probes, as well as for significantly improving the
tribotechnical characteristics of units operating in dry
friction conditions, in particular for protection against
fretting wear in read and write heads for hard drives.
DLC is actively used to strengthen the surface of cutting
instruments – from high-speed cutting tools to kitchen
knives and razor blades. In some cutting applications,
only one surface of the cutting edge is coated. As a
result, the blade self-sharpens as one side wears faster
than the other. Positive results were obtained when
using tools with DLC coatings for polishing copper,
brass, aluminum, steel, hard alloys and superhard
materials based on cubic boron nitride. Being
chemically inert and biocompatible, DLC has broad
potential for biomedical applications, including
cardiovascular valves, orthopedic implants, joint
endoprostheses, and surgical instruments. In most
existing applications, it is sufficient to apply fairly thin
coatings from a few to hundreds of nanometers to
achieve a positive effect. In all these areas, the search
for better technical solutions is ongoing, which are often
associated with the need to reduce production and
operating costs. Despite the significant progress made
over the past decade in hard coating technology, the
many different deposition systems and processes that
have been developed introduce additional challenges in
terms of coating uniformity, deposition rate, process
cost.
A restraining factor on the way to expanding the
scope of use of ta-C coatings is the problem of
insufficient adhesion of thick (≥0.5 μm) layers. Low
adhesion is largely due to a high level of internal
mechanical stresses. As the coating becomes thicker, the
deformation energy as a result of residual stresses
increases, and the adhesion energy remains unchanged,
which inevitably leads to delamination when a certain
thickness is reached. This fact does not allow to increase
the thickness of coatings more than a few hundred
nanometers, which is too small for many technical
needs. The main types of damage of DLC coatings
include surface deformation, development of cracks,
chipping of individual areas, peeling off the coating
from the substrate. Critical factors for this can be
insufficient strength of the coating itself, insufficient
adhesion to the substrate, high internal compressive
stresses, mismatch of mechanical properties between the
coating and the substrate. This complex situation
explains why the number of applications of hard carbon
films is still more limited than originally anticipated
[23, 27, 29, 75–77].
Searching for opportunities to expand the
application of coatings in various areas makes sense to
start with the analysis of test results. Optimized wear
resistance, for example, is not necessarily achieved
using the hardest coating materials, but also depends on
the modulus of elasticity, adhesion, chemical and
thermal resistance, coefficient of friction and other
mechanical properties [77]. The stability of the coating
properties during service is important, as the coefficient
of friction, hardness and adhesion can deteriorate with
temperature. The number of sp
3
-bonds is not the only
criterion for the quality of “diamond-like” properties.
The best coating material is useless if the coating has
insufficient adhesion. However, it is obvious that a
better material with strong adhesion will provide better
results.
Various techniques can be used to overcome the
above-mentioned problems and ensure the synthesis of
thick, high-quality DLC coatings. According to the
classification given in work [75], such methods can be
divided into three large groups: alloying of coatings,
creation of multilayer structures, application of
transition layers. All techniques commented above and
typical structures obtained in this way are presented in
Fig. 6. Stress relaxation is possible by alloying (Si, N, P,
Cr, Ti, Mo, W, etc.), as well as by annealing or
introducing nanometer particles (creation of DLC
nanocomposites). But these operations usually reduce
the hardness and modulus of elasticity of the coatings.
Low stress values are also achieved by alternating hard
and soft DLC coating layers. The resulting multi-
layered structure can provide a reduction in overall
stresses with less significant changes in hardness. Multi-
layer coatings, in which DLC layers alternate with
metal, nitride or carbide layers, can also contribute to
improving properties.
82 ISSN 1562-6016. Problems of Atomic Science and Technology. 2023. №2(144)
Fig. 6. Schematic representation of the main methods of modification of DLC coatings to solve problems arising
from their application [75]
Deposition of gradient DLC coatings with good
tribological performance is possible due to the high
sp
3
/sp
2
ratio in the surface, which gradually decreases
from the surface to the substrate to enhance adhesion. A
traditional way to improve coating adhesion is to use a
transition layer (Ti, Cr) between the base and the DLC.
Also, carbides or nitrides can be used in transition layers
[29, 75].
The concept of multilayer structures appears most
promising for thick diamond-like coatings, in terms of
overcoming some of the limitations of single-layer films
associated with insufficient ta-C adhesion. In addition,
this approach allows you to create coatings with
additional functional properties. Various options for
forming a multilayer structure of the coating allow
solving a complex of problems [29]:
– reduce compressive stress in the coating;
– adapt mechanical behavior (hardness, development
of cracks, etc);
– adjust the tribological behavior of the surface;
– optimize the adhesion between the substrate and
the DLC coating by using adhesive layers such as
carbide-forming metals or by structural cross-linking;
– increase the ability to withstand mechanical loads
due to the buffer layer;
– regulate interaction with the external environment,
including bioreaction;
– tune other physical properties such as electrical
resistance etc.
It is clear that the simplest multilayer type is a two-
layer system, for example, a homogeneous functional
diamond-like coating with an adhesive sublayer,
however, to achieve a certain coating thickness of
several micrometers, it is better to use a package of at
least two separate monolayers of different composition
or structure, alternating. To achieve the desired
properties, individual layers in a multi-layer coating
package may contain:
– layers with different sp
3
/sp
2
ratios;
– a-C:Me and a-C:X layers with different doping
elements;
– metal layers;
– nitride, carbide or carbonitride layers.
Additional degrees of freedom associated with the
thickness of individual layers are added to the
considerable variety of possible combinations.
From the point of view of ease of practical
implementation, the option of forming a multilayer
structure in a coating that is formed exclusively from
carbon atoms and does not contain additional alloying
elements appears to be the most economical and
promising for industrial implementation. Traditional
existing equipment and graphite cathodes can be used
for the synthesis of such coatings, and synthesis
processes can be based on previously developed
processes for single-layer coatings. In the following
sections of the review, the main ways of modifying
DLCs consisting of carbon and containing no alloying
elements are considered in more detail.
4. IMPROVEMENT OF THE MECHANICAL
PROPERTIES OF NON-ALLOYED
DLC COATINGS
According to the conclusions of works on the
development of thick hard ta-C coatings, the first
requirement for the synthesis process is to ensure a high
level of adhesion, for which it is necessary to increase
the coupling of the coating material and the base, as
well as to reduce the level of internal stresses. At the
same time, they try not to reduce significantly the
hardness, but to improve the strength of the coating by
reducing the modulus of elasticity. In addition, in new
developments, as a result of the modification, they try
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not to increase the coefficient of friction and the rate of
wear, the low values of which are the advantage of DLC
coatings. A wide range of forms and varieties of
amorphous carbon allows combining carbon layers with
different physical and mechanical properties in the
coating. In this way, variants of pure carbon (unalloyed)
spatial structures of coatings with improved
characteristics are realized. The most efficient creation
of such coatings is achieved by changing the energy of
deposited ions by changing the value of the substrate
potential. Different approaches are used here. First,
stress relief, which is necessary for the synthesis of
thick coatings, is achieved thanks to ion-induced
thermal annealing when high-voltage pulses are applied
to the substrate [77–87]. On the other hand, a similar
effect can be achieved by alternating more stressed hard
and less stressed soft layers. Coating layers enriched
with the sp
3
phase and sp
2
one are called “hard” and
“soft” respectively, which corresponds to their relative
hardness. If the value of the potential is switched
stepwise during the deposition, a layered structure is
formed in the coating. When the hardness of each
subsequent layer is greater than the previous one, we
speak of a quasi-gradient structure of the coating. If the
potential of the substrate is changed smoothly, the
properties of the coating material also change smoothly,
and a gradient structure is created. In this way, it is
possible to form a coating structure with a hardness
gradient from the base to the surface [88–93]. Designs
with periodic alternation of hard and soft layers with
different modulation coefficients are more common
[94–117].
4.1. APPLICATION OF HIGH-VOLTAGE
PULSED SUBSTRATE BLAS POTENTIAL TO
REDUCE THE LEVEL OF RESIDUAL STRESSES
IN COATINGS
Application of technologies that combine deposition
and implantation processes is quite promising for
improving methods of synthesis of protective coatings.
The main feature of such technologies is intensive ion
bombardment of the surface during coating deposition.
Deposition of coatings by the method of Plasma
immersion ion implantation and deposition (PIII&D) is
carried out by applying to the substrate microsecond
pulses of negative bias potential with an amplitude of
several hundred to several thousand volts. In contrast to
the high DC bias potential, in such conditions it is
possible to minimize the effects associated with
sputtering of the coating surface, and at a low substrate
temperature form metastable high-temperature
structures with a reduced stress level. The coating
thickness increases mainly between potential pulses,
and during the pulse the processes of ion implantation,
sputtering, and radiation-stimulated annealing of already
formed coating layers prevail. Pulse parameters (f –
repetition frequency, tp – duration, V – amplitude) are
key characteristics that allow you to control the
structure of the coating, the level of residual stresses in
them, and therefore their properties. The amplitude of
the potential must be of sufficient magnitude to
accelerate the ions to an energy that ensures their
penetration deep into the substrate [77–79].
The details of the use of the PIII&D method in the
formation of DLC coatings depend on the method of
creating the carbon plasma from which the deposition is
carried out. Supply modes and high-voltage potential
parameters are slightly different for different methods
(PECVD, FCVAD, MS, HIPIMS, PLD). The energy of
the ions generated in most sources of carbon plasma
does not exceed a few tens of electron volts, however,
the degree of ionization of the plasma flow varies
considerably. Highly ionized streams of filtered
vacuum-arc plasma allow to change the conditions of
deposition by the PIII&D method in the widest possible
range [78].
Initially, this approach was used in order to reduce
the level of high compressive stresses, which are
characteristic of ion-plasma coatings and can be the
cause of low operational properties and even their
destruction [80, 81]. In [81], it was shown that during
the deposition of carbon vacuum-arc coatings, the
supply of pulses with a duration of 20 μs to the substrate
leads to decrease in stresses at ion energies above
500 eV, however, the decrease can be achieved both by
changing the displacement potential and the pulse
frequency. It is substantiated that stress relief is
achieved due to ion-induced annealing in thermal peaks.
Fig. 7 illustrates that the residual compressive stresses
decrease exponentially by an order of magnitude with
the growth of a parameter equal to the product of the
amplitude by the pulse frequency (V·f). A wide range of
pulse frequencies from 100 to 1200 Hz and amplitudes
in the range of 0.5…20 kV were used in study. In these
ranges the value of stress remains the same if reduce the
amplitude V and simultaneously increase the pulses
repetition frequency f by the same number of times. In
industrial applications lower voltage processing is
favoured over high voltage both because of cost of
equipment and safety issues. The stress reduction allows
the PIII&D method to deposit thicker DLC coatings
compared to DC potential [78].
It was later shown that the impulse potential
significantly affects not only the stress level, but also
the coating structure. In [82] compared hydrogen-free a-
C and hydrogenated a-C:H coatings deposited by the
FCVAD and PECVD methods, respectively, which
were deposited under PIII&D conditions. Measurements
of internal stresses also showed that for both types of
coatings with increasing pulse amplitude, the stress
level first increased and then decreased, with a peak of
8 GPa at approximately 150 V. The parameters of the
pulses during the deposition of a-C coatings were:
amplitude 0…20 kV, duration 20 μs, repetition rate
200 Hz, and during deposition of a-C:H coatings:
amplitude 0…30 kV, duration 400 μs, repetition rate
60 Hz. It was found that the change in amplitude affects
the ratio of sp
3
/sp
2
-bonds in the coating. In the case of
hydrogen-free a-C, hard coatings with the maximum
percentage of sp
3
-bonds of carbon atoms and a hardness
of 40…60 GPa were deposited at bias potentials in the
range of 80…150 V. Outside this range, sp
2
-bonds of
carbon atoms prevailed in the coating material, and
coatings were deposited, the hardness of which is much
lower, 20…30 GPa, but the level of mechanical stress is
also much lower.
84 ISSN 1562-6016. Problems of Atomic Science and Technology. 2023. №2(144)
Fig. 7. Stress in a-C coating as a function of voltage–
frequency product for a range of voltages between 1.7
and 20 kV and frequencies from 200 to 1200 Hz [81]
Thus, the non-monotonic nature of the dependence
of the sp
3
content and the hardness of DLC coatings on
the amplitude of the pulsed potential is similar to such
dependence for a DC one, only the position of the
maximum is shifted towards higher values of the
potential [82, 83]. Since the use of high-voltage pulses
significantly changes the sp
3
/sp
2
ratio, the properties
based on this ratio may change.
In work [84], the change in the characteristics of
FCVAD ta-C coatings depending on the amplitude of
the high-voltage pulse potential of the substrate in the
range of 3…7 kV (pulse frequency 600 Hz, duration
25 μs) was studied in comparison with a low DC
potential of 85 V. Morphological and mechanical
characteristics were measured, as well as adhesion and
tribological properties of DLC films. The level of
mechanical stresses at potential of 85 V is 10 GPa, and
at pulsed voltage it decreases to 1 GPa and is practically
unchanged in the studied range of amplitudes.
Nanohardness at DC potential of 85 V is 52 GPa, and at
pulsed potential it decreases from 36 to 26 GPa. In
deposition regimes with increased potential amplitude,
an improvement in adhesion is observed, which is
associated with the formation of a thicker transitional
mixed layer of the coating material and the substrate,
and the surface of the film tends to be rougher. All
coatings show a very low coefficient of friction (from
0.07 to 0.09) regardless of the amplitude. The rate of
wear, on the contrary, increases with an increase in the
amplitude of the substrate bias potential by
approximately 35 times from 0.2∙10
-7
to 7∙10
-7
mm
3
/Nm.
The results of [83] show that high hardness is an
important requirement to ensure wear resistance if the
coatings adhesion is sufficient. This conclusion is
confirmed by the authors of [84], who studied ta-C
coatings deposited by the FCVAD method at DC
50…200 V and pulsed 0.5…2.0 kV substrate bias
potential, as well as at floating potential and grounded
substrate. They found a clear correlation between the
hardness of the coatings and their wear resistance
(Fig. 8,a). The hardness, in turn, was determined by the
content of sp
3
-bonds, which was evidenced by a
negative correlation with the ratio of Id/Ig Raman
scattering peaks (see Fig. 8,b) [19, 85]. The coefficient
of friction of the coatings, obtained when applying both
DC and pulsed substrate potential, changed slightly and
was within 0.20…0.27 for dry test conditions and
0.09…0.12 under lubrication conditions. However, it
should be noted that sufficiently thin films with a
thickness of 200 nm were studied, while the advantages
of the pulse mode are manifested in thicker coatings,
where good adhesion is more important. The use of
high-voltage impulse potential contributes to a
significant increase in the adhesion of diamond-like
coatings, both due to the formation of transition layers
when mixing the coating material and the substrate, and
due to the reduction of residual stresses [78].
а
b
Fig. 8. Correlation diagrams between hardness and
wear depth (a) and the ratio of Raman scattering
peaks (b) for ta-C coatings obtained by the FCVAD
method at different values of DC and pulse substrate
bias potentials [84]
Currently, there is no clear understanding regarding
the optimal values of the pulse potential parameters
(amplitude, frequency, duration of pulses) which
promote reaching the best desired properties of DLC.
Theoretical studies of radiation-stimulated processes of
their formation can be of great benefit in determining
the optimal deposition regimes of diamond-like
coatings, in particular, the concept of nonlocal
thermoelastic peaks (NTP) [49, 50, 86, 87], which, by
means of mathematical modeling, effectively allows one
to estimate the level of residual stresses in coatings and
determine the parameters of the deposition process,
which ensure the formation of sp
3
- or sp
2
-bonds, based
on the analysis of the trajectories of the ions
thermoelastic peaks on the carbon P,T phase diagram.
Theoretically, it is shown that the internal stresses in the
DLC in the pulse substrate bias mode of FCVAD
deposition can be reduced several times without a
significant decrease in the concentration of sp
3
-bonded
carbon, compared to the coating obtained in the DC bias
mode, however, there are certain limitations. For
example, with an amplitude of 1000 V pulses with a
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duration of 5 μs, increasing the frequency from 0 to
200 kHz leads to a linear decrease in the stresses in the
coatings from 8.5 to 0.5 GPa, but at frequencies above
130 kHz, the trajectory of the ion peaks on the phase
P,T diagram go beyond the stability region of diamond,
which evidences the graphitization of the coating [86].
In addition, the important role of the deposition
temperature in controlling the internal stresses in the
deposited coating is noted [87].
4.2. GRADIENT COATINGS
Gradient DLC coatings are characterized by the
feature that the content of the sp
3
fraction and,
accordingly, the hardness of the deposited amorphous
carbon increases monotonically from the substrate to the
surface. To form a gradient structure, the substrate bias
potential changes monotonically throughout the
deposition time [88–90]. If the potential is changed
stepwise, a quasi-gradient structure is synthesized [91–
93]. The range of potential change, as well as the
direction (increase or decrease) depend on the features
of the DLC manufacturing method. So, gradient ta-C
coating was deposited on a hard alloy base from a
magnetron source of carbon plasma [88]. The potential
of the substrate during deposition was increased linearly
from 0 to 300 V. At the same time, the microhardness of
the coating in the direction from the base to the surface
increased from 1800 to 4100 HV. The gradient design
made it possible to reduce the stress level in the coating
to 3.8 GPa and to apply an ultrahard coating 1 μm thick
with adhesion up to 50 N on a hard alloy base. Similar
results were obtained for magnetron quasi-gradient
coatings up to 1.6 μm thick that were deposited on
stainless steel with a stepwise increase potential from 20
to 150 V in steps of 2 V every 100 s. Internal stresses in
such a coating of 1.5 GPa turned out to be 2.5 times
lower than in a coating deposited at a DC potential of
140 V [91].
During fabrication the gradient ta-C coatings by
FCVA method, as a rule, value of substrate potential is
decreased. Micron-thick coatings deposited under
gradually decreasing the amplitude of the pulsed
substrate bias potential from 3 kV to 0 V (pulse duration
25 μm, frequency 600 Hz) demonstrate hardness and
wear properties close to ta-C and a stress level of
1.5 GPa, which is 6 times less than in the coating
deposited at DC substrate potential 100 V [89]. Quasi-
gradient (graded) coating deposited on rotated silicon
substrate under stepwise decreased negative DC
substrate potential (1500, 1000, 500, 80 V) have low
stress level without significant reduction in hardness
and Young's modulus, due to the fact that the average
content of sp
3
-bonds remains high. Scratch testing
demonstrates favorable scratch resistance and improved
adhesive strength [90].
Thus, deposition of gradient ta-C coatings with good
protective properties is achieved due to the high sp
3
/sp
2
ratio at the surface, which gradually decreases towards
the substrate to enhance adhesion. The surface of the
coating is hard, which provides a low coefficient of
friction and a low rate of wear, however, to achieve a
significant thickness of coatings, this method is less
effective than the formation of a multilayer structure.
4.3. FORMATION OF MULTILAYER CARBON
STRUCTURES
Creation of multilayer DLC coatings with
alternating hard and soft amorphous carbon layers with
different sp
3
content is achieved by changing the energy
of the deposited ions by changing the bias potential of
the substrate. The parameters of the potential depend on
the method of manufacturing the multilayer coating:
FCVAD [53, 94–104], MS [105–112] or PECVD [113–
117]. A change in the DC potential [53, 102–107, 111–
115] or the pulse amplitude [94–97] is applied.
Alternation of layers leads to a significant reduction of
residual stresses in comparison with single-layer ta-C
coatings, which makes it possible to obtain carbon
coatings with a total thickness of several to 10 μm [29,
78, 94, 97, 104, 117]. A less common way to implement
this alternation is to periodically interrupt the coating
process followed by Ar ion bombardment to create an
sp
2
-bonds on the surface before restarting the coating
process [104].
In the case of the synthesis of hydrogen-free
multilayer DLC, hard layers with a high percentage of
sp
3
bonds and a hardness of 50…80 GPa are usually
deposited at bias potential in the range 80…150 V.
Beyond this range, the content of sp
2
-bonds of carbon
atoms in the coating material increases, these are
conditionally soft coatings, the hardness of which is
much lower (20…30 GPa), but most importantly, the
level of mechanical stress is much lower. Thus, the non-
monotonic course of the dependence of the carbon
coating properties on the substrate bias potential opens
up two ways of synthesizing soft layers. In one of them,
during the deposition of the soft layer, the forced bias
potential is not applied, or it has rather low values
(<40 V), in the other, the potential is hundreds of volts
or even several kilovolts. Each of these ways leads to a
significant improvement in adhesion, however, it should
be taken into account that at too low particle energies,
less dense, more defective and rough layers can be
formed [82].
Fig. 9 shows typical electron microscopic images of
the cross-section of a nanoscale multilayer coating at
different magnifications. The microscopic image (see
Fig. 9,a) clearly shows alternating soft (light) and hard
(dark) layers about 30 nm thick. The difference in
contrast is the result of different densities between the
layers deposited by MS at a bias of 40 and 120 V. The
image of the boundary between the soft and hard layers
in Fig. 9,b, obtained at a higher magnification, indicates
that both layers have an amorphous structure [112].
Fig. 9. Electron microscopic images of the cross section
of a multilayer DLC coating with alternating hard
and soft layers (1/1) at different magnifications [112]
86 ISSN 1562-6016. Problems of Atomic Science and Technology. 2023. №2(144)
Multilayer DLC coating designs with alternating soft
and hard layers have been mentioned in publications
since 1994 [94]. Coatings consisting of four carbon
bilayers were deposited from filtered vacuum-arc
plasma in a PIIID mode with pulse duration of 2 μs and
repetition rate of 120 kHz. The pulse amplitude during
the deposition of a hard layer with sp
3
content of 85%
and a hardness of 60 GPa was 100 V, and of a soft layer
with sp
3
content of 40% was 2 kV. Three variants of
multilayer constructions were produced with different
ratios of the duration of the hard/soft layer deposition:
10/90, 50/50 or 90/10. It turned out that the hard layers
are noticeably thinner than the soft ones. For the 50/50
variant, measurements give values of 7 nm for the hard
layer and 22 nm for the soft layer. The use of high-
energy 2 kV ions to deposit the soft layers limits the
thickness of the individual layers to about 20 nm, since
the hard layer of less thickness is destroyed by the
subsequent deposition of the soft layer. Nanoindentation
showed that the hardness of the investigated multi-layer
coatings decreases with increasing content of soft layers
and is in the range of 33…23 GPa. Thanks to the multi-
layer structure, the overall compressive stresses in the
coatings were reduced compared to a hard single-layer
coating, and the wear resistance was significantly
increased, especially at high loads [95, 96].
In other experiments, the deposition parameters were
tried to be chosen in such a way that during the
deposition of the soft layer, the effects of implantation
and partial destruction (transformation) of the part of the
hard layer located below were avoided. For example,
during the application of the PIIID method on the
OPDB-FCVAD industrial equipment, coatings with a
total thickness of 1 μm with equal thicknesses (of
12.5 nm and more) of soft and hard layers were
deposited. A soft DLC layer with 60% sp
3
fraction and a
hardness of 25 GPa was deposited under a pulse bias
potential of 3 kV, 600 Hz, 25 μs, and a hard layer with
80% sp
3
fraction and a hardness of 52 GPa was
deposited in the absence of pulses [97, 98]. Also,
nanoscale layers with a thickness of 15 nm were
obtained by changing the DC bias potential. In FCVAD
multilayer coatings – when switching the potential
between 50 V (hard layer, 60% sp
3
) and 150, 250 or
350 V (soft layer, 51, 44 or 36% sp
3
, respectively) [53].
In MS coatings – between 120 (hard layer, 39 GPa) and
40 V (soft layer, 14 GPa) [112].
Many works were aimed at studying the influence of
the internal architecture of multilayer coatings on their
mechanical characteristics. It was found that the
properties of the coating are determined both by the
ratio of the layers thickness and by the modulation
period in the composition [53, 87–100, 105, 109–112,
114, 116, 117]. In most studies on the synthesis of
unalloyed diamond-like coatings, the greatest positive
effect is achieved if the modulation period is within
50…100 nm, i.e., a nanostructure is formed in the
coatings. The hardness value of the nanolayer structure
is usually close to the weighted average of the hardness
of the constituent layers, the H/E ratio is sometimes
higher, and the total residual compressive stresses are
much smaller than would be expected based on the
proportions of the layer components. Compared to a
single-layer film, changing the thickness or the ratio of
layer thicknesses has little effect on the roughness and
friction coefficient, however, the wear rate of multilayer
diamond-like films is effectively limited. The lowest
wear rate is recorded in films with alternating hard and
soft layers of approximately the same thickness, mainly
due to the balance between hardness and residual
stresses. Thus, the modulation factor appears to be
optimal 1/1.
As an example, Fig. 10 shows the results of tests of
multilayer DLC coatings produced by MS [111]. The
wear rate and characteristic curves of the coefficient of
friction for single-layer coatings and multilayer coatings
with different percentages of the thickness of the hard
layer and different thickness of the bilayer depending on
the load are shown. Among them, the coating with 50%
hard layer and 61 nm period has better wear resistance
and lower friction coefficient, especially at high contact
load of 3.65 GPa (80 N). It is noted that under high
load, strength is critical in influencing wear resistance,
while under low load wear rate is strongly dependent on
hardness. The lowest rate of wear is more often
demonstrated by coatings characterized by the highest
H/E ratio. Adding layers with lower sp
3
content in a
multilayer structure promotes plastic deformation by
reducing high compressive stresses. More ductile
coatings may exhibit better adhesion. For example, the
authors note a correlation between the high adhesion
strength of multilayer diamond-like coatings and higher
values of H
3
/E
2
compared to single-layer coatings. In
addition, the interfaces between the soft and hard layer
in the multilayer architecture create barriers to limit the
nucleation and propagation of cracks [53, 102, 108,
111].
In a number of works, the importance of the
formation of a strong adhesive sublayer between the
substrate and the coating is noted. It is advisable to start
the deposition of the coating by applying a high-voltage
pulsed bias potential to the substrate to ensure the
implantation of carbon ions. In deposition regimes with
a high potential, an improvement in adhesion is
observed due to the formation of a transitional mixed
layer with an increased thickness of up to several tens of
nm. If the substrates consist of carbide-forming
elements (Si, Ti, Fe, etc.) or are covered with them, a
carbide zone is created, which increases the adhesion
strength of DLC coatings. In addition, it is advisable to
use a soft coating layer in contact with the substrate to
ensure a smoother transition from the soft base to the
hard coating [53, 94, 95, 97, 103, 112].
It should be noted that in most studies of the
tribological characteristics of multilayer DLC coatings,
wear resistance was measured under conditions of low
loads (1…10 N) [83, 96, 100, 103, 107, 116]. In the few
works containing tribological characteristics at high
contact loads (up to 80 N) [111, 112], the significant
influence of the additional surface layer is noted. In
[112], it was shown that a soft top layer with a thickness
of 50 nm significantly improved the wear resistance of
magnetron multilayer films with a period of 60 nm.
ISSN 1562-6016. Problems of Atomic Science and Technology. 2023. №2(144) 87
a c
b d
Fig. 10. Wear rate (a, b) and friction coefficient curves(c, d) for multilayer DLC coatings with different
percentages of hard-layer thickness (a, c) and with different bilayer thicknes (b, d) [111]
Fig. 11 shows the results of tribological tests of such
coatings with different percentages of the thickness of
the hard layer, which had an additional soft top layer, as
well as without it. The tests were carried out according
to the ball-on-disc scheme under dry sliding conditions
under loads of 20 and 80 N, corresponding to initial
Hertzian contact stresses of 2.5 and 4 GPa. It can be
seen that with a load of 20 N (see Fig. 11,a), the
presence of an additional layer reduces the wear of all
coatings by 2–3 times. Fig. 11,b shows the wear volume
of DLC coatings with an additional top layer under an
extreme applied load of 80 N. Tests lasting 2000 s did
not withstand a single-layer hard (36 GPa) coating and a
multilayer coating with a low content of a hard layer of
30% (15 GPa). Very small wear was shown by a coating
with a 50% hard layer, which had a hardness of 18 GPa.
a b
Fig. 11. Volume of wear of DLC coatings with different percentages of hard layers content:
a – comparison of wear of coatings with and without an additional soft top layer under a load of 20 N;
b – wear of coatings with an additional top layer at 80 N [112]
The dependences of the coating friction coefficients
on the number of test cycles, which are shown in
Fig. 12, show that the presence of a soft top layer
reduces the time required for the formation of the
transfer layer, ensuring a low coefficient of friction and
reducing wear.
Various fields of application are affected not only by
mechanical stress, but also by high temperature, which
can create a problem for the ta-C protective coating. In
[103], the effect of applying a soft or hard additional
layer with thickness of 120 nm on the surface of
multilayer ta-C coatings with a period of about 60 nm
and a modulation factor of 1/1 was compared from the
point of view of friction processes at high temperature
(400…600 C). The hardness of the hard and soft top
layer measured by nanoindentation tests was 55.2 and
36.7 GPa. The results showed that the upper layer of the
multilayer structure had a decisive influence on the
process of high-temperature friction of the coating as a
whole. In Fig. 13,a shows the design of the multilayer
structure of DLC coatings with an additional soft and
hard layer and the schematic diagrams of their wear
mechanisms.
88 ISSN 1562-6016. Problems of Atomic Science and Technology. 2023. №2(144)
a b
Fig. 12. Curves of the dependence of the coefficient of friction at a load of 20 N on the number of test cycles for
multilayer DLC coatings without an additional soft top layer (a) and with it (b) [112]
a b
Fig. 13. Diagrams of the multilayer construction of DLC coatings with an additional soft and hard layer and their
wear mechanisms at elevated temperature (a) and the dependence curve of the friction coefficient on the number of
test cycles at different temperatures for a coating with a hard top layer (b) [103]
The hard top layer contributes to an excellent
lubrication effect and a negligible wear rate
(4.010
−7
mm
3
/Nm) at 400 C due to sufficient load-
bearing capacity and reduced wear residue formation. In
addition, the strong sp
3
-bonded carbon restricted the
formation of a graphitized tribolayer, which weakened
the adhesion force at the sliding interface. Unpaired
bonds on the sp
3
-enriched surface of ta-C were
effectively passivated by active compounds in the
atmosphere. The soft top layer worsened the frictional
properties because it had limited mechanical properties
and insufficient ability to withstand the load, which led
to an increase in the contact area and strong friction.
The low wear resistance of the sp
2
-rich upper layer
contributed to the formation of wear debris and a
graphitized transfer layer. The sp
2
-rich surface layer
strongly interacts with the graphitic transfer layer,
which sticks to the counterpart at high temperature,
resulting in severe adhesive interaction and undesirable
friction behavior.
The ta-C multilayer coating with a hard top layer
maintains a low coefficient of friction (0.11…0.12) at
500 °C as can be seen from Fig. 13,b, while at 600 C
the coefficient of friction increases rapidly, indicating
wear of the coating, which is explained by the oxidation
and evaporation of carbon atoms. Thus, the addition of a
hard top layer contributes to a low coefficient of friction
and high wear resistance, which are maintained at
temperatures up to 500 °C [103].
It should be noted that in most studies of the
mechanical properties of coatings, the total thickness of
multilayer compositions was relatively small (<0.5 μm),
which may not be sufficient for some mechanical and
tribological applications. In addition, the effect of the
upper layer on the tribological characteristics of
multilayer DLC coatings is not clear enough, as
evidenced by the conflicting results of papers [103] and
[112] The data presented in the literature are not
complete enough, so the practical application of this
approach requires further comprehensive research.
Summarizing the results of the reviewed works, it is
possible to propose a generalized structure of the
developed multi-layer carbon coatings in the form of a
perspective design, scheme of which is presented in
Fig. 14. The structure includes three basic zones. Each
of them implements certain function, can be flexibly
configured for specific tasks and is important for the
final promotion of high protective properties of the
coating. The first zone is formed on the surface of the
substrate, it plays the role of binder, which is used to
optimize adhesive properties by mixing carbon with the
substrate material, generating carbide phases and
ISSN 1562-6016. Problems of Atomic Science and Technology. 2023. №2(144) 89
smoothly transitioning from a softer base to a hard
coating. The second one is a buffer zone that has a
multilayer structure with alternating hard (with a higher
sp
3
content) and soft (with a lower sp
3
content) layers
with a period of 50…100 nm and a modulation factor of
1/1, which allows you to provide the required coating
thickness of several µm The third one is a functional
zone with a thickness of 100...300 nm, the properties of
which are chosen depending on the conditions of use of
the coated product. In the case of high loads, it is
advisable to use a hard layer with a high content of sp
3
-
bonds as a functional one.
Fig. 14. A promising design of a multilayer structure of
DLC with high protective properties
CONCLUSIONS
DLC coatings offer excellent opportunities to
improve wear resistance and reduce friction, making
them useful for many industrial applications from
cutting tools and friction units to biomedical devices.
The decisive factor determining the properties of
hydrogen-free (a-C or ta-C) DLC coatings is the ratio of
the content of diamond-like sp
3
and graphite-like sp
2
-
bonds. Hardness and wear resistance correlate with sp
3
content. A key parameter in the synthesis affecting the
sp
3
/sp
2
ratio is the energy of carbon ions coming the
surface of the growth, which is controlled by the bias
potential on the substrate.
A restraining factor on the way to expanding the
spheres of use of hydrogen-free ta-C coatings with
properties closest to diamond is the problem of
unsatisfactory adhesion of thick (≥0.5 μm) layers, high
stress level and insufficient strength. When modifying
coatings, they try to maintain high hardness, low
coefficient of friction, stability and at the same time
improve strength and wear resistance due to reducing
level of stress and fragility.
The concept of multilayer structures looks most
promising for thick diamond-like coatings. From the
point of view of ease of industrial implementation, the
option of multilayer structure that is formed exclusively
from carbon atoms and does not contain additional
alloying elements appears to be the most economical
and promising. For deposition of thick multilayer
hydrogen-free films based on ta-C, which have the best
diamond-like characteristics, the most promising in
industrial production is the use of highly ionized filtered
cathode vacuum-arc plasma. For the synthesis of such
multilayer coatings, it is possible to use the equipment
available in the production and traditional graphite
cathodes, and the synthesis processes are based on the
previously developed processes for single-layer
coatings.
In the multi-layer design of the coating based on
unalloyed DLC, which is promising for mechanical and
tribological applications at high loads, it is advisable to
combine three basic zones, each of which performs a
certain function and is important for the final promotion
of high protective properties. The first – bonding zone is
used to optimize adhesion properties by mixing carbon
with the substrate material, generating carbide phases
and ensuring a smooth transition from a softer base to a
hard coating.
The second is a buffer zone with alternating
hard/soft layers (high/low sp
3
content), which allows
you to provide the necessary coating thickness of
several microns. The parameters of the buffer zone are
chosen based on the fact that the greatest positive effect
is achieved if the modulation period is within 50-
100 nm, that is, a nanostructure is formed in the
coatings. The hardness of the nanolayer structure is
usually close to the weighted average of the hardness of
the constituent layers, the H/E ratio is higher, and the
total residual compressive stresses are much lower than
would be expected based on the proportions of the layer
components. Compared to a single-layer film, changing
the thickness or modulation period of the layers has
little effect on the roughness and coefficient of friction,
however, the wear rate is effectively limited. The lowest
rate of wear is achieved by coatings with a modulation
coefficient 1:1.
The third is a functional zone with a thickness of
100…300 nm, the properties of which are chosen
depending on the conditions of use of the coated
product. In the case of high loads, it is advisable to use a
hard layer with a high content of sp
3
-bonds as a
functional layer. The hard top layer contributes to a low
coefficient of friction and a negligible rate of wear.
Hard and soft layers can be deposited both at DC
substrate bias potentials or in high-voltage pulse mode.
Applying high-voltage pulses to the substrate allows to
additionally reduce the stress in individual layers of the
coating due to ion-induced thermal annealing, as well as
to increase the thickness of the bonding zone.
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Article received 08.02.2023
ОПТИМІЗАЦІЯ АЛМАЗОПОДІБНИХ ВУГЛЕЦЕВИХ ПОКРИТТІВ
ДЛЯ МЕХАНІЧНИХ ТА ТРИБОЛОГІЧНИХ ЗАСТОСУВАНЬ. ОГЛЯД
О.М. Решетняк, О.А. Лучанінов, В.Є. Стрельницький
Алмазоподібні вуглецеві покриття використовуються для підвищення якості промислових виробів
завдяки широкому спектру виняткових фізичних, механічних і трибологічних властивостей. Розглянуто
проблеми, що обмежують сферу застосування твердих негідрогенізованих алмазоподібних покриттів із
властивостями, які найбільш близькі до алмазу. Проведено огляд наукової літератури, що присвячена
покращенню характеристик зносостійких покриттів на основі алмазоподібного вуглецю. Проаналізовано
сучасні підходи до зниження внутрішніх напружень стиску, покращення адгезії до основи та підвищення
міцності покриттів. Розглянуто аспекти оптимізації параметрів осадження, легування, побудови градієнтної
та багатошарової структури. На основі узагальнення результатів розглянутих публікацій зроблено висновок
про переваги використання покриттів із багатошаровою структурою. Розглядається перспективна
конструкція нелегованих багатошарових DLC-покриттів з високими захисними властивостями.
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