12 research outputs found
Sustainable super-hard and thick nanodiamond composite film deposited on cemented carbide substrates with an interfacial Al-interlayer.
Get PDFSuper-hard nanodiamond composite (NDC) films, synthesized via cathodic arc plasma deposition on unheated WC−Co substrates, offer an eco-friendly solution for cutting tools. A 100 nm-thick Al-interlayer mitigates Co catalytic effects, improving adhesion and yielding smooth and dense 10 µm-thick films at a deposition rate of 3.3μm/hr. These grain-boundary-rich nanostructured films, with an impressive 58 GPa hardness attributed to a substantial 70% C sp3 fraction, prove optimal for hard coatings. The Al-interlayer effectively suppresses Co catalytic effects, forming a dense Al-oxide layer, enhancing film hardness and adhesion (Lcr=18.6N). NDC films present a promising eco-friendly option for high-performance hard coatings
Influence of droplet-free ta-C coatings and lubrication conditions on tribological performance and mechanical characteristics of WC−Co.
Get PDFCemented carbide (WC−Co) tools suffer from surface abrasion, limiting their performance. This study explores droplet-free tetrahedral amorphous carbon (ta-C) coatings deposited via arc ion plating as a solution. The coatings possess a dense, sp3-rich structure, leading to a remarkable hardness of 60 GPa compared to 37 GPa of WC−Co, and strong adhesion with a critical scratch load of 41 N. Tribological tests confirm their effectiveness. Dry sliding tests show reduced wear and lower CoF (0.123) compared to uncoated tools (0.159). Notably, water-soluble lubricants yielded the best performance (lowest CoF: 0.092, superior wear resistance), while water and mineral oil also improved performance
Wear-resistant and adherent nanodiamond composite thin film for durable and sustainable silicon carbide mechanical seals.
Get PDFIn response to environmental concerns, there is a growing demand for durable and sustainable mechanical seals, particularly in high-risk industries like chemical, petroleum, and nuclear sectors. This work proposes augmenting the durability and sustainability of silicon carbide (SiC) ceramic seals with the application of a nanodiamond composite (NDC) film through coaxial arc plasma deposition (CAPD) in a vacuum atmosphere. The NDC coating, with a smooth surface roughness of Ra = 60 nm as substrate, demonstrated a thickness of 1.1 μm at a deposition rate of 2.6 μm/hr. NDC film has demonstrated exceptional mechanical and tribological characteristics, such as a hardness of 48.5 GPa, Young’s modulus of 496.7 GPa, plasticity index (H/E) of 0.098, and fracture toughness of H3/E2 = 0.46 GPa, respectively. These NDC films showcased commendable adhesion strength (> 60 N), negligible wear, and low friction (≤ 0.18) during dry sliding against a SiC counter material. Raman analysis has confirmed the nanocomposite structure of NDC film, emphasizing the role of highly energetic carbon ions in enhancing film adhesion by forming SiC intermetallic compounds at the interface through the diffusion of silicon atoms from the substrate into the films. The abundance of grain boundaries and rehybridization of carbon sp3 to sp2 bonding is perceived to improve tribological performance. CAPD excels in synthesizing long-life eco-friendly NDC coatings for durable and sustainable mechanical seals, featuring smooth surfaces, superior adhesion, outstanding hardness, and wear resistance, making them high potential candidates for various tribological applications
Disclosing mechanical and specific structural characteristics of thick and adherent nanodiamond composite hard coating deposited on WC−Co substrates.
Get PDFNanodiamond composite (NDC) films, with a notable hardness of 65 GPa and a substantial thickness of 10 µm, were successfully fabricated on unheated WC−Co substrates using cathodic arc plasma deposition (CAPD) technology. Raman and synchrotron-based structural analysis, comparing NDC films with similarly hard tetrahedral amorphous carbon (ta-C) films and chemical vapor deposition (CVD) diamond, unveiled distinctive features. Visible Raman spectroscopy highlighted NDC's unique nanostructured composition, characterized by nanodiamond grains embedded in an amorphous carbon matrix, resulting in a high fraction of C−C sp3 bonds (70%) and intense σ* C−C resonance contributing to its observed hardness. The small size of diamond crystals induced numerous grain boundaries, as evident through intense t-PA Raman peaks, effectively suppressing internal stress to 2.77 GPa and enabling the deposition of an impressive thickness (10 µm), surpassing the thinness of hard ta-C (< 1 µm). Despite the substantial thickness, NDC films demonstrated remarkable films-substrate adhesion, with no delamination and minimal spallation, in contrast to observed buckling and delamination in CVD diamond during Rockwell testing at various loads (60 Kg and 100 Kg). Additionally, NDC films maintained a stable and low coefficient of friction (≤ 0.1) against an Al2O3 counter-body, compared to the higher coefficient (≥ 0.25) of the bare WC-Co substrate. Furthermore, NDC deposition boasted a rapid rate (3.5 µm/hr), significantly exceeding both ta-C and diamond coatings, enhancing its practical applicability. Significantly, the deposition process for NDC films stands out for its environmental friendliness and cost-effectiveness, involving no external heating, chemical reactions, chemical etching of Co, or nanodiamond seeding. The findings underscore the exceptional potential of NDC as a strong competitor to hard ta-C and CVD diamond coatings, especially in advanced cutting tool applications
Clean and durable thick nanodiamond composite hard coating deposited on cemented carbide towards sustainable machining: eco-friendly fabrication, characterization, and 3-E analysis.
Get PDFThis research explores a sustainable approach for fabricating high-performance nanodiamond composite (NDC) hard coatings for dry machining. Aiming to address limitations in conventional coatings, such as environmental concerns, restricted film thickness, and compromised performance. The study utilizes Coaxial Arc Plasma Deposition (CAPD), a clean and efficient technique, to deposit thick (10 μm) NDC films directly on WC−Co substrates without chemical etching. Compared to traditional Chemical Vapor Deposition (CVD), CAPD offers significant advantages: lower temperature deposition, faster growth rate, and precise control over film thickness and morphology. The resulting NDC films boast exceptional durability due to their unique nanostructure, diamond nanocrystallites embedded in an amorphous carbon matrix. The addition of Al-interlayers (100–500 nm thickness) optimizes film properties. The optimal interlayer at 100 nm thickness not only mitigates the catalytic effects of Co but also enhances film hardness (50.4–58 GPa), Young's modulus (516–613.75 GPa), and adhesion (13–18.5 N) compared to films without an interlayer. Notably, the 100 nm Al-interlayer triples the deposition rate to 3.3 μm/h, achieving the desired thickness for effective hard coatings. The high density of grain boundaries within the films allows for exceptional stress release, enabling this increased thickness. Furthermore, these grain boundaries and the graphitic phase contribute to the film's superior tribological performance – a low coefficient of friction (0.1) and minimal wear rate (1.5 × 10⁻7 mm³/N⋅m) under dry machining conditions. These findings demonstrate the immense potential of CAPD-deposited NDC films as a sustainable alternative for advanced cutting tools, promoting environmental responsibility, economic viability, and energy efficiency
Nanomechanical and structural characteristics of nanodiamond composite films dependent on target-substrate distance.
Get PDFThis study explores the optimization of target-substrate distance (TSD) in coaxial arc plasma deposition technique for depositing nanodiamond composite (NDC) films on unheated WC–Co substrates, with a focus on enhancing properties relevant to cutting tool applications. TSD significantly impacted film growth and adhesion, while hardness and Young's modulus remained stable within the 10–50 mm TSD range. Increased TSD led to reduced deposition rates and film thickness, but improved quality by eliminating macroparticles and reducing surface roughness. Notably, the NDC film deposited at 10 mm TSD exhibited exceptional adhesion resistance, a thickness of 11.45 μm, low compressive internal stress (2.8 GPa), and a surface roughness (Sa) of 280 nm, coupled with an impressive hardness of 49.12 GPa. This film also achieved a favorable deposition rate of 1.05 nm/s. In comparison, the film deposited at 15 mm TSD displayed a maximum hardness of 51.3 GPa, lower Sa of 179 nm, but a reduced deposition rate of 0.29 nm/s. The estimated C sp3 fraction correlated well with the nanoindentation measurements, while internal stress showed a consistent relationship with film adhesion. These findings suggest that a TSD of 10 mm is optimal for balancing hardness, adhesion, deposition rate, and surface roughness, making NDC films a promising candidate for cutting tool applications
Eco-friendly thick and wear-resistant nanodiamond composite hard coatings deposited on WC–Co substrates.
No full textNanodiamond composite (NDC) films, synthesized using an environmentally friendly PVD coaxial arc plasma deposition technique on commercial cemented carbide (Co6 wt%) substrates without the need for substrate heating, chemical etching of Co, and chemical gases. These NDC coatings, crafted under specific discharge power conditions (5.2 J/pulse, 120 V, and 1 Hz), with or without a substrate biasing (−100V, 40kHz, and 35% duty cycle), exhibit a distinctive nanostructure characterized by nanodiamond grains embedded in an amorphous carbon (a-C) matrix. Highlighting remarkable mechanical characteristics attributed to highly energetic ejected carbon ion. The coatings boast high hardness (H = 65–82 GPa), Young's modulus (E = 688–780 GPa), plasticity index (H/E = 0.094–0.105), and brittle fracture resistance (H3/E2 = 0.58–0.9 GPa). Additionally, these NDC films manifest a substantial thickness of 7 μm due to low internal stress, along with superior adhesion, anti-wear resistance, and a low friction coefficient (0.1–0.09) through dry sliding against an Al2O3 counterpart. Raman analysis substantiates the nanocomposite structure of the film, underscoring the influential role of biasing in enhancing the characteristics of these environmentally friendly and wear-resistant NDC coatings. Nevertheless, the application of a negative bias led to increased internal stress levels (1.28 to 4.53 GPa), adversely impacting the adhesion between the film and substrate, resulting in a decrease from HF3 to HF6 as per Rockwell C indentation. NDC coatings hold significant potential for extending the lifespan of cutting tools and improving overall machining performance
Negative Bias Effects on Mechanical Properties of Ultrananocrystalline Diamond on Cemented Carbide Substrate Prepared by Coaxial Arc Plasma Deposition
No full textWear-resistant and Adherent Nanodiamond Composite Thin Film for Durable and Sustainable Silicon Carbide Mechanical Seals
No full textIn response to environmental concerns, there is a growing demand for durable and sustainable mechanical seals, particularly in high-risk industries like chemical, petroleum, and nuclear sectors. This work proposes augmenting the durability and sustainability of silicon carbide (SiC) ceramic seals with the application of a nanodiamond composite (NDC) film through coaxial arc plasma deposition (CAPD) in a vacuum atmosphere. The NDC coating, with a smooth surface roughness of Ra = 60 nm as substrate, demonstrated a thickness of 1.1 μm at a deposition rate of 2.6 μm/hr. NDC film has demonstrated exceptional mechanical and tribological characteristics, such as a hardness of 48.5 GPa, Young’s modulus of 496.7 GPa, plasticity index (H/E) of 0.098, and fracture toughness of H3/E2 = 0.46 GPa, respectively. These NDC films showcased commendable adhesion strength (> 60 N), negligible wear, and low friction (≤ 0.18) during dry sliding against a SiC counter material. Raman analysis has confirmed the nanocomposite structure of NDC film, emphasizing the role of highly energetic carbon ions in enhancing film adhesion by forming SiC intermetallic compounds at the interface through the diffusion of silicon atoms from the substrate into the films. The abundance of grain boundaries and rehybridization of carbon sp3 to sp2 bonding is perceived to improve tribological performance. CAPD excels in synthesizing long-life eco-friendly NDC coatings for durable and sustainable mechanical seals, featuring smooth surfaces, superior adhesion, outstanding hardness, and wear resistance, making them high potential candidates for various tribological applications
Effects of Air Exposure on Hard and Soft X-ray Photoemission Spectra of Ultrananocrystalline Diamond/Amorphous Carbon Composite Films
No full textHard X-ray photoemission spectroscopy (HAXPES) was employed for the structural evaluation of ultrananocrystalline diamond/amorphous carbon (UNCD/a-C) composite films deposited on cemented carbide substrates, at substrate temperatures up to 550 °C by coaxial arc plasma deposition. The results were compared with those of soft X-ray photoemission spectroscopy (SXPES). Since nanocrystalline diamond grains are easily destroyed by argon ion bombardment, the structural evaluation of UNCD/a-C films, without the argon ion bombardment, is preferable for precise evaluation. For samples that were preserved in a vacuum box after film preparation, the sp3 fraction estimated from HAXPES is in good agreement with that of SXPES. The substrate temperature dependencies also exhibited good correspondence with that of hardness and Young’s modulus of the films. On the other hand, the sp3 fraction estimated from SXPES for samples that were not preserved in the vacuum box had an apparent deviation from those of HAXPES. Since it is possible for HAXPES to precisely estimate the sp3 fraction without the ion bombardment treatment, HAXPES is a feasible method for UNCD/a-C films, comprising nanocrystalline diamond grains
