Functional Multi-Nanolayer Coatings of Amorphous Carbon/Tungsten Carbide with Exceptional Mechanical Durability and Corrosion Resistance

Interface Amorphization Controls Maximum Wear Resistance of Multinanolayer DLC/WC Coatings

Multilayer coatings offer significant advantages in protecting materials' surfaces by shielding the underlying materials hierarchically from damage and wear. The layering morphology and structure of multilayer coatings directly affect their wear resistance capacity. Using a systematic set of experiments and molecular dynamics (MD) simulations, we studied the effect of layering thickness on the macroscale wear response of DLC/WC multinanolayer coatings. Our study revealed the existence of a critical bilayer thickness where maximum scratch hardness and wear resistance can be achieved. Our large-scale MD simulations showed that reducing the WC layer thickness to a certain limit increases the scratch hardness due to the confinement of dislocation motion. However, when the thickness of the WC layers falls below 2 nm, the deformation mechanism transitions from the interface-induced dislocation confinement to the interface-mediated amorphization of WC layers, reducing the scratch hardness of the coating. This finding offers a procedure for optimizing the macroscale wear performance of multinanolayer coatings.

Tungsten Carbide Nanolayer Formation by Ion Beam Mixing with Argon and Xenon Ions for Applications as Protective Coatings

A novel nanolayer is formed by means of ion irradiation applicable as protective coating. Tungsten carbide (WC)-rich nanolayers were produced at room temperature by applying ion beam mixing of various carbon/tungsten (C/W) multilayer structures using argon and xenon ions with energy in the range of 40-120 keV and fluences between 0.25 and 3 × 10¹⁶ ions/cm². The hardness of the nanolayers was estimated by means of standard scratch test applying an atomic force microscope equipped with a diamond-coated tip (radius < 10 nm); the applied load was 2 μN. The irradiation-induced hardness of the nanolayers correlated with the areal density of the WC; with the increasing amount of WC, the hardness of the nanolayer increased. The produced layers had an order of magnitude better corrosion resistance than a commercially available WC cermet circular saw. If the WC amount was high enough, the hardness of the layer became higher than that of the investigated WC cermet. These findings allow us to tune and design the mechanical and chemical properties of the WC protective coatings.

Probing the Impact of Tribolayers on Enhanced Wear Resistance Behavior of Carbon-Rich Molybdenum-Based Coatings

Minimizing friction and wear is one of the continuing challenges in many mechanical industries. Recent research efforts have been focused on accelerating the antifriction and antiwear properties of hard coatings through the incorporation of self-lubricant materials or the development of new architectures. In this present study, carbon-rich MoC, MoCN, and multilayer MoC/MoCN coatings were deposited using reactive magnetron sputtering. X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), and Raman spectroscopy were used to evaluate their properties, which revealed the presence of ceramic cubic crystallites, covalent bonds between primary elements, and an excess of amorphous carbon (a-C) in all of the coatings. The multilayer architecture and possible segregation of a-C around the ceramic crystallites resulted in improved mechanical properties for all coatings, with MoC/MoCN coatings having a maximum hardness of 21 GPa and elastic modulus of 236 GPa. Friction and wear behavior are initially determined by the structural-composition-property relationships of the respective coatings; later, the tribological characteristics are altered depending on the nature of tribolayer on both mating surfaces at the contact interface. The highest wear resistance of multilayer MoC/MoCN coating (8.7 × 10^-8 mm³/N m) and MoC coating (3.9 × 10^-7 mm³/N m) was due to the dissipation of contact stress by the tribofilm consisting of carbon tribo products like graphitic sp² carbon, diamond-like sp³ carbon, and pyrrolic-N. On the other hand, MoCN coating depicted a lower wear resistance due to the frequent termination of C-H bonds by N, which restricts the strong formation of tribofilms as well as poor mechanical properties.

Formation of discrete periodic nanolayered coatings through tailoring of nanointerfaces-Toward zero macroscale wear

Notwithstanding the success of nanolayered coatings in the reduction of wear at nano-/microscales, the improvement of the wear resistance at the macroscale remains an issue. Moreover, the effects of nanointerfaces in nanolayered coatings on their macrotribological properties are not understood well. This paper reports on the engineering of nanointerfaces in diamond-like C/Cr nanolayered coatings to tailor their characteristics including the degree of intermixing, defects, and Cr growth mode. The result was the fabrication of a coating with subnanometer-thick periodic albeit discrete Cr interlayers. This was achieved using our patented deposition technique. This coating contained less interfacial defects compared to classic nanolayered coatings with continuous nanolayers and presented record-breaking wear rates at the macroscale. Finite Element analysis was performed and micropatterning strategy was used to reduce the wear rate further. Last, we report on discovery of a dimensionless parameter that can be used to predict the wear resistance of carbon-based nanolayered coatings.

In vitro and in vivo biocompatibility and bio-tribological properties of the calcium/amorphous-C composite films for bone tissue engineering application

Carbon-and diamond-like-carbon coated Ti alloys hold great promise for tissue engineering applications. Unfortunately, their strong intrinsic stress leads to the adhesion failure of the films. Herein, a series of a-C films with different Ca content were prepared on Ti₆Al₄V via co-sputtering deposition technology. Homogeneous spherical Ca nanoclusters, with an inner diameter of 2-6 nm, were formed in an amorphous carbon matrix. The addition of Ca induced indistinctive variation in either phase composition or topography. However, the introduction of Ca not only improved the mechanical properties of a-C film but also significantly strengthened its adhesion to osteoblasts. The bio-tribological properties of Ca/a-C films were also assessed using a tribometer in FBS solution. The Ca/a-C films exhibited a low friction coefficient of 0.083 and a low wear rate of 1.02-1.24×10^-6 mm³/Nm. The low coefficient of friction (COF) of the Ca/a-C films indicates their superior mechanical properties, making them the promising target of nanocomposite films used in bio-tribological applications. Well-stretched cells and the developed actin filaments were distinctly observed on the Ca/a-C films in the osteoblast cell adhesion experiments. In addition, the Ca/a-C films promoted cell proliferation and showed high cell viability. After being implanted for 4 weeks, the Ca/a-C implant material still adhered well to the muscle tissue, without inducing hyperergic or inflammatory reactions. Collectively, our results suggest that the Ca/a-C film is an ideal mounting material for bone tissue engineering.

Surface Fatigue Behavior of a WC/aC:H Thin-Film and the Tribochemical Impact of Zinc Dialkyldithiophosphate

In wind turbine gearboxes, (near-)surface initiated fatigue is attributed to be the primary failure mechanism. In this work, the surface fatigue of a hydrogenated tungsten carbide/amorphous carbon (WC/aC:H) thin-film was tested under severe cyclic tribo-contact using polyalphaolefin (PAO) and PAO + zinc dialkyldithiophosphate (ZDDP) lubricants. The film was characterized in terms of its structure and chemistry using X-ray diffraction, analytical transmission electron microscopy, including electron energy loss spectroscopy (EELS), as well as X-ray photoelectron spectroscopy (XPS). The multilayer carbon thin-film exhibited promising surface fatigue performance showing a slight change in the hybridization state of the aC:H matrix. Dehydrogenation of the thin-film and subsequent transformation of cleaved C-H bonds to nonplanar sp² carbon rings were inferred from EELS and XPS results. While tribo-induced changes to the aC:H matrix were not influenced by a nanometer-thick ZDDP reaction-film, the rate of oxidation of WC and its oxidation state were affected. While accelerating surface fatigue on a steel surface, the ZDDP-tribofilm protected the WC/aC:H film from surface fatigue. In contrast to the formation of polyphosphates from ZDDP molecules on steel surfaces, it appeared that on the WC/aC:H thin film surface, ZDDP molecules decompose to ZnO, suppressing the oxidative degradation of WC.

Corrosion of Al2O3-Ti composites under inflammatory condition in simulated physiological solution

Alumina-titanium composites have shown good mechanical properties which makes them promising for orthopedic applications. The placement of an orthopedic implant involves an invasive procedure which stimulates a localized inflammatory response causing an acidic environment around the implant. This makes the study on corrosion more critical. Therefore, the aim of the present paper was to study the corrosion behavior of the composites with 75 vol% and 50 vol% Ti content (with alumina balance) fabricated by Spark Plasma Sintering under acidic condition representing inflammation and in two elapsed times (1 h and 1-day) using polarization and electrochemical impedance spectroscopy tests. For comparison, the experiments were also conducted in normal physiological solution after 1 h, and pure Ti (100vol%Ti) was fabricated by the same process and analyzed, similarly. Furthermore, behavior of the samples was studied after 48 days of immersion in the acidic and normal solutions using SEM, ATR-FTIR, AFM, and ICP-OES. The results of corrosion tests showed very good passivation behavior of 100vol%Ti and the composite containing 75vol.%Ti. The superiority of the 75vol.%Ti composite in corrosion characteristics in both solutions was also found. Its corrosion resistance was 20.3 MΩcm² under the inflammatory condition after 1-day, which was 39% higher than that of 100vol.%Ti under the same condition. The results of SEM indicated both corroded and mineral deposition zones on all materials' surfaces and the ATR-FTIR results revealed additional adsorbed bands related to water adsorption, OH and carbonate groups after immersion. The AFM analysis showed rougher morphology, particularly for 75 vol% Ti where the Rq was increased about 50 nm, and the ICP-OES results indicated 65.87% and 61.94% deposition of solution calcium on 75vol.%Ti and 50vol.%Ti, respectively. The acidic/inflammatory condition influenced the corrosion processes of all materials. Lower pH caused the passivation to occur sooner and the corrosion resistance to be higher.

Highly durable and biocompatible periodical Si/DLC nanocomposite coatings

Functional nanocomposite coatings comprised of periodically stacked nanolayers of diamond-like carbon (DLC) and amorphous silicon were developed for biomedical applications. The periodical nanocomposite structure provided high surface durability while silicon aided in reducing the residual stress. The structural, mechanical, tribological, and biomedical properties of the Si/DLC coatings deposited by magnetron sputtering were investigated systematically. The effect of the negative substrate bias on the structure and properties of the coatings was also assessed. The coatings demonstrated high durability and high biocompatibility. The bias voltage and bias mode affected both the hardness and residual stress of the Si/DLC coatings. Particularly, application of 60 V negative bias during the DLC layer deposition resulted in the lowest wear rate. FEM simulations showed that the wear resistance of the coatings was dictated by the hardness as well as the adhesion between the coatings and a chromium sub-layer. The periodical alternation of Si and DLC nanolayers led to a significant improvement of MC3T3 cell adhesion compared to the previously published data for Si-DLC composites.