Applications of Diamond-like Carbon Coatings

Abdul Wasy Zia, PhD, is an academic at the Institute of Mechanical Process and Energy Engineering, School of Engineering and Physical Sciences at Heriot-Watt University in Edinburgh, United Kingdom. He has over twelve years’ experience working with diamond-like carbon coating solutions with technological, environmental, and socio-economic applications.

• List of Contributors xPreface xivSection I Diamond-like Carbon Coatings 11 Introduction of Diamond-like Carbon Coatings 3Naveen Joshi, Jagdish Narayan, Roger J. Narayan1.1 Introduction 31.2 DLC Coatings for Mechanical and Transportation Applications 61.2.1 DLC Coatings for Lubricants 61.2.2 DLC Coatings for Pipelines, Tubes, and Molds 71.3 DLC Coatings for Medical Applications 81.3.1 DLC Coatings for Orthopedics 101.3.2 DLC Coatings for Antimicrobial Performance 101.3.3 DLC Coatings for Cardiovascular Implants 111.4 DLC Coatings for Electrical and Optical Devices 121.4.1 DLC Coatings for MEMS 121.4.2 DLC Coatings for Nonvolatile Storage, Low-K Dielectrics, and Field Emitters 131.5 DLC Coatings for Optical Applications 141.6 Emerging Applications of DLC Coatings 151.6.1 DLC Coatings for Energy Storage Applications 151.6.2 DLC Coatings for Polymers and Textiles 171.6.3 Optimizing DLC Coatings Through the Utilization of Artificial Intelligence Tools 171.7 Limitations of DLC Coatings 181.8 Q-Carbon as a Superior Coating Material 191.9 Summary 222 Deposition Methods of Diamond-like Carbon Coatings 31Pranay Kalakonda, Jagdish Narayan, Roger J. Narayan2.1 Introduction 312.2 Classification of Carbon Coatings 342.3 Deposition Methods 362.3.1 Physical Vapor Deposition 372.3.1.1 Ion Beam Deposition 372.3.1.2 Mass Selected Ion Beam Deposition 382.3.1.3 Cathodic Arc Deposition 392.3.1.4 Sputtering 422.3.1.5 Ion Beam-assisted Deposition 432.3.1.6 Pulsed Laser Deposition 442.3.2 Chemical Vapor Deposition 482.4 Deposition Mechanisms 502.5 Influence of Deposition Parameters 532.6 Properties and Analysis Methods 542.7 Applications 562.8 Conclusions 573 Properties of Diamond-like Carbon Coatings 71Muhammad Abdul Basit, Ramsha Zafar, Nawal Haider3.1 Introduction to Diamond-like Carbon Coating 723.2 General Categorization of DLC Coatings 723.3 Preparation of DLC Coatings 743.4 Characterization Techniques of DLC Coatings 743.5 Properties of DLC Coatings 763.5.1 Physical Properties of DLC Coatings 763.5.1.1 Density 773.5.1.2 Surface-free Energy 773.5.1.3 Thermal Conductivity 793.5.2 Chemical Properties of DLC Coatings 803.5.2.1 Reactivity and Chemical Stability 813.5.3 Anticorrosion Properties of DLC Coatings 823.5.4 Biocompatibility of DLC Coatings 833.5.5 Opto-electrical Properties of DLC Coatings 843.5.5.1 Electrical Resistance 843.5.5.2 Bandgap 863.5.5.3 Refractive Index 863.5.6 Tribological Properties of DLC Coatings 873.5.6.1 Friction Coefficient 883.5.6.2 Wear Resistance 913.5.7 Adhesion of DLC Coatings to Substrates 923.5.8 Mechanical Properties of DLC Coatings 943.5.8.1 Hardness and Young’s Modulus 943.5.8.2 Fatigue Strength of DLC Coatings 963.6 Improving the Properties of DLC Coatings 963.6.1 Modification Through Alloy Addition 973.6.2 Modification Through Multilayer and Hybrid Coatings 983.7 Applications and Uses of DLC Coatings 1003.8 Summary and Future Outlook 100Section II Diamond-like Carbon Coatings for Mechanical and Transportation Applications 1074 Diamond-like Carbon Coatings for Tools and Molds 109Farooq Ahmad, Raies Abdullah, Jamile Mohammadi Moradian4.1 Introduction 1094.2 Hot Forging Die Tool Failure Mechanisms 1114.3 Surface Treatments in Die Tools and Molds 1114.4 Deposition of DLC Coatings 1134.4.1 Physical Vapor Deposition 1134.4.2 Chemical Vapor Deposition 1144.4.3 Hybrid Coating Techniques 1154.5 Structural Properties of DLC Coatings 1154.6 Mechanical and Tribological Properties of DLC Coatings 1174.7 Applications of DLC Coatings in Die Tools and Molds 1184.8 Challenges and Future Perspective of DLC Coatings 1215 Diamond-like Carbon Coatings for Solid Lubrication: Production Techniques, Properties, and Applications 129Deepak Kumar, Virendra Pratap Singh, Himanshu Rai5.1 Introduction 1305.2 Classifications of DLC Coatings 1315.2.1 Hydrogenated Dip-layer Capacitors (a-DLC) 1325.2.2 DLC Coatings Devoid of Hydrogen (ta-C) 1325.2.3 DLC Coatings Doped With Nitrogen (a-C:N) 1325.2.4 Fluorinated DLC coatings (a-C:F) 1335.2.5 Silicon-doped DLC coatings (a-C:Si) 1335.2.6 Anhydrous Carbon Nitride Amorphous (a-CN:H) 1335.3 Deposition Methods of DLC Coatings 1335.3.1 Sputtering 1335.3.1.1 Direct Current Magnetron Sputtering 1335.3.1.2 Sputtering at Radio Frequency 1345.3.2 Ion Beam Deposition 1355.3.3 Cathodic Arc 1355.3.4 Pulsed Laser Deposition 1365.3.5 Chemical Vapor Deposition 1375.3.6 Physical Vapor Deposition 1385.4 Tribology of DLC Coatings 1405.4.1 Effect of Surface Roughness on Wear and Friction 1405.4.2 Effect of Environment on Wear and Friction 1415.4.3 Effect of Substrate on Wear and Friction 1425.5 Modification of DLC Coatings for Reduced Wear and Friction 1435.5.1 DLC Coatings With Interlayers 1445.5.2 Metal-doped DLC 1445.5.3 Cr-based Interlayers DLC Coatings 1455.6 Applications of DLC Coatings 1455.7 Summary and Future Directions 1466 Diamond-like Carbon Coatings and Green Lubricants 155Irfan Nadeem, Muhammad Shahid Arshad, Marko Polajnar6.1 Introduction 1556.2 DLC Coatings in Sustainable Tribology: Navigating Green Engineering Concepts 1586.2.1 Biodegradable Oils 1596.2.2 Low-SAPS Lubricants 1606.2.3 Fatty Acids 1616.2.4 Nanoparticles as Lubricant Additives 1626.2.5 Ionic Liquids 1676.2.6 Water-based Lubricants and Polyhydric Alcohols 1696.3 Role and Importance of Doping Elements on DLC Lubricating Properties 1716.3.1 Influence of Dopants on the Surface Energy of DLC Coatings 1716.3.2 Influence of Dopants on the Wetting Properties of DLC Coatings 1746.4 Interactions of DLC Coatings with Green Additives 1766.5 Lubrication Behavior of DLC Coatings with Base Lubricants 1796.6 Conclusion 182Section III Diamond-like Carbon Coatings for Medical Applications 1917 Diamond-like Carbon Coatings for Artificial Implants 193Benedict Rothammer, Max Marian7.1 Introduction 1937.2 Requirements for DLC Coatings When Employed to Artificial Implants 1957.2.1 Coating-Substrate Adhesion 1967.2.2 Biological Compatibility 1987.3 Application for Load-bearing Implants 1987.3.1 Biotribological Studies on the Model Level 2017.3.2 Biotribological Studies on the Component Level 2137.4 Application for Dental Implants and Braces/Retainers 2167.4.1 Dental Implants 2167.4.2 Braces/Retainers 2197.5 Concluding Remarks 2228 Diamond-like Carbon Coatings for Orthopedic Implants and Surgical Tools 245Witold Kaczorowski, Krzysztof Jastrzębski, Piotr Niedzielski8.1 Introduction 2458.2 Orthopedic Substrates and DLC Coating Techniques 2468.3 Carbon Coatings as Part of Multilayer Systems or as a Base for Doping 2488.4 Properties of DLC Coatings and Their Use in Orthopedics and Surgical Instruments 2498.5 Examples of Applications of Carbon Coatings in Orthopedics and on Surgical Instruments 2618.6 Conclusion 263Section IV Diamond-like Carbon Coatings for Electrical and Optical Devices 2779 Diamond-like Carbon Coatings for Electric Storage Batteries 279Muhammad Ihsan-Ul-Haq9.1 Introduction 2799.2 Applications of DLC Coatings in Secondary Batteries 2809.2.1 DLC Coatings on Alkali Metal Anodes 2829.2.2 DLC Coatings on Carbon or Alloy-based Anodes 2839.2.3 DLC Coatings on Cathodes 2849.2.4 DLC Coatings on the Separator 2869.3 Conclusions and Future Research 28710 DLC Coatings for Optical and Optoelectronic Applications 293Mümin Mehmet Koç, Naim Aslan10.1 Introduction 29310.2 Production and Characterization Methods 29510.3 Optical and Optoelectronic Properties 29910.4 Effect of Production Methods/Parameters on DLC Film Properties 30110.5 DLC Films in Optical and Optoelectronic Applications 30310.6 Conclusion 307Section V Emerging Applications of Diamond-like Carbon Coatings 31311 Diamond-like Carbon Coatings for Polymers and Textiles 315Witold Kaczorowski11.1 Introduction 31511.2 Polymer Substrates and Techniques for Developing DLC Coatings on Them 31711.3 Properties of DLC Coatings for Which They Find Application in Polymer Modification 31811.4 Application Areas for Carbon Coatings for Polymers and Textiles 33111.5 Conclusion 33512 Diamond-like Carbon Coating Applications in MEMS 345Muhammad Usman, Hafiz Mahmood Ilahi, Muhammad Umar Farooq, Mudassar Rauf , Muhammad Asim, Sarmad Ali Khan12.1 Introduction 34612.2 Mechanical Properties of DLC Coatings 34812.3 DLC Applications for Sensors 35112.3.1 DLC Applications for Force Sensors 35112.3.2 DLC Applications for Temperature Sensors 35412.3.3 DLC Applications for Piezoresistive Sensor 35512.3.4 DLC Applications for Strain Sensors 35512.3.5 DLC Applications for Pressure Sensors 35612.4 DLC Applications for Nanoactuators 35712.5 Industrial Processing 35812.6 Applications of DLC Coatings Structural Integrity 35912.7 DLC Applications for MEMS Tribology 35912.7.1 Nanofretting 36012.7.2 Nanodot Contacts 36112.7.3 Lubricant Life Assessment 36312.8 DLC Coatings System and Performance 36312.8.1 Hydrogenated and Non-hydrogenated DLC Coating 36312.8.2 Role of Substrate Material 36412.8.3 Wear at Microscopic Scale 36512.8.4 Static Friction 36612.9 Conclusion 36613 Data-centric Process, Property, and Performance of Carbon Coatings 373Muhammad Ikhlaq, Abdul Wasy Zia13.1 Introduction 37313.2 Data-centric Manufacturing Process of Carbon Coatings 37513.3 Data-centric Virtual Synthesis and Structural Design of Carbon Coatings 38013.4 Understanding the Properties of Carbon Coatings With Data-centric Approaches 38313.5 Data-centric Performance Assessment of Carbon Coatings 38713.6 Applications of Carbon Coating in Enhancing the Heat Transfer Processes 39713.6.1 Condensation Heat Transfer 39813.6.2 Boiling Heat Transfer 40213.7 Conclusion 40514 Circularity and Techno-economic Analysis of Carbon-coated Products 413Ashmal James, Abdul Wasy Zia14.1 Introduction 41314.2 Potential Reprocessing Methods for Carbon De-coating 41514.3 Decision Matrix of Carbon De-coating Methods 41714.3.1 Process Robustness for De-coating 41714.3.2 Process Efficiency to De-coat Carbon-coated Components 41814.3.3 De-coating Processes and Base Material Safety 41814.3.4 Sustainability Aspects of De-coating Processes 41814.3.5 Technology Readiness Level of De-coating Processes 41914.3.6 Cost 41914.4 Technical Analysis of Carbon De-coating Methods 41914.4.1 Robustness of De-coating Processes 42014.4.2 Circularity Index for De-coating Processes 42114.4.3 Safety Factor Index for De-coating Processes 42114.4.4 Technology Readiness Levels of De-coating Processes 42214.5 Economic Analysis of Carbon De-coating Methods 42214.5.1 Capital Cost 42214.5.2 Running Cost 42214.6 Case Study – Carbon De-coating from Cutting Tools 42314.7 Conclusion 426Index 429