Diamond-like carbon (DLC) is a form of amorphous carbon that has many attractive properties such as high hardness values, chemical inertness, high electrical breakdown voltage, transparent to visible and infrared light, and strong wear-resistance. These desirable properties give DLC widespread applications. This project explores innovative DLC coatings structures and deposition technologies to address the needs for protecting soft surfaces.An electrochemical boriding of low carbon steel and subsequent laser arc deposition of DLC were combined to create durable, low friction, low wear, and corrosion-resistant surfaces for harsh environmental conditions. The friction and wear properties of this duplex coating were studied and compared with each corresponding single layer. Finite element modeling of nanoindentation was performed to interpret the optimum thicknesses of the coatings combinations and study the mechanical properties of the duplex system. Corrosion experiments were performed to study the resistance to pinhole defects, as it is a common cause of coating delamination. Fatigue impact tests were conducted to study the resistance against indentation and crack formations. Ultimately, the duplex coating created by boride-carbon hybrid technology showed proof of the concept of low-friction, wear, impact fatigue, and corrosion-resistant in one solution.For the first time, a single beam plasma source was demonstrated for depositing fully transparent DLC coatings at room temperature. The DLC coatings are particularly useful for protecting soft and heat-sensitive surfaces.
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