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In this study, we examined the improvements in friction and wear properties between steels for aircraft parts, resulting from the surface modifications with electroless plating film and amorphous carbon coating or diamond‐like carbon (DLC) coating. Friction and wear properties are measured using a pin‐on‐flat wear‐testing machine with reciprocating sliding. From measurements of the coefficient of friction and wear amount, observations during sliding motion and visual inspection of wear traces, the following was clarified. A remarkable improvement of friction and wear properties is realized by DLC coating. Electroless plating increased the hardness of the plated surface considerably. However, it does not contribute to improved friction and wear properties.

This study aims to introduce a strategy that permits well-defined contact areas in forming tools for improving both wear and friction properties by a selective laser treatment of a hydrogen-free diamond-like carbon layer (DLC), for substituting lubrication in forming processes. The need of lubricant substitution in forming processes is given because, besides the positive technological aspects, lubrication leads to numerous negative economic and ecological effects such as lubricant appliance and removal costs as well as its disposal.

Hydrogen-free DLCs with an sp³-ratio of 60-70 per cent are deposited on steel surfaces and subsequently micro-structured using direct laser interference patterning (DLIP). To find the optimal structure parameters for reducing friction and wear, line-like and cross-like patterns with three different structure sizes were fabricated onto the DLC layer. Tribological measurements are performed with a ball-on-disk tribometer on the differently DLIP-structured surfaces and compared to polished steel and unstructured DLC reference surfaces.

A reduction of the coefficient of friction, from 0.18 to 0.11, is observed for the laser-structured DLC surfaces, reaching values comparable to lubricated and polished steel surfaces, with a friction coefficient of 0.10.

Using DLIP, it was possible to show how this method can reduce friction on DLC-coated specimens. The observed characteristics are relevant to improve the tribological performance of forming processes, without usage of lubrication.

This paper aims to investigate the effects of reciprocating frequency, large normal load on friction and wear behavior of hydrogenated diamond-like carbon (H-DLC) coating against Ti-6Al-4V ball under dry and lubricated conditions.

The friction and wear mechanisms are analyzed by scanning electron microscope, energy dispersive spectroscopy and Raman spectroscopy.

The results show that as reciprocating frequency increases under lubricated conditions, the friction coefficient decreases first and then increases. When the reciprocating frequency is 2.54 Hz, the value of friction coefficient reaches the minimum. The friction reduction is because of the transformation from sp³ to sp², the formation of transfer layer on Ti-6Al-4V ball and the reduction in viscous friction, whereas the increase of friction coefficient is related to wear. In dry conditions, the friction coefficient is between 0.06 and 0.1. And, the service life of H-DLC coating decreases with the increase in reciprocating frequency and normal load.

It is confirmed that adding the lubricant could prolong the service life of H-DLC coating and reduce friction and wear efficiently. And, the wear mechanisms under dry and lubricated conditions encompass abrasive wear and adhesive wear.

The results are helpful for application of diamond-like carbon coating.

This paper aims to address the coating and compound analysis of diamond-like carbon (DLC) on steel, to understand the frictional behavior in tribological gear systems presented in paper Part I. Here, the Ti and Zr modified DLC coating architectures are analyzed regarding their chemical, mechanical and thermophysical properties. The results represent a systematic analysis of the thermal insulating effect in tribological contact of DLC coated gears.

The approach was to evaluate the effect of the substitution of Zr through Ti at the reference coating ZrCg to TiCg and the effect on thermophysical properties. Furthermore, the influence of different carbon and hydrogen contents on the coating and compound properties was analyzed. Therefore, different discrete Ti or Zr containing DLC coatings were deposited on an industrial coating machine. Thereby the understanding of the microstructure and chemical composition of the reference coatings is increased.

Results prove comparable mechanical properties of metal modified DLC independent of differences in chemical compositions. Moreover, the compound adhesion between TiC_g/16MnCr5E was improved compared to ZrC_g/16MnCr5E. The effect of hydrogen content Ψ and carbon content x_c on the thermophysical properties is limited by Ψ = 18 at.% and x_c = 90 at.%.

The findings of the combined papers Part I and II show a high potential for industrial application of DLC on gears. Based on the results DLC coatings and gears can be tailored to each other.

Systematic analysis of DLC coatings were conducted to evaluate the effect of titanium, carbon and hydrogen on thermophysical properties.

The purpose of this paper is to study the frictional behaviors of CuAl10Fe3 journal bearings sliding against chromium electroplated 42CrMo shafts and diamond-like carbon-coated 42CrMo shafts, respectively, under two different conditions and to compare the two kinds of friction pairs.

All journal bearing samples underwent 24 h running-in and repeatability verification. Then, the journal bearing friction experiments were carried out under two different conditions. After testing, the torques, friction coefficients, power consumptions and other parameters were obtained.

The pair of CuAl10Fe3 journal bearing and diamond-like carbon–coated shaft could drive greater load to start up than the pair of CuAl10Fe3 journal bearing and chromium electroplated 42CrMo shaft, but it had greater power consumption during the steady running period under the identical condition. With the changing of specific pressure or rotational speed, the friction coefficients had different variations. The frictional oscillations appeared at 32 rotations per minute under heavy loads for both kinds of pairs, the oscillation frequencies were equal to rotational frequency of the test shaft and the oscillation amplitude for diamond-like carbon coating was much greater.

These results have guiding significance for practical industrial applications.

This paper aims to analyze the characteristics of friction vibration signals and identify the vibration excitation source at the start and stop stage of microtextured end face of dry gas seals.

The friction pair consists of a diamond-like carbon (DLC) film microtextured seal ring and a spiral groove seal ring. Friction vibration signal feature extraction method based on harmonic wavelet packet and spectrum analysis was proposed. Signals were collected using acceleration sensor, acquisition card and LabVIEW software. Vibration acceleration signal was decomposed into 32 frequency bands using MATLAB wavelet packet transformation. The 32nd band coefficient was extracted for reconstruction, time-domain and spectral waveforms were obtained and spectra before/after denoising were compared.

The end face of the DLC film microtextured seal ring generates a good dynamic pressure effect, and the friction and vibration reduction effects are obvious. The harmonic wavelet packet can decompose the vibration signal conveniently and precisely. In the case of this experiment, the frequency of vibration of the seal ring is 7500 HZ.

The results show that the method is effective for the processing of friction vibration signal and the identification of vibration excitation source. The findings will provide ideas for the frictional vibration signal processing and basis for further research in the field of tribology of dry gas seal ring.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-03-2024-0084/

Diamond‐like carbon coatings (DLC) combine high wear resistance with low friction coefficients. Both properties enable the protective layers to sustain wide ranges of loading and environmental conditions. At present, low friction coatings are commonly used on an empirical basis but not as a design element. The reason for the empirical approach is the lack of tools for a description of the interaction between the coatings and the substrate. Furthermore it is difficult to obtain information on the fracture properties of the coating substrate system (e.g. fracture toughness, adhesion, residual stresses). A spherical indentation provides a simple technique to measure quantitatively the fracture toughness and the adhesion of brittle coatings on a ductile substrate with standard laboratory equipment. DLC coatings on a 100 Cr 6 steel substrate are indented by silicon nitride balls with different diameters and different loads. Fracture patterns (circular and radial cracks, delamination) are analyzed by finite element calculation and the fracture toughness of the coating itself along with the interface toughness are estimated.

7075-T6 is the most widespread structural aluminium alloy due to its high mechanical strength. However, use of this alloy in critical aeronautic, maritime, and automotive sectors is limited by the susceptibility of T6 treatment to cracking and pitting corrosion. To improve fatigue behaviour in aggressive environments, several authors have proposed the use of different coatings to protect the substrate. Studies have investigated the application of thin hard coatings on light alloys by physical vapour deposition (PVD). Different contributions of residual stresses, thermal modification of the substrate, and mechanical interaction between the coating and aluminium substrate were investigated. The purpose of this paper is to investigate the rotating bending fatigue behaviour (R=−1) of 7075-T6 PVD diamond-like carbon (DLC)-coated specimens in air and in a corrosive environment. Tests were conducted at different applied stresses. Scanning electron micrographs of the fracture surface are provided to investigate the influences of mechanical and environmental driving forces on the failure mechanism.

The paper conducted an experimental study of the fatigue resistance of DLC coatings on a 7075-T6 substrate for corrosion protection at long and short fatigue lives, which includes rotating bending fatigue tests, step-loading fatigue test procedure, tests in aggressive environment (methanol), tests at high and low fatigue lives, analysis of the fracture surface, and analysis of the driving forces.

Tests performed in air showed that the coating anticipates crack nucleation for high applied loads, whereas for lower loads, the difference among fatigue curves decreases. This result is very interesting from an industrial standpoint because the obtained material shows improved corrosion and wear resistance, without the fatigue resistance loss generally associated with hard coatings. The methanol environment accelerates crack nucleation and propagation, resulting in a sensible deterioration of the fatigue behaviour. A minimum soaking time seems to be necessary before the damaging effect of the environment begins. The coating has a certain protective effect against the environment, but this protection is insufficient for the specimen to achieve fatigue limits beyond those of the uncoated specimens. This deficiency can be related to small pores or defects in the coating, which allow contact between the substrate and the environment. Further tests are necessary to verify whether there exists a load under which the fatigue behaviour of the coated specimens is better than that of the uncoated specimens. Crack nucleation due to fatigue occurs close to the outer surface for all observed samples. For coated samples tested at the lowest stress level, crack nucleation seems to be located below the surface. This observation means that premature coating cracking, which characterises the nucleation mechanism at higher loads, did not occur at lower stress levels. The fracture surface of uncoated samples was clearly damaged by the aggressive solution, justifying the poor fatigue resistance.

The obtained data do not represent actual S-N curves, which would necessitate a larger number of tests with proper statistics. Nevertheless, some indications of the DLC effects on 7075-T6 specimens in air and methanol environments can be deduced. The step-loading technique seems to be critical for tests in corrosive environments, probably because the total soaking time in the corrosive environment is generally higher than it is for the single-run test.

The originality of the paper lies in the application of the step-loading test procedure to quickly detect the mechanical and chemical driving forces that control the damage and structural integrity of light alloys components in very aggressive environments.