studied the influence of the coating thickness on the structure and abrasive wear resistance of DLC coatings with thicknesses of 0.7, 1.5, and 3 µm thick coatings deposited on Ti6Al4V. studied the tribological behavior and wear mechanisms of 2-µm thick DLC coatings using the pin-on-disc testing method. Conrads and Schmidt reviewed the most commonly used methods for plasma generation, with particular emphasis on nonthermal, low-temperature plasma for technological applications. Below are some published works on the deposition and tribology of DLC coatings and their applications in cutting tools. Many manufacturers produce tools using oxides, ceramics, carbides, and titanium nitride coatings. Manufacturers use commercially available coatings to enhance tool life and improve cutting efficiency. Manufacturers ensure the economical mass production of cutting tools by applying thin-film coatings onto the cutting tools, which have low friction and prevent metal from sticking to the tool surfaces otherwise, it leads to increased power consumption, tool wear, and material property changes. Manufacturing applications include plastic molds, extrusion dies, stamping devices, and cutting tools. DLC has also been applied in biomedical applications, such as coating for hip joints and knee replacement. In recent years, more emphasis has been placed on applying DLC films to mass-produced mechanical components, particularly in the automotive sector, such as gears, bearings, piston rings, shafts, cams/tappets, rocker shafts, and roller pins. DLC films were initially found to improve the tribology of magnetic-head sliders and magnetic storage media. This is due to the low coefficient of friction and low wear loss of the DLC coatings.ĭiamond-like carbon (DLC) coatings are amorphous carbon-based coatings with high hardness and low coefficient of friction thus, they are promising materials for tribological application. The dry-cutting test showed that coated drill bits produce a better surface finish and consume less power in the drilling operation than uncoated drill bits. Results showed that the DLC-coated substrate had less wear loss and coefficient of friction than the uncoated substrate. Furthermore, the optimized DLC coatings tribological test and the effect of DLC coating on the tool life were performed. Coating deposition and optimization were carried out as per the Taguchi method. Coating’s chemical, composition, topography, and mechanical properties measurements were checked using Fourier transform infrared (FTIR), micro-Raman spectroscopy, atomic force microscopy, and intrinsic stress and nano-hardness/micro-hardness tester, respectively. DLC coatings were grown over the silicon, high-speed steel, and stainless-steel pin substrate. DLC coatings are deposited using plasma-enhanced chemical vapor deposition (PECVD) process by varying the process parameters, bias voltage, bias frequency, gas mixture, and working pressure. This study demonstrates the performance enhancement of drill bits during dry cutting operation of LM6 aluminum alloy and bright mild steel using optimized diamond-like carbon (DLC) coatings.
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