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Tailoring the performance of DLC coatings through interlayer engineering.

Mohsen Samiee1, Mohamad Javad Eshraghi2, Keivan Asadian1

  • 1Department of Semiconductors, Materials and Energy Research Center, Karaj, Iran.

Scientific Reports
|October 13, 2025
PubMed
Summary

Adding zirconium nitride (ZrN) and tantalum nitride (TaN) interlayers significantly improves diamond-like carbon (DLC) coatings. These enhanced DLC coatings show superior wear and corrosion resistance for demanding applications.

Keywords:
CorrosionDLCPECVDSS420Wear

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Area of Science:

  • Materials Science
  • Surface Engineering
  • Tribology

Background:

  • Diamond-like carbon (DLC) coatings offer excellent properties like hardness and low friction.
  • Internal stress and poor adhesion limit DLC coating applications.
  • Interlayers are crucial for improving DLC coating performance on metallic substrates.

Purpose of the Study:

  • To investigate the impact of plasma nitriding (PN), ZrN, and TaN interlayers on DLC coatings.
  • To evaluate the effects on microstructure, wear, and corrosion resistance.
  • To identify optimal interlayer strategies for enhanced DLC coatings.

Main Methods:

  • Fabrication of DLC coatings with PN, ZrN, and TaN interlayers.
  • Microstructural analysis using Field Emission Scanning Electron Microscopy (FESEM).
  • Surface topography assessment via Atomic Force Microscopy (AFM).
  • Wear behavior evaluation through weight loss measurements.
  • Corrosion resistance testing using impedance spectroscopy.

Main Results:

  • All samples exhibited dense, uniform, crack-free, and pore-free DLC coatings.
  • TaN+DLC and ZrN+DLC coatings displayed significantly smoother surfaces (3.31 nm, 3.42 nm) than PN+DLC (42.34 nm).
  • The TaN+DLC coating demonstrated the lowest weight loss (8 mg) and wear rate.
  • TaN+DLC coatings exhibited the highest corrosion resistance based on impedance curves.

Conclusions:

  • ZrN and TaN interlayers substantially improve DLC coating surface characteristics, including roughness and uniformity.
  • These interlayers enhance both wear resistance and corrosion performance of DLC coatings.
  • TaN and ZrN interlayers represent effective strategies for advancing DLC coating applications.