Modification Methods of Diamond like Carbon Coating and the Performance in Machining Applications: A Review

Wang, Lijun; Liu, Yan; Chen, Hui; Wang, Mengchao

doi:10.3390/coatings12020224

Cited by 29 publications

(10 citation statements)

References 97 publications

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“…Adhesion properties of the surface for the gravure printing process are rarely found in the literature. However, there exist methods to evaluate the adhesion of DLC films on various metal surfaces used in machining applications. − …”

Section: Methodsmentioning

confidence: 99%

Sustainable and Eco-Friendly DLC Fabrication for Replacing Chrome on a Gravure Cylinder Surface

Seetharamiahsrinivasaraju,

Shetty,

Sood

et al. 2024

Langmuir

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This paper evaluates the potential of diamond-like carbon (DLC) as a durable surface protection to replace the chromium (Cr) layer, which is traditionally applied to gravure print cylinders and other components through a galvanic electroplating process. The fabrication of DLC is more eco-friendly and could reduce the environmental hazard posed by hexavalent chromium in liquid form that is used in Cr application and better adhere to environmental regulations. This could encourage businesses to bring the DLC fabrication process in-house, sharing resources such as materials, labor, and equipment, to help reduce costs. Four DLC variants (standard DLC, A-DLC, S-DLC, and organic silica) and chrome were analyzed and tested for their surface properties and durability. Data suggest that both standard DLC and S-DLC had higher surface free energy, allowing for good ink wetting on the surface when compared to chrome. In addition, the standard DLC and S-DLC surfaces are generally smoother than the chrome, resulting in lower relative hydrophilicity and allowing for easier removal of ink in the nonimage regions with the doctor blade. The elcometer adhesion test demonstrated that the bond strength of the DLC variants to their base layer was comparable to the bond strength of chrome, indicating that the adhesion strength of the two materials was similar. Furthermore, in the abrasion test, the wear on the standard DLC surface and the corresponding wear on the lamella tip of the metal doctor blades were notably lower than that observed on chrome. This distinction is particularly evident in each of the test trials, specifically run 1, which involved 2,000,000 wiping actions of a metal doctor blade in the presence of abrasive TiO 2 ink pigments. Statistical analysis on standard DLC versus chrome suggests that DLC fabrication is effective and durable on plain and patterned surfaces. Therefore, from a sustainable and eco-friendly perspective, standard DLC and S-DLC would be good alternative durable surfaces for print cylinders and other components used in various industries due to superior wear resistance properties.

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Section: Methodsmentioning

confidence: 99%

Sustainable and Eco-Friendly DLC Fabrication for Replacing Chrome on a Gravure Cylinder Surface

Seetharamiahsrinivasaraju,

Shetty,

Sood

et al. 2024

Langmuir

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“…The two coating surfaces had similar roughness, but the NCD coating, in which numerous nanobeads are gathered to form grain boundaries, had a relatively hydrophilic surface because its area was larger than that of the MCD coating. Depending on the wettability of the cutting tool surface, it can serve as a storage of lubricant in a lubrication environment to reduce the tool wear [ 16 ].…”

Section: Methodsmentioning

confidence: 99%

Analysis of Tool Wear and Roughness of Graphite Surfaces Machined Using MCD and NCD-Coated Ball Endmills

2022

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The high-purity G5 graphite material is widely used for glass moulding and provides high hardness and brittleness because it is sintered to fine particles unlike other graphite materials. Hence, tool cutting of a G5 workpiece is performed by local fracture instead of plastic deformation of the machined surface. Although a diamond-coated tool with outstanding hardness is used to machine very hard graphite, the tool shows variability regarding the service life and machining performance depending on the grain size, even in the same machining environment. We investigated the wear and change trend of machined surface roughness considering microcrystalline diamond (MCD) and nanocrystalline diamond (NCD)-coated tools, which are generally used to machine graphite materials, and analysed their relation with coating. For rough machining, the MCD-coated tool, for which the delamination of coating occurred later, showed less wear and improved machined surface roughness. For precision machining, the NCD tool showed less tool wear rate relative to the cutting length, leading to a small difference in the machined surface roughness between the two tools. We conclude that if rough and precision machining processes are performed using the same cutting tool, the MCD-coated tool is advantageous in terms of service life, while the difference in roughness of the final machined surface between the tools is negligible.

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“…Shock wave synthesis process, also called detonation process allows the detonation of any carbon-containing material to synthesize nanodiamond particles [2,3]. One more method for producing synthetic diamond powder and grit in which graphite is used as carbon source is High-pressure high-temperature (HPHT) [4,5]. The direct deposition of diamond as coatings on surfaces using shock wave synthesis and HPHT techniques is inefficient [6].…”

Section: Introductionmentioning

confidence: 99%

Enhancing machining performance of EN24 steel with CVD diamond coated tool and minimal quantity lubrication

Parray,

Din,

Wani

2024

Eng. Res. Express

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The research aims to investigate the effect of chemical vapour deposition (CVD) diamond coatings on cemented tungsten carbide (WC-Co) inserts when machining EN24 steel. In addition to the diamond coating, the research also incorporates the use of minimal quantity lubrication (MQL) technique during the machining process. The research involves experimental studies to evaluate the machinability characteristics of EN24 steel using tungsten carbide cutting inserts with diamond coatings and MQL. Diamond-coated tools are extremely effective in machining EN24 steel, particularly in applications requiring high precision, wear resistance, and long tool life. They are commonly used in industries such as aerospace, automotive, and manufacturing, where quality and durability of the machined components are critical. L12 orthogonal array was used to design experiments with the type of cutting insert used, test condition and cutting speed as control factors. Various parameters such as tool wear, cutting temperature and surface roughness were measured and compared with conventional machining techniques. The results reveal that average flank wear of cutting inserts decreased by 67.4% as a result of MQL when compared with dry machining conditions. Average flank wear decreased by 77.6% after diamond coating were applied compared with uncoated inserts. Diamond coated inserts subjected to MQL exhibit largest percentage reduction of 74.11% for surface roughness when compared to uncoated inserts. The average cutting temperature decreased by 53.09% due to MQL compared to dry machining.

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Modification Methods of Diamond like Carbon Coating and the Performance in Machining Applications: A Review

Cited by 29 publications

References 97 publications

Sustainable and Eco-Friendly DLC Fabrication for Replacing Chrome on a Gravure Cylinder Surface

Sustainable and Eco-Friendly DLC Fabrication for Replacing Chrome on a Gravure Cylinder Surface

Analysis of Tool Wear and Roughness of Graphite Surfaces Machined Using MCD and NCD-Coated Ball Endmills

Enhancing machining performance of EN24 steel with CVD diamond coated tool and minimal quantity lubrication

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