Applying diamond-like coating (DLC) involves a multistep process. Here are the steps involved:
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Precleaning: The parts to be coated are carefully cleaned to remove any contaminants or impurities. This ensures proper adhesion of the coating.
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Placement of parts in a planetary fixture: The parts are placed in a planetary fixture, which allows for single-, double-, or triple-axis rotation. This rotation helps to ensure uniform coating coverage on all surfaces of the parts.
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Pump-down under vacuum: The fixture, along with the parts, is placed in a vacuum chamber. The chamber is then pumped down to create a vacuum environment. This is important to prevent any unwanted reactions or contamination during the coating process.
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Low-temperature preheating process: The parts are preheated to a specific temperature, typically at a low temperature. This helps in achieving better coating adhesion and reduces the risk of thermal damage to the parts.
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Ion Bombardment: The parts are subjected to ion bombardment. This involves bombarding the surface of the parts with high-energy ions, which helps to clean and activate the surface. This step further enhances the adhesion of the diamond-like coating.
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Underlayer deposition (PVD process): A thin underlayer is deposited on the surface of the parts using a Physical Vapor Deposition (PVD) process. This underlayer acts as a bonding layer between the substrate and the diamond-like coating.
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Amorphous carbon layer deposition: The main step in the DLC process is the deposition of an amorphous carbon layer. This is typically achieved using a Chemical Vapor Deposition (CVD) process. The activated carbon atoms recombine to form a pure diamond-like carbon film over the entire surface of the parts.
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Cooling: After the deposition of the diamond-like carbon layer, the parts are cooled down gradually to room temperature. This helps in stabilizing the coating and ensuring its integrity.
It's worth noting that the selection of the proper tool material is crucial for the success of the diamond coating process. The prolonged high temperature during the coating process can damage most tool materials, except for cemented tungsten-carbide and ceramic cutting tool materials. Additionally, careful preparation of the tool surface, including roughening and removal of cobalt, is necessary for consistent performance.
The diamond-coated tools can be used for various applications, and the coating process allows for the optimization of the film based on specific requirements. The ability to grow a wide range of surface structures, such as thin and smooth films or thicker films with abrasive resistance, makes the DLC process versatile for different tooling needs.
In summary, the process of applying diamond-like coating involves precleaning, placement in a planetary fixture, pump-down under vacuum, low-temperature preheating, ion bombardment, underlayer deposition, amorphous carbon layer deposition, and cooling. This process ensures the adhesion and quality of the diamond-like coating on the tools.
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