Tribological and Functional Coatings

Extremely hard carbon-based ”Diamor” coatings play a key role on the path to superlubricity. Fraunhofer IWS wants to add chemical elements such as boron to these coatings so that they combine with particular lubricant molecules and create low-friction interfaces during operation. This is expected to reduce friction in engines by about half compared to today.
© Jürgen Jeibmann/Fraunhofer IWS Dresden
Extremely hard carbon-based ”Diamor” coatings play a key role on the path to superlubricity. Fraunhofer IWS wants to add chemical elements such as boron to these coatings so that they combine with particular lubricant molecules and create low-friction interfaces during operation. This is expected to reduce friction in engines by about half compared to today.

Diamond-like carbon coatings (ta-C) are developed for a wide range of customer applications using laser arc technology on an industrial scale. We are pioneers in ta-C deposition with high coating rates, homogeneous layer thickness distribution, and long-term process stability. Smooth, virtually defect-free layers are produced using special modular plasma filter technology. Special adhesive layer designs enable the deposition of ta-C layers up to 100 µm thick. By vaporizing composite graphites, a wide variety of dopants can be adjusted, thereby imparting a wide range of functional properties to ta-C:X layers. Laser arc technology can also be used to produce dense, robust MoS2 layers that are significantly superior to conventionally sputtered layers.

Our Range of Services:

  • Extremely wear-resistant ta-C coatings for sliding components and tools
  • Functionalized ta-C:X coatings for electrical/electrochemical applications, e.g., bipolar plates, electrodes, and sensors
  • Robust MoS2 coatings for tribological vacuum applications
  • Adaptation of laser arc technology to industrial requirements (e.g., inline coating)
 

Highlight

Plasma filtered ta-C coatings

A plasma filter was developed especially for the Laser-ArcTM technology and the coating module LAM 500. The filter replaces the adapter flange, which usually connects the source chamber to the coating machine. In filtered operation the technology deposits smooth ta-C coatings of low defect densities, which significantly outperform unfiltered coatings. The deposition rate is reduced by about 40% compared to unfiltered deposition.

 

Applications

IWS developed Diamor® coatings are made from tetrahedral amorphous carbon (ta-C). They are extremely wear resistant and have low friction properties. They are well suited as wear resistant coatings for tools, parts and components in lubricated and non-lubricated conditions.

 

Technologies

For the industrial introduction of Diamor® coatings IWS collaborates with commercial partners to provide coatings and systems technologies including the Laser-Arc coating source and the laser acoustic test apparatus LAwave for quality control and coating optimization.

 

Basics

  • Basics of ta-C coating fabrication
  • Conditions for producing ta-C coatings
  • ta-C coating formation

Highlights and Scientific Experise

 

Tribology Innovation Center Dresden (TICD)

Tribological coatings and surface modifications – expertise in friction reduction and wear protection

Projects

Fraunhofer Max-Planck Cooperation Program

TritiumStopp

Permeation-dense Layer Systems as Tritium Barriers in Fusion Application
Duration: 2025–2028