Effects of WC phase contents on the microstructure, mechanical properties and tribological behaviors of WC/a-C superlattice coatings.

Nanocomposite WC/a-C coatings with variable contents of tungsten carbide (WC 1− x ) and amorphous carbon (a-C) were successfully fabricated using a magnetron sputtering process. The microstructure, mechanical properties and tribological behaviors of the as-fabricated coatings were investigated and compared. The results showed that the “superlattice coating” feature of an alternating multilayer structure with a-C and WC 1− x nanocrystallites layers on the nanoscale was formed. These multilayer superlattice structures led to diminished residual stress and improved the strength of the adhesion to the substrate. The WC/a-C coating with W 5.43 at.% exhibited low friction coefficients of 0.05 at 25 °C and 0.28 at 200 °C. This significant improvement in the tribological performances of the WC/a-C coating was mainly attributed to the superior “superlattice” microstructure and the formation of a continuously compacted tribofilms, which was rich in graphitized carbon at 25 °C and dominated by the friction triggered WO 3 at 200 °C. Moreover, the WC/a-C coating with W 5.43 at.% achieved optimal anti-wear properties at 25 °C due to the synergistic combination of the enhancement effects of the WC 1− x nanoparticles and the partition effect from the transfer film that restricted direct contact of the steel ball with the coating and thus prevented further intense wear. The accelerated wear of the WC/a-C coating with the increase of the WC phase content at 200 °C might be due to the combination of oxidation wear and abrasive wear that originated from the WC 1− x phase. [ABSTRACT FROM AUTHOR]