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Tribology Online, 9, 3 (2014) 135-142.

ISSN 1881-2198
DOI 10.2474/trol.9.135

Review

Diamond-Like Carbon Coating Applied to Automotive Engine Components


Makoto Kano

Department of Mechanical and Material Engineering, Kanagawa Industrial Technology Center


705-1 Shimoimaizumi, Ebina, Kanagawa 243-0435, Japan
Corresponding author: mkano@kanagawa-iri.jp

( Manuscript received 7 May 2014; accepted 31 July 2014; published 30 September 2014 )

The application of DLC coatings in the automotive industry has increased significantly both in terms of
production volume and the kinds of applications involved. However, elucidation of the fundamental evaluation
and mechanism of friction and wear properties for DLC coating are still far from sufficient level. This article
discusses recent topics concerning the application of DLC coatings to automotive engine components and the
related research for tribological issues of DLC coating. For the application to engine components, several
typical examples are described. As an advanced one, the ta-C coated piston ring which has been applied
recently to both the compression ring and the oil ring of a new mass-produced inline 3-cylinder compact
gasoline engine is shown. The ta-C coated piston ring can reduce engine friction substantially compared with
the conventional Cr plating ring. Additionally, the a-C:H coated aluminum piston which can be accomplished
by shot-peening aluminum alloy substrate with fine tungsten particles shows exellent wear resistance. For
the research, three issues of the super-low friction, the evaluation of adhesion strength and wear resistance and
the rolling fatigue are discussed.

Keywords: diamond-like carbon, engine component, valve lifter, piston ring, piston, friction, wear resistance,
engine application, a-C:H, ta-C

significantly both in terms of production volume and the


1. Introduction. kinds of applications involved. However, elucidation of
the fundamental mechanism of super-low friction
The special issue on “DLC and Diamond Films” had obtained by DLC coating is still far from sufficient level.
been published in the Journal of Japanese Society of
One of this reason is that quantitative evaluation for the
Tribologists at vol. 47, 11. (2002). In this number, construction of the carbon coating is too difficult to
several topics such as “Structure and Properties of
Diamond and DLC Films”, “Recent Deposition
Techniques of DLC and Diamond Films and Their
7000
Properties”, “Improvement in Adhesion of DLC
Coating”, “Application of DLC Coating to Plastic
DLC coating sales value,million Yen

6000 Leaman
shock
Working Tools” and “Application of DLC Coating to 15th Sep.
Sliding Parts in Engine” were reported. In the first topic, 5000
it was described that the word of DLC was not
established as an academic term. Additionally, it is found 4000

that the mass-produced application of DLC coating had


not been started yet. However, DLC coating has been 3000

applied increasingly to actual industrial products in this


2000
last decade.
The total value of sales of DLC coatings in Japan 1000
from 2001 to 2012 (estimated) is shown in Fig. 1 [1]. The
sales value increased linearly from 2 billion yen in 2001
2001 2004 2008 2010 2012
to 7 billion yen in 2012, even though the world economy Budget year
estimated
Yano Research Institute Ltd.
was drastically affected by the collapse of Leman Fig. 1 DLC coating sales of Japanese coating
Brothers on 15th September in 2008. The application of producers [1]
DLC coatings in the automotive industry has increased

Copyright © 2014 Japanese Society of Tribologists 135


Makoto Kano

obtain sufficiently due to the thin film about 1 micron K, which means no additional surface finishing is needed.
thickness made of carbon element mainly with the For the application to the front fork of motorcycles, an
amorphous construction. The other one is difficulty of amorphous hydrogenated carbon (a-C:H) coating was
detecting very thin tribochemical-reacted film adsorbed applied to the steel inner tube of the fork to reduce
on the sliding track directly by conducting surface friction [3]. This friction reduction helps to give the rider
analysis. an excellent driving feel. This coating technology has
This article discusses recent topics concerning the also been applied to the sliding members of the
application of DLC coatings to automotive engine suspension system on luxury vehicles.
components and the research for DLC tribology. Next, we will look at several applications to engine
components. For the fuel injection systems of automotive
2. Application to automotive engine components engines, DLC coatings have been applied to several
components such as the plunger of high-pressure diesel
Typical examples of automotive components coated fuel pumps. Because the sliding conditions of the fuel
with DLC coatings are shown in Table 1. In this last injector and other pump sliding parts have become
decade, applications have increased markedly both in
severer due to higher contact pressure, several types of
terms of production volume and variety. First, we will DLC coatings were evaluated for the purpose of
look at some applications other than engine components. obtaining higher wear resistance under boundary
For the coupling clutch application, an amorphous
lubrication in the fuel [4]. The engine valve lifter is the
Si-doped hydrogenated carbon (a-C:H:Si) coating was most successful application of DLC coatings to a
applied to the steel plate that slides against the friction mass-produced component because a fuel-saving effect
plate in the torque control system used on 4WD SUVs.
is clearly obtained by reducing friction. The shape of the
The high wear resistance and high friction coefficient of valve lifter is adjusted to obtain stable coating quality
the a-C:H:Si coating resulted in a compact clutch system. because the lifter surface to be coated is flat. A
Additionally, the fact that the friction coefficient of this tetrahedral amorphous carbon (ta-C) coating, deposited
coating has a positive slope relative to increasing sliding by an arc ion plating physical vapor deposition (PVD)
velocity provides higher shudder resistance [2]. For the
method, has been applied to the valve lifters and piston
SUV differential gear application, a tungsten carbide rings of mass-produced gasoline engines (Fig. 2) to
doped amorphous hydrocarbon (WC/a-C:H) coating was improve fuel economy by a few percent. This ta-C
applied to the gear teeth to improve wear resistance. DLC
coating has been applied recently to both the
coatings can increase the life of gears by suppressing compression ring and the oil ring of a new
scuffing wear or spalling wear. In gear applications, it is mass-produced inline 3-cylinder compact gasoline
easy to coat a DLC film directly on the gear teeth as a
engine [5]. Friction force, indicated as the distance
measure for improving wear resistance because the film between the positive and negative values, was evaluated
is very thin, around 1 micrometer in thickness, and the in an engine firing test using a single-cylinder gasoline
temperature in the coating process is very low, below 473
engine lubricated with standard gasoline engine oil, as

Table 1 Applications of DLC coatings to automotive parts

Applied parts DLC Coating DLC properties

SUV 4WD torque controlled a-C:H-Si Excellent friction property and


coupling clutch PECVD
wear resistance

SUV differential gear WC/a-C:H PECVD High wear resistance to increase


life of gear

Motor bike front fork, Excellent driving feel and high


a-C:H PECVD
Luxury vehicle suspension wear resistance

High wear resistance in fuel at


Fuel injector, pump a-C:H PECVD
boundary lubrication

High wear resistance mating with


Motor bike engine piston ring WC/a-C:H PECVD
aluminum alloy of cylinder

Ultra-low friction and high wear


Automotive engine valve lifter ta-C PVD resistance

Ultra-low friction and high wear


Automotive engine piston ring ta-C PVD resistance

Japanese Society of Tribologists (http://www.tribology.jp/) Tribology Online, Vol. 9, No. 3 (2014) / 136
Diamond-Like Carbon Coating Applied to Automotive Engine Components

cylinder wall during actual engine operation.


Recently, the application of DLC coatings to
aluminum alloys with sufficiently strong adhesion for
Valve lifter
バルブリフター obtaining high wear resistance has been developed [7].
This can be accomplished by shot peening the aluminum
Piston
ピストンリングring alloy substrate with fine tungsten particles. A DLC
ピストンピン
(a-C:H:PCVD) coating deposited on the substrate of
Piston pin
A2017 and A5052 aluminum alloys (Japanese Industrial
Standards) with this new process showed 40-80% higher
wear resistance and adhesion strength than DLC coatings
formed by conventional processes. This original DLC
coating technology has been applied to aluminum alloy
pistons of motorcycles. An A2618 aluminum alloy with a
low Si content was used for the pistons because the
development concept was to reduce Si precipitates that
Fig. 2 DLC coated engine components
are characterized by poor workability. Si precipitates also
showed the formation of many cracks after the tungsten
shown in Fig. 3 [6]. It was found that a large friction shot-peening process. Therefore, the critical load of DLC
reduction was obtained for the ta-C coated compression coatings on aluminum alloys containing a large amount
and oil rings at different crank angles, specifically around of silicon did not show any improvement. Engine firing
0 deg. for the compression ring and over a wide range of tests to evaluate the wear resistance of the DLC coated
angles of 180, 360, -180, and -360 deg., but excluding piston were conducted as shown in Fig. 4. The DLC
0 deg., for the oil ring, as shown in Fig. 3. These results coated piston clearly showed better scuffing wear
suggested that a severe boundary lubrication condition resistance than the non-coated piston. The DLC-coated
probably formed at these different crank angles for the aluminum piston is a promising technology for
compression and oil rings. It would be too difficult to application to automotive gasoline engines to improve
measure these different friction properties directly at the fuel economy substantially and for other sliding parts in
sliding interfaces between the piston rings and the various industrial machines.

3. Research for DLC coating tribology


3.1. Research for reducing friction
In a technical paper entitled “Near-frictionless carbon
coatings for use in fuel injectors and pump systems
operating with low-sulfur diesel fuels” [8], it was
reported that hydrogenated amorphous diamond-like
carbon (DLC) coatings showed a super-low friction
coefficient below 0.01 in sliding tests conducted in an
inert atmosphere such as that of dry nitrogen gas as
shown in Fig. 5 [8-12]. That new finding about the
superior friction property of DLC coatings in the specific
atmosphere triggered their accelerated application to
Piston-Bore friction by engine with DLC on compression ring automotive engine components for reducing friction.
Since all sliding engine components are usually
lubricated with engine oil, it is very important to
investigate the friction properties of DLC coatings under
a lubricated condition. This section describes the effect
of lubricants on the friction of DLC coatings.
The super-low friction property of DLC coatings is
affected by the operating environment conditions, as
mentioned earlier. Therefore, it has been very important
to evaluate the friction properties of DLC coatings under
a lubricated condition to find the right additives for
substantially reducing friction. Because automotive
engine oil contains many kinds of complex additives
Piston-Bore friction by engine with DLC on oil ring
such as zinc dialkyl dithiophosphate (ZDDP), it was
Fig. 3 Friction reduction by using DLC coated piston difficult to identify clearly the interactions between the
ring [6] additives and DLC coatings [13-18]. Pin-on-disc sliding

Japanese Society of Tribologists (http://www.tribology.jp/) Tribology Online, Vol. 9, No. 3 (2014) / 137
Makoto Kano

Engine test : Eng.Rev. 1000~13000rpm , 10min.

Severe
scuffing

Low silicon aluminum alloy, A2618 A2618⇒W peening+Polishing+P-CVD, DLC


Cylinder bore: Ni-P plating Cylinder bore:P-CVD DLC

Fig. 4 Superior wear resistance of DLC coated aluminum alloy piston

tests were conducted to evaluate the effect of one simple containing 1 mass% of ester (PAO+GMO) showed an
modifier on the friction properties of DLC coatings. ultra-low friction coefficient of 0.02, whereas an a-C:H
Typical DLC coatings selected for evaluation in this way coating/steel pair displayed a much higher friction
included hydrogenated amorphous carbon (a-C:H) and coefficient of 0.09 and that of a steel/steel pair was 0.100,
hydrogen-free tetrahedral amorphous carbon (ta-C). as shown in Fig. 6 [19,20].
Sliding tests were conducted at high Hertzian pressure of Friction properties of DLC coating pairs lubricated
700 Mpa under oil lubrication at a temperature of 353 K. with PAO+GMO at a temperature of 353 K were also
The effect of various friction modifier additives on the evaluated in SRV tests to make clear the reason for
friction properties of these DLC coatings was evalauted ultra-low friction. Figure 7 shows the friction
when used with a poly-alpha-olefin (PAO) based oil. coefficients obtained for different kinds of material
Many types of friction modifier additives were examined, combinations lubricated with PAO+GMO and pure
including amine, amide and ester (GMO). It was found glycerin [21]. Amazing results were obtained for the
that a ta-C coating/steel pair lubricated with a PAO oil ta-C/ta-C coating combination. The friction coefficients
of the ta-C pairs were substantially lower than those of
the a-C:H ones. These results strongly suggest that
ultra-low friction was obtained by the interaction
between the ta-C coating and the ester-containing oil;

0.140
0.120
Friction coefficient

0.100 80%
reduction
0.080 Break
Break through
through
0.060
0.040
0.020
0.000

5W-30 5W-30 5W-30 PAO PAO+GMO


PAO+GMO
PAO+GMO
Fig. 5 Frction performance of two commercially Material combinations
available diamond-like carbon(DLC) films
and Argonne’s near frictionless carbon (NFC) Fig. 6 Ultra-low friction property of ta-C under
in dry nitrogen [8] GMO containing oil lubrication [19]

Japanese Society of Tribologists (http://www.tribology.jp/) Tribology Online, Vol. 9, No. 3 (2014) / 138
Diamond-Like Carbon Coating Applied to Automotive Engine Components

0,2
PAO+GMO SRV tribometer
0,18 Glycerol SRV tribometer

0,16

0,14
Friction coefficient

0,12

0,1

0,08

0,06

0,04

0,02
Unmeasurable
0
steel/steel a-C:H/a-C:H ta-C/ta-C

Material combinations Fig. 9 T-shaped filtered arc deposition process [25]

Fig. 7 Super-low friction of self-mated ta-C under gradually to a final level of 0.085. That of the a-C:H pair
glycerol lubrication [21] (a-C:H/a-C:H) decreased from 0.08 to 0.045 for 1200
seconds and then stayed at a stable level. That of the ta-C
pair (ta-C/ta-C) decreased continuously from a high level
this property is attributable to the formation of a very thin, of 0.09 to 0.045. In contrast, that of the ta-C (T) pair
low-shear-strength tribofilm on the ta-C sliding surface (ta-C(T)/ta-C(T)) decreased from a very low level of 0.02
and a better lubrication condition. Moreover, super-low to a super-low friction regime below 0.01 in a very short
friction and zero-wear behaviour was notably obtained time and stayed at a very low level of 0.015 for 1800
for the ta-C/ta-C coating combination lubricated with seconds. The ta-C (T) coated by the T-shaped filtered arc
pure glycerin at 353 K. As shown in Fig. 7, the friction deposition method (Fig. 9) had very smooth surface
coefficient was below 0.01 and was actually not without lots of droplets [25]. The steel pair showed an
measurable with the equipment used. Moreover, the wear ultra-low friction coefficient initially, which was
scar was not visible when viewed under an optical probably due to the tribochemical reaction with oleic
microscope. This result suggests that superlubricity is acid. The friction coefficient then increased gradually
related to an alcohol chemical function (OH), which is above 0.08 due to increasing surface roughness caused
common to both GMO and glycerol molecules. by wear. For the DLC pairs, the ta-C pair showed a much
Further fundamental research on an optimum larger friction coefficient reduction than the a-C:H pair.
material combination of a DLC coating and a simple The higher friction coefficient especially in the initial
lubricant for reducing friction to super-low level was period for the ta-C pair was presumably caused by the
reported [22-24]. The Pin-on-disc reciprocating sliding larger surface roughness due to the presence of many
test under oleic acid lubrication was conducted at droplets compared with that of the ta-C (T) pair.
ambient temperature. Friction curves with greatly Therefore, the effect of the ta-C pair on reducing friction
different shapes were observed for sliding times from 0 was probably comparable to that of the ta-C (T) pair. Of
to 30 minutes as shown in Fig. 8. The friction coefficient course, the mechanism of the super-low friction
of the AISI 52100 steel pair (steel/steel) was at a very properties of these DLC coatings must be made clear
low level of 0.02 for 300 seconds and then increased [26,27], but it will take a long time to obtain definitive
evidence due to the difficulty of conducting surface
analyses. It can be concluded that DLC coatings have an
0 .1 exceptionally high potential to provide super-low friction
0 .0 9
SUJ2/SUJ2 properties in combination with environmentally friendly
0 .0 8
fluids such as oleic acid lubrication.
Coefficient of Friction

0 .0 7
0 .0 6 ta-C/ta-C 3.2. Research for evaluation of adhesion strength and
0 .0 5 wear resistance
0 .0 4
a-C:H/a-C:H
The test method for evaluating the adhesion strength
0 .0 3 and wear resistance of DLC coating is described shortly.
0 .0 2 ta-C(Filter)/ Conventional test methods for evaluating the adhesion
ta-C(Filter)
0 .0 1 strength of DLC coatings include the Rockwell hardness
0
test for measuring material hardness[28,29] and the
0 600 1200 1800
Time , s
scratch test procedure for scratching coatings with a
diamond-tipped indenter[30-32]. These test methods
Fig. 8 Super low friction of self-mated ta-C under push an indenter into the coating or drag it along the
oleic acid lubrication [24] surface while applying downward pressure on the device,

Japanese Society of Tribologists (http://www.tribology.jp/) Tribology Online, Vol. 9, No. 3 (2014) / 139
Makoto Kano

Therefore, it is required to accomplish the test method


which simulate the adhesion and wear resistance of DLC
coating for actual sliding condition.
Additionally, the wear mode and wear mechanism of
DLC coating is also too complicated to be elucidated. For
the wear of a-C:H coating after the ball on disc sliding
test, it was found that a-C:H coating layer had bending
deformation and fine cracks at the top and bottom of the
film as shown in Fig. 11 [36]. It was observed that the
cracks formed perpendicular through the coating
thickness and the coating film was still intact with the
substrate without delamination despite the crack
formation. Although the stress and strain modelling of
Fig. 10 Critical load of DLC film evaluated by coated systems can increase the understanding of coated
continuously increasing load sliding test [34] system performance, it is insufficient to accomplish the
evaluation based on the wear mechanism.
The research for this evaluation is too late to establish
thereby inducing plastic deformation in the DLC coating the standard test method to use the actual industrial field
and base material, causing the coating to fracture. The although DLC coating has been applied to the mass
adhesion strength of the coating is then evaluated from produced components as mentioned before. It is required
the damage condition. Specifically, adhesion strength is to address this issue to apply DLC coating technology to
evaluated based on the applied load at the time the sliding components in various industries.
friction coefficient rises sharply in the scratch test and by 3.3. Research for rolling fatigue
confirming the damage condition of the coating around Finally, the research for the rolling fatigue of DLC
the edge and at the bottom of the indentation produced in coating which is not established well is described here
the Rockwell test and the scratch mark produced in the briefly. The application of DLC coating for rolling
scratch test [33]. contact to the actual produced component successfully is
However, the Rockwell test and scratch test, in which not reported yet.
adhesion strength is evaluated on the basis of plastic The improvements of the life for the rolling contact
deformation, induce damage as a result of the application fatigue by using DLC coating were reported in several
of one load. This makes it is difficult to obtain a good papers [37-39]. The DLC coating improves the life of
correlation with the adhesion strength evaluation results the rollers by more than two orders of magnitude
for actual parts that undergo any number of repeated compared with that of non-coated carburized steel, as
sliding cycles.
The evaluation method of the adhesion strength and
wear resistance of DLC coatings using test procedures
that simulate sliding behavior under actual usage
conditions was proposed [34,35]. The evaluation
methods used in this study apply a continuously
Coating Layer
increasing load during repeated rotating sliding cycles.
1.26μm
Then, the critical load which the friction coefficient and
AE (Acoustic Emission) signal increased markedly was
measured as shown in Fig. 10. The friction coefficient
and the AE signal that were simultaneously measured in
the delamination and wear tests for the rotating sliding
test. For this example, the fixed alumina ball was pressed
on the a-C:H coated rotating disc. When the applied load
exceeded 6 kg, it is seen that the friction coefficient and
the AE signal increased. From this result, the critical load
of the delamination and wear was judged as 6 kg.
Evaluations of the adhesion strength and wear resistance
of the three types of DLC coatings revealed that the
results obtained with the conventional Rockwell test and
scratch test procedures differed from the results obtained Crack in Coating Layer
with the delamination and wear test procedures applied
in this study. This result suggests that the judgment of Fig. 11 The wear surface of 1.0 micron meter thick
adhesion strength and wear resistance for DLC coating a-C:H coating and close-up picture of the
depend on the test method and how to slide strongly. coating cross Section [36]

Japanese Society of Tribologists (http://www.tribology.jp/) Tribology Online, Vol. 9, No. 3 (2014) / 140
Diamond-Like Carbon Coating Applied to Automotive Engine Components

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Japanese Society of Tribologists (http://www.tribology.jp/) Tribology Online, Vol. 9, No. 3 (2014) / 142

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