Low-Frictional Properties of Si-DLC Coatings Sliding Against Aluminum Alloy Under Humid Conditions

Silicon-doped diamond-like carbon (Si-DLC) coatings against aluminum alloy (A5052) were investigated for reducing friction under humid conditions. The coatings were deposited on high-speed steel (SKH51) substrates using a bipolar-type plasma-based ion implantation and deposition (PBII&D) technique, with Si content controlled by varying the tetramethylsilane (TMS)-to-toluene precursor ratio. Structural characterization by Raman spectroscopy and X-ray photoelectron spectroscopy (XPS) confirmed the progressive evolution of Si–C bonding with increasing TMS ratio. The Si-DLC coating with Si 5.0 at.% exhibited the lowest coefficient of friction (COF) of 0.033 and reduced wear volume under a high normal load of 150 N in humid conditions (relative humidity > 90%). However, Si-DLC coatings with higher Si contents (Si 7.7 and 14.3 at.%) led to deteriorated tribological performance, including coating delamination and severe wear. Surface analyses of the coatings revealed that the low-friction behavior was associated with the presence of oxidized Si species at the outermost surface, which undergo hydroxylation in humid environments to form Si–OH groups. These hydroxylated surfaces promote the formation of a hydrated boundary layer that provides a low-shear sliding interface.