Innovative hybrid deposition enables high-performance TiCx coatings on soft elastomeric substrates

Achieving durable adhesion and exceptional tribological performance on soft elastomeric substrates remains a formidable challenge in surface engineering. This study pioneers a hybrid deposition strategy integrating cathodic arc ion plating and magnetron sputtering to fabricate architecturally graded TiC x -based multilayer films on fluorocarbon elastomer (FKM) substrates. Through precise modulation of the Cr/Ti bonding layer thickness (363–477 nm), we demonstrate its critical role in governing structural evolution, mechanical properties, and tribological responses. Thin bonding layers (363 nm) promote extensive surface graphitization, enabling low friction (μ = 0.28), while thicker layers (477 nm) facilitate the development of robust amorphous-nanocrystalline structures that enhance hardness and interfacial adhesion. The proposed approach successfully resolves the fundamental trade-off between friction reduction and wear resistance, presenting a transformative solution for advanced sealing systems operating under extreme conditions. This research establishes new paradigms for interface engineering in hard-soft material systems and opens avenues for developing next-generation tribological components. • A hybrid technique fabricates graded multilayer TiCx coatings on soft elastomers. • Adhesion layer thickness critically controls carbon phase evolution between sp 2 and sp 3 . • Ultra-low friction (μ=0.28) is achieved with an optimized thin bonding layer. • Excellent adhesion and wear resistance are obtained with thicker bonding layers. • A stable lubricating interface forms via tribo-induced graphitization and functional transfer films.