Clean and durable thick nanodiamond composite hard coating deposited on cemented carbide towards sustainable machining: Eco-friendly fabrication, characterization, and 3-E analysis

This research explores a sustainable approach for fabricating high-performance nanodiamond composite (NDC) hard coatings for dry machining. Aiming to address limitations in conventional coatings, such as environmental concerns, restricted film thickness, and compromised performance. The study utilizes Coaxial Arc Plasma Deposition (CAPD), a clean and efficient technique, to deposit thick (10 μm) NDC films directly on WC−Co substrates without chemical etching. Compared to traditional Chemical Vapor Deposition (CVD), CAPD offers significant advantages: lower temperature deposition, faster growth rate, and precise control over film thickness and morphology. The resulting NDC films boast exceptional durability due to their unique nanostructure, diamond nanocrystallites embedded in an amorphous carbon matrix. The addition of Al-interlayers (100–500 nm thickness) optimizes film properties. The optimal interlayer at 100 nm thickness not only mitigates the catalytic effects of Co but also enhances film hardness (50.4–58 GPa), Young's modulus (516–613.75 GPa), and adhesion (13–18.5 N) compared to films without an interlayer. Notably, the 100 nm Al-interlayer triples the deposition rate to 3.3 μm/h, achieving the desired thickness for effective hard coatings. The high density of grain boundaries within the films allows for exceptional stress release, enabling this increased thickness. Furthermore, these grain boundaries and the graphitic phase contribute to the film's superior tribological performance – a low coefficient of friction (0.1) and minimal wear rate (1.5 × 10⁻⁷ mm³/N⋅m) under dry machining conditions. These findings demonstrate the immense potential of CAPD-deposited NDC films as a sustainable alternative for advanced cutting tools, promoting environmental responsibility, economic viability, and energy efficiency.