Engineered interfaces for adherent diamond coatings on large thermal-expansion coefficient mismatched substrates

Adhesion of thin or thick films on substrates is a critical issue in systems where the thermal-expansion coefficients of the coating and bulk material are significantly different from each other. The large mismatch of the expansion coefficients results in the generation of very high stresses in the coating that may lead to delamination, cracking, or other deleterious effects. A method to increase the adherence of diamond coatings on tungstencarbide and stainless steel substrates is reported based on a substrate-modification process that creates a three-dimensional thermally and compositionally graded interface. Scratch and indentation tests on diamond-coated steel and tungsten-carbide samples did not exhibit film fracture at the interface and concomitant catastrophic propagation of interfacial cracks.