Fabrication of Cu-doped Diamond-like Carbon Film for Improving Sealing Performance of Hydraulic Cylinder of Shearer

During shearer operation, piston rod is susceptible to wear from invasion of pollutants, and then ruins sealing ring in hydraulic cylinder. This work attempts to conduct a systematical investigation of Cu-DLC (Cu-doped Diamond-like Carbon) film to improve the seal performance. Failure process of hydraulic cylinder was analyzed, and relevant parameters were determined. Several Cu-DLC films were deposited on the substrate of piston rod in a multi-ion beam assisted system, and their structures and combined tribological performances were investigated. As a result, dust particles attached to the piston rod may enter the cylinder, and damage the sealing ring under the radial force. Cu grains prefer to orientate (111) crystal plane with increase of Cu content, and may induce drop of hardness and internal stress for the film. Friction coefficient of the film ranges from 0.04 to 0.15, and rise of IG/ID ratio from 1.4 to 2.3 in Raman data indicates that bond transition from sp3-C to sp2-C may lower the friction coefficient. Modification mechanism of Cu-DLC film for the seal performance may come from synergistic effects of (i) contact force and friction heat induce the film graphitization, (ii) Cu doping improves toughness of the film and acts as a solid lubricant, and (iii) transfer layer plays a role of self-lubrication.