Diamond-like carbon (DLC) films have a promising tribological application in green precision manufacturing, but their toughness represents a serious issue in the way of their application perspective. The film thickness is on the micrometer scale and makes conventional methods unsuitable for its toughness characterization. The absence of an accepted method for characterizing the DLC toughness has hindered the related research on the development of toughening methods and understanding the mechanism. This work intends to explore a relatively simple and acceptable characterization method to measure the film toughness. Moreover, toughening mechanisms of DLC films are proposed during the characterization to reveal the toughening mechanism. The toughness can be fully characterized through combining impact toughness and scratch toughness. The impact toughness can be obtained by observing the size of the indentation and the crack state around the indentation in the impact experiment. The scratch toughness could be assessed by combining the scratch morphology and Crack Propagation Resistance (CPRS). The improvement of film toughness should be carried out from two aspects: preventing microcrack initiation and suppressing crack propagation. Appropriate doping of non-carbide metal particles can effectively improve the toughness of the film, and there are seven main factors affecting the toughening of the film. Five toughening mechanisms of non-carbide metals from film preparation to test stage are revealed during the investigation of the change patterns.

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.