Graphite-like carbon films catalytically grown on a carburized substrate with an antenna structure at the interface: Experiments and first-principles calculations

[Display omitted] •A simple method to produce GLC films via catalytic growing and interface matching.•An antenna structure was observed at the interface, which is helpful for GLC films.•GLC films on carburized layers have stronger bonding, which agrees with calculations.•Fe3C has a stronger catalytic effect on GLC films than Fe3C(N) based on calculations. This article reports a novel process to produce high-performance GLC films on steel substrate by successive steps in a plasma nitriding system. Different from those made by conventional PVD/CVD, the GLC film reported here was grown on carburized/carbonitrided steel surface involving catalytic reactions. An antenna structure was observed at the interface with the substrate, which benefits the GLC film with improved durability, since such a structure could block or split cracks, leading to elevated adhesion strength and resistance to spallation. With combined experiments and first-principles calculations, we demonstrate that Fe3C has a stronger catalytic effect on GLC films than Fe3C(N), and the GLC films grown on carburized layers are thicker with stronger bonding and superior tribological properties due to the beneficial structure at the interface. The findings demonstrate a simple and low-cost method to produce high-performance GLC films via catalytic growth and interface matching mechanisms.