Tribological behavior of diamond coated reaction-bonded silicon carbide under dry and seawater environment

Ceramic seal materials such as Silicon carbide (SiC) and Reaction-Bonded SiC (89%SiC and 11 % free Silicon) are widely used in mechanical pumps, compressors, and feed water pumps to prevent the fluid leakage between the two rotating shafts. In a continuously harsh environment, these mechanical seal materials undergo high friction and wear due to the high asperity-to-asperity contact between the two mating parts and generate high frictional heat at the interface. This scenario induces seal failure under high operating conditions. Especially in corrosive mediums such as acids, high pH value solutions, and hard abrasive media can cause aggressive seal failure. To reduce production downtime and improve the longevity of the mechanical seal, the surface of the seal material needs to be engineered with a suitable coating that will satisfy the required properties of high hardness, chemically inertness, and low friction coefficient. In this regard, we have come up with a super hard coating material such as diamond (Micro-crystalline) on the surface of Reaction-Bonded SiC using the hot filament CVD (HFCVD) method to meet the above-required properties. In this work, we have carried out a systematic study on the tribological effect of uncoated, and diamond-coated seal material against silicon nitride ceramic under a dry and seawater environment. The initial physical characteristics such as surface morphology, surface roughness, and Raman analysis were performed on the samples before and after coating. To understand the friction and wear characteristics, the linear reciprocating tribometer test (Ball on Flat) was conducted on the uncoated and diamond-coated samples using a universal tribometer for an operating period of 36,000 cycles. The experimental results show that the diamond-coated sample exhibits a low friction coefficient (0.05 ± 0.01) compared to the uncoated sample (Friction coefficient (CoF) = 0.24 ± 0.037) at a normal load of 10 N with a frequency of 10 Hz under a seawater environment. Similarly, under dry conditions for the same tribo-test parameters, the diamond-coated sample (CoF = 0.06 ± 0.02) outperforms compared with the uncoated sample (CoF = 0.42 ± 0.17) at a percentage improvement of 85 %. From the observed results, we conclude that diamond-coated ceramic seals are considered a suitable alternative to commercially available seals in terms of high operating conditions and durability under both wet (seawater) and dry running operations. •The Microcry