We demonstrate enhancements of performance and energy efficiency of cutting tools by deposition of diamond-like carbon (DLC) coatings on machine parts. DLC was deposited on steel drill bits, using plasma enhanced chemical vapour deposition (PECVD) with the acetylene precursor diluted with argon, to produce a surface with low friction and low wear rate. Drill bit performance in dry drilling of aluminium was quantified by analysis of power consumption and swarf flow. Optimised deposition conditions produced drill bits with greatly enhanced performance over uncoated drill bits, showing a 25% reduction in swarf clogging, a 36% reduction in power consumption and a greater than five-fold increase in lifetime. Surface analysis with scanning electron microscopy shows that DLC coated drills exhibit much lower aluminium build up on the trailing shank of the drill, enhancing the anti-adhering properties of the drill and reducing heat generation during operation, resulting in the observed improvements in efficiency. Variation of drilling efficiency with argon dilution of precursor is related to changes in the microstructure of the DLC coating.

A nitinol stent may be suitable for aortic graft fixation, has characteristics similar to the Palmaz stent and has shape memory effect which may overcome the difficulties of introduction of wider diameter stents through narrow arteries.

The effectiveness of a plasma-deposited, diamond-like carbon (DLC) coating on aluminium alloy based surgical instruments is investigated. Surgical instruments must satisfy a number of important criteria including biocompatibility, functional performance, sterility and cleanability, structural integrity, and fatigue resistance. The integrity of the DLC layer and the diffusion barrier properties are of paramount importance due to biocompatibility considerations of the underlying aluminium metal. We investigate optimisation of the coating with incorporation of silicon and variation in negative self bias, and highlight the design and manufacture of a lightweight laparoscopic assist instrument from aluminium alloy coated with diamond-like carbon, which has been used successfully in the clinical environment to improve operations such as cholecystectomy (gall bladder removal) and exploratory techniques for the diagnosis of cancer.

Prolonged operation of piezoelectric ceramic devices under high dc electric fields promotes leakage currents between the electrodes. This paper investigates the effects of ceramic porosity, edge conduction and electrode materials and geometry in the development of low resistance conduction paths through the ceramic. Localized changes in the ceramic structure and corresponding microscopic breakdown sites are shown to be associated with leakage currents and breakdown processes resulting from prolonged operation in harsh environments. The role of barrier coatings in mitigating the effects of humidity is studied, and results are presented on improved performance using composite diamond-like carbon/polymer coatings. In contrast to the changes in the electrical properties of the ceramic, the measurements of the piezoelectric properties showed no significant effect of humidity.

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