Faceted PVD films with metallic separator

In the paper we describe attempts to improve performance characteristic of the parts operating in sliding couple by creating 3-dimensional surface structures. In contrast to the well-known multi-layered films, we created the real 3D surface structure consisting of the faceted multi-layered hard-ceramic film with the facets separated with the pure metal (metallic separator), such as copper and silver. For deposition of these films, we used the round-hole masks with various transparency (from 0.7 to 0.5), and various facet shapes (rounds and ellipses). The films were deposited using vacuum-arc equipment. The wear tests performed showed considerable increase in the wear-resistance and decrease in friction coefficient when the polished steel was used as the rider. The influence of plasma parameters and film-separator geometry on the film properties is studied. The model developed provides the means for optimization of film parameters and calculation of the plasma parameters used in the process of film deposition.