A novel radial anode layer ion source for inner wall pipe coating and materials modification-Hydrogenated diamond-like carbon coatings from butane gas

We report a new ion source development for inner wall pipe coating and materials modification. The ion source deposits coatings simultaneously in a 360 degrees radial geometry and can be used to coat inner walls of pipelines by simply moving the ion source in the pipe. Rotating parts are not required, making the source ideal for rough environments and minimizing maintenance and replacements of parts. First results are reported for diamond-like carbon (DLC) coatings on Si and stainless steel substrates deposited using a novel 360 degrees ion source design. The ion source operates with permanent magnets and uses a single power supply for the anode voltage and ion acceleration up to 10 kV. Butane (C4H10) gas is used to coat the inner wall of pipes with smooth and homogeneous DLC coatings with thicknesses up to 5 mu m in a short time using a deposition rate of 70 +/- 10 nm min(-1). Rutherford backscattering spectrometry results showed that DLC coatings contain hydrogen up to 30 +/- 3% indicating deposition of hydrogenated DLC (a-C:H) coatings. Coatings with good adhesion are achieved when using a multiple energy implantation regime. Raman spectroscopy results suggest slightly larger disordered DLC layers when using low ion energy, indicating higher sp(3) bonds in DLC coatings. The results show that commercially interesting coatings can be achieved in short time. (C) 2014 AIP Publishing LLC.