Toughness Characterization Methods for Diamond-like Carbon Films

Diamond-like carbon (DLC) films exhibit superior tribological properties; however, their widespread adoption in precision manufacturing is hampered by inherent brittleness and a lack of reliable toughness characterization methods at the micrometer scale. This review critically examines existing techniques for evaluating DLC film toughness, highlighting limitations due to film thickness constraints and subjective failure definitions. We focus on two prominent micro-scale methods: impact testing and scratch testing. Impact toughness is assessed through energy absorption analysis based on impact crater morphology, including crack patterns and delamination areas. Scratch toughness is evaluated using critical loads (Lc1, Lc2) and the derived Crack Propagation Resistance (CPRS) parameter, complemented by microscopic failure analysis. We argue that neither method alone suffices for comprehensive toughness assessment. Instead, we propose a synergistic strategy integrating both techniques to provide a practical and comprehensive evaluation encompassing energy- and stress-based failure mechanisms under varying loading conditions. This approach offers a practical framework for developing tougher DLC coatings.