By reducing waste and minimizing the use of harmful chemicals, DLC coatings offer an eco-friendlier option for surface treatment. As the demand for sustainable manufacturing practices continues to grow, developing eco-friendly DLC coating methods will become increasingly important.

On the other hand, an AR-coated germanium will feel right at home in a low power pulsed laser setup. One particularly noteworthy application is in quantum cascade lasers (QC), which is used in high-end materials science. Quantum cascades are used by such institutions as the Max Planck Institute of Quantum Optics in Garching to produce ribbons and strip structures as well as to produce new materials for use in medical applications. Pretty cool stuff!

Frequently, DLC coatings are often paired with Broadband AR Coatings (BBAR) to not only up the mechanical performance but also the transmission properties. Typically, a window is coated on one side with DLC and the other side with BBAR (typically in the 7-14μm range to boost both of these properties in tandem. This combination can increase the transmission to well over 85% in the target wavelength range. Optical windows treated in this manner will pass a variety of tests including MIL-C-675-C, MIL-STD-810 and APCM-01071.00001 and can survive salt water, humidity, high and low temperatures and hard smacks.

One approach to minimizing waste involves recycling materials used in the DLC process. For example, leftover DLC material can be reclaimed and reused, reducing the waste produced. Another way to reduce waste is to optimize the coating process to minimize material usage.

High refractive index enables excellent performance for lenses, ATR optics or beamsplitters. For optical windows, AR coatings can be added to boost performance.

Silicon (Si) is germanium’s next door neighbor who frequently borrows sugar. Both have an atomic number of 14, absorb visible light and have sharp cut-offs making them also function as long pass filters. In addition, there is similarity with their transmission ranges with silicon transmitting from 1.2-7µm. However, this is where they begin diverging. Silicon is far lighter with a density of 2.33g/cm3, making it ideal for weight-sensitive applications and less than half the density of germanium. Moreover, it is more thermally resistant than germanium and with a Knoop Hardness of 1150 it is also harder and less brittle. Silicon also costs less making it a better candidate in several applications.

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Surface preparation is critical in achieving high-quality DLC coatings. It involves cleaning, degreasing, and removing any contaminants from the substrate. This process can be done through various methods, such as chemical cleaning, mechanical cleaning, and plasma cleaning. Choosing the appropriate cleaning method is essential depending on the substrate and its intended use.

You definitely don’t want to breathe in germanium dust so care must be taken while handling these optics. Using gloves whenever possible and washing hands should be part of any standard operating procedure.

While DLC is a popular coating method employed by several industries for different applications, other coating methods, including TiN and CrN, are also used for material surface finish. Nevertheless, DLC and these other coating alternatives have their best use cases based on their unique properties, substrate shape, complexity, and size, even though their suitability for most anti-corrosion and anti-wear coating, TiN, and CrN has limitations where thermal stress and extreme temperatures are part of the process. DLC, on the other hand, is ideally suited for high-temperature applications and other anti-corrosion and anti-wear coatings. Nevertheless, it is less effective where high adhesive power is required considering that DLC has low adhesive capabilities. When carefully examined, these considerations help decide the best coating method for your coating project.

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objective = 400X total magnification). Tube: Where the eyepieces are dropped in. Also, they connect the eyepieces to the objective lenses. Base: ...

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Also, a critical examination of the quality of the coating process is a requirement, and essential non-destructive testing tools like Raman spectroscopy are effective for detecting any errors. These techniques ensure the quality of the coating using factors such as the microstructure of the film and its content to ascertain its quality. Faults and anomalies like discontinuity and cracks are some of the coating defects that these quality assessment methods help to identify.

For a coating process like DLC, unique deposition processes make it more accessible and allow it to be used for various scenarios and project needs. However, each has its own set of pros and downsides. PVD, CVD, and PECVD are three prominent DLC coating processes.

We’ve already explored why you would pick germanium over sapphire but why would you pick germanium over silicon or vice versa?

PECVD is a kind of CVD that employs plasma to speed up the deposition process. The gas-phase precursor is activated by plasma in PECVD, which subsequently interacts with the substrate surface to generate a solid coating. PECVD has the ability to create high-quality, homogeneous coatings with outstanding adhesion and mechanical qualities.

To begin with, critical parameters, including pressure, temperature, and film deposition rate, are essential and need careful assessment and inspection during the coating process. Monitoring these values ensures a quality coating job that leaves a consistent DLC coat on the substrate.

Assessing ROI for implementing DLC coatings involves considering the potential cost savings and performance improvements resulting from the coating. For example, DLC coatings can improve components’ wear resistance and durability, leading to longer service life and reduced maintenance and replacement costs.

Firebird Optics manufactures these types of windows in various geometries, coatings and can also produce lenses, prisms and various other optical components from germanium. Now back to your regularly scheduled programming…

On the flip side, one way to make the most out of the increased demand for DLC coating is to invest in researching alternative materials and methods that can give you an edge as a coating provider.

It is critical to maintain the optimal performance and functionality of Diamond-Like Coatings (DLC) by ensuring appropriate adherence and homogeneity. As a result, quality control and inspection are critical components of the DLC coating process.

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get wrecked! damage done to germanium windows by high power lasers. source: http://www.mdpi.com/2076-3417/10/10/3578/htm

Another industry with critical use of DLC coatings is the aerospace sector, where the allowable margin for error in performance is very small. DLC is often used to increase the performance and quality of several components assembled to form critical modules of various aircraft. Some DLC-coated elements include gears and rotating parts often subjected to friction and rapid wear.

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Various BBAR coatings typically requested are 3-5µm, 3-12µm, 2-14µm and 8-12µm though we can do even more customization. You can fill out our custom request form and see what Firebird Optics can do for your application.

However, both kinds of DLC coatings have various other advantages, such as corrosion resistance, decreased friction, and biocompatibility, which is important when constructing medical equipment. Though it is not without its downsides, including high cost and decreased film thickness, it still provides more benefits that outweigh its drawbacks.

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The best way to clean the windows is to use either ethanol, isopropyl alcohol, methanol, reagent-grade acetone or lint-free lens cloths. You can also use nitric acid but this material, while okay for germanium can corrode other optics or mounts that may be nearby in your system.

You can be sure to find DLC useful for various types of applications based on its unique features. DLC coatings are notable for their remarkable hardness, wear resistance, and low coefficient of friction. These qualities are obtained by depositing an amorphous carbon thin layer on a substrate. The hardness of DLC coatings is one of its most noteworthy characteristics. DLC coatings are exceptionally hard relative to other coating types, including CrN and TiN.

There will also likely be an increase in the demand for DLC coating for industries like the automotive and medical sectors, where the need to improve product performance will majorly depend on the material.

It might be almost impossible to put a cost to the peace of mind that having a preservation method like a diamond-like coating (DLC) gives a manufacturer, among other numerous benefits like wear resistance. But it might be quite instructive to carefully consider the requirements of any project before deciding to use DLC for material protection in your project. While it also offers dividends in terms of environmental benefits, DLC understands that choosing a DLC service provider can determine if you can enjoy these environmental benefits. Working with the right DLC service provider gives you ample opportunity to enjoy the many benefits DLC can offer you on your project, including high-performing material. The information laid out in this post should come in handy the next time you want to improve your project material’s durability.

Overall, DLC coatings are an appealing solution for a variety of applications because of their superior hardness, wear resistance, low friction, corrosion resistance, biocompatibility, and unique optical and electrical features.

Germanium ends up in some interesting places including defense aircraft navigation, reconnaissance and surveillance systems soaring in the stratosphere on an airplane or even as part of a satellite.

Again, bioengineers rely on DLC coating’s biocompatibility when building medical equipment such as implants and medical gadgets that must never become contaminated. At the same time, it is being used, as this can be fatal. DLC coating’s biocompatibility ensures that implants remain sterilized and unreactive to chemicals or other biological compounds inside the body. This feature also guarantees the longevity of the medical device.

Next, assess the technical knowledge and capabilities of the service provider. Do they thoroughly understand DLC coating technology and the latest advancements in the field? Can they provide the specific type of coating you need for your application?

Regardless of the coating processes used, DLC coatings created by any of the technologies listed above have remarkable qualities that make them acceptable for a variety of applications.

Material wear has been one of the biggest reasons for many manufacturers’ sleepless nights and worries. The fear of being unable to protect the integrity of a product due to wear often leads manufacturers in many directions to seek a viable solution for maintaining the durability of their products. Thank heavens, diamond-like coating (DLC) has been the saving grace for many manufacturers over the years, helping them keep their products serving their purposes for several years. Fortunately, this article gives you all the information you need to start applying the diamond-like coating in your next project. So, if you are ready, hop on, and let’s ride together.

Furthermore, the cost savings from using DLC coatings can be significant when compared to alternative surface treatments or material upgrades. Evaluating the potential cost savings and weighing them against the initial investment and ongoing costs is crucial to determine the ROI of implementing DLC coatings.

One very common scenario we see germanium utilized is inside high and low speed wind tunnels for jet propulsion studies. Typically, these windows are much larger than stock configurations reaching sizes in excess of 190-200mm.

Furthermore, there is every likelihood that companies and industries will continue to adopt DLC coating as they seek increased product performance which will open opportunities for providers of DLC coating.

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Materials with greater durability and anti-wear properties are predicted to improve DLC coating compatibility for even higher performance and lifetime. Consequently, markets will open for investors willing to fund research and development to proffer solutions to the problem of material corrosion. There is also the possibility of integrating coating into mold manufacturing rather than the post-manufacturing coating process presently available.

One common application for germanium is in night vision goggles. For these types of applications, both the inside and outside surfaces of the germanium is polished to a mirror finish and coated with multi-layered thin film filters to reduce any reflection of IR light. This enables optimal IR transmission essential to night vision/thermal imaging. As these windows will have excellent sensitivity at long range, this enables warfighters to retain long stand-off distances increasing safety and mission-effectiveness. Germanium is a literal life-saver.

Because it improves the durability, performance, and lifetime of their goods, the unique qualities of this material-enhancing technology easily attract manufacturers and designers. These benefits also reflect the increased profit of many manufacturers, and it’s no wonder they use DLC.

Testing and evaluation methods such as microhardness, tribological, corrosion resistance, and scratch testing can be used to assess the mechanical and physical properties of the DLC coatings. These tests can also determine the durability and wear resistance of the coating under different environmental conditions and stress levels.

Firstly, using harsh chemicals is unacceptable when cleaning a DLC-coated material, as it can adversely affect the integrity of the coat. Also, abrasive materials should never be an option when cleaning these coated components. Soft fabric or brush with water is often adequate.

Furthermore, innovative manufacturing procedures such as plastic injection molding consider DLC coating during the mold design phase as it can help increase the effectiveness of the molds. Furthermore, DLC coating is frequently applied to equipment and machine bits to enhance performance and minimize wear on the cutting tool, hence increasing the tool’s lifespan. DLC continues to save manufacturers from an early loss and replacement of tools and equipment that can cost significant amounts of money while increasing their efficiency and performance.

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DLC coatings are therefore suited for use in situations where abrasion and wear are a problem since they can provide greater wear and tear resistance.

Diamond-like coating (DLC) is a versatile material protection method used across several industries. It is employed majorly for the preservation of the mechanical properties of a material, including wear resistance and hardness. However, this coating method uses a thin film containing hydrogen, carbon, and other minor elements to enhance the surface finish of most manufacturing materials. Furthermore, the addition of this coating layer gives the substrate or the coated material similar mechanical properties to that of diamond, considering that diamonds are the hardest naturally occurring substance on earth.

Another equally crucial consideration is the professionalism of the customer service team. Look for a responsive, communicative, and willing provider to work closely with you throughout the coating process. There is an excellent chance that a company with such a customer service team will attend adequately to your coating needs.

Also, the chemical composition of this coat can vary depending on the proportion giving rise to different types of DLC coating. Tetrahedral amorphous carbon and amorphous carbon, a softer, more malleable variant of the coating, are two DLC coating types. It is also noteworthy that the harder grade of the coating, the tetrahedral amorphous carbon, has more resistance to wear and is applicable for projects with high stress and impact as a critical consideration.

Nevertheless, challenges will be inevitable as limitations of DLC coating, including peeling and chipping of coating layers under extreme conditions, will require extensive research to solve these challenges. Other limitations that will be extensively researched include environmentally friendly coating techniques.

Innovations and advances in eco-friendly DLC coating practices continue to emerge. For example, some companies are working to develop sustainable DLC coating methods that use renewable energy sources, such as solar power. A couple of other companies are seeking ways to employ sustainable, eco-friendly solvents to replace conventional cleaning chemicals.

Secondly, preparing the substrate surface appropriately before coating is important to ensure proper adhesion and avoid coating delamination.

High-quality DLC coatings require good material compatibility and substrate preparation. Choosing the appropriate cleaning and pre-treatment method can significantly improve the adhesion and performance of the coating.

An uncoated germanium window is a decent IR generalist but specific optical coatings can really kick things up a notch. Diamond-Like Carbon (DLC) coatings can make this already hard material even more resistance to severe abrasions, environmental damage, mechanical strikes, thermal shock and whole other host of adversities.

PVD is a popular technique for depositing thin films, including DLC coatings. PVD involves depositing coating material onto a substrate by transferring atoms or molecules from a solid or liquid source through a vacuum or low-pressure gas environment. The arrangement of the substrate and the coating machine is such that the substrate is always in line with the coating equipment, allowing for easy coat deposition on the substrate. The most common PVD methods used for DLC coatings are magnetron sputtering and cathodic arc deposition. In magnetron sputtering, the coating material is vaporized by ion bombardment in plasma, while cathodic arc deposition involves the vaporization of a metal target by an electric arc.

Use the carabiner to hang the gloves when drying or not in use.

Germanium windows are optical windows that are completely impermeable to UV and VIS light giving them a dark, metallic appearance to the naked eye. However, when it comes to the IR range this is where germanium truly shines with an excellent, broad transmission range from 2-16μm making it an ideal candidate for Mid-Wave-IR (MWIR) and Long-Wave IR (LWIR) applications. The sharp transmission cut-off before 2µm also enables germanium to be used as a long pass filter, only transmitting wavelengths in excess of 2µm and fully blocking everything before it.

... Lens Simulator Logo. author image Fu Kwun Hwang; Fremont Teng; lookang. © 2020, Fu Kwun Hwang; Fremont Teng; lookang. Compiled with EJS 6.0 ...

When not in use, we recommend storing your germanium windows wrapped in lens tissue with humidity below 30% and between 15 and 25ºC. While germanium is pretty tough stuff, these are the ideal conditions that will prolong the life of your window.

A comprehensive cost-benefit analysis is necessary to assess the financial feasibility of implementing DLC coatings, especially in manufacturing procedures like rapid prototyping. Considering the long-term benefits and ROI, many companies find that investing in DLC coating technology is a wise decision that can lead to improved performance, reduced costs, and increased profitability.

One of the more common applications we see at Firebird Optics for germanium windows is in low power CO2 laser systems. With a Laser Induced Damage Threshold (LIDT) of 10 J/cm2, germanium windows are not suited for high power or continuous wave (CW) lasers. Part of the reason for this is higher powered lasers cause temperature increases, dramatically dropping transmission properties over 100ºC and eventually damaging the substrate itself once temperatures near 600ºC are reached.

As you’d imagine, since germanium tags along with warfighters, it needs to be durable in all adverse conditions from desert, sea, high altitude, etc. The DLC coatings can take a serious beating with temperatures ranging from -80ºF to 160ºF, 24 hours of continuous sea spray, ocean immersion for over 24 hours and being immersed in a sandstorm. Additionally, the coatings can withstand heavy mechanical damage and chemical attacks.

Now for some fun stuff. We hear from plenty of our customers where their germanium windows are seeing action. Here are some highlights:

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The associated overhead cost is another crucial consideration, as the cost of maintaining and running equipment can quickly rack up in a short time. Again, the power consumption and cost of coating materials all add to the cost of running a DLC operation.

With the world going green, it is safe to say that a company with an eco-friendly bouquet of services will be innovative. Choosing an environmentally conscious provider that uses eco-friendly coating methods can help minimize the environmental impact and promote sustainability.

Once the substrate is clean and free from impurities, it is subjected to pre-treatment methods such as ion implantation, surface roughening, or surface activation. Ion implantation involves bombarding the substrate with ions to modify its surface properties. Surface roughening, on the other hand, improves the adhesion of the coating by increasing the surface area. Surface activation techniques such as plasma treatment enhance the wetting and adhesion of the coating to the substrate.

If high transmission is the only consideration, you’d be best served to double coat your windows with BBAR over particular wavelength ranges and you can see transmissions all the way up to 99%. Now we’re talking!

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In fact, at an eye-popping Knoop Hardness of 2000kg/mm2, one might wonder, why wouldn’t I just use sapphire windows instead of germanium? While sapphire is the undisputed champion of robust optics in the UV/VIS and mid-IR with a wavelength range that dips into the far UV range at 150nm, it can only be used up to 4.5µm. This leaves germanium as the best and only choice for brutally tough IR applications. This is typically why you will see germanium windows and lenses serving in places as inhospitable as outer space, battlefields and in the middle of high-powered CO2 laser systems. More on this later.

Before applying DLC coatings, it is vital to ensure that the coated material is compatible with the coating. Commonly used materials include stainless steel, titanium, and aluminum sometimes after going through CNC machining or other forms of preparation. Substrates prone to corrosion or having poor adhesion properties may require pre-treatment before coating.

Several factors, most of which are apparent, can significantly affect the cost of carrying out a DLC coating process. One is the complexity of the substrate’s geometry, and another is its size. Also, the coating method adopted during design can significantly add to the coating cost. However, despite the initial investment required, many companies find that the benefits of DLC coating can outweigh the costs, resulting in a positive return on investment (ROI).

Since germanium windows have a high index of refraction of approximately 4.0 in the range of 2-16μm, transmission with minimal refraction is guaranteed but without any additional coatings only around 50% of the beam is able to pass through. Those are rookie numbers and in most applications we’ll need to boost our window signals via various coatings. While this may be a disadvantage for optical windows this property comes in handy for novel lens designs and ATR optics where refraction is desired.

The initial investment for DLC coating equipment and setup can range from tens of thousands to millions of dollars, depending on the size and capacity of the coating system.

To say the future of DLC coating is bright might be an understatement considering the rate at which new technologies keep popping up daily.

Employing an innovative coating method such as DLC coating is one thing. Keeping it effective throughout its lifetime is another ball game entirely. The maintenance of these coated items requires consistency and careful consideration.

Proper quality control and inspection ensure that the DLC coatings meet the desired specifications and performance requirements.

Alternatively, you can use liquid CO2 from a specialized nozzle for cleaning though this requires additional cost in terms of equipment. While you will get a better, more controlled cleaning and can be used for stubborn stains, care must be taken to work in a controlled moisture-free environment and we do not recommend this for typical end-users.

Germanium (Ge) is a shiny, hard element with a Knoop Hardness of 780kg/mm2 making it, along with its far stronger sister sapphire, the default candidate for applications where the environment is likely to put a beating on the material. For a full breakdown of how to wade through all of the major optical window choices check our optical window guide.

A typical example of an avid user of DLC is the automotive industry, where several of the parts manufactured will be in motion and in constant contact with other components causing friction. DLC helps significantly reduce these components’ wear, thereby increasing their durability and lifespan. These components include valves, pistons, shafts, and gears coated using DLC coats to improve performance.

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DLC coating, in addition to its mechanical qualities, provide high corrosion resistance, making them appropriate for severe situations. You’ll find them very useful in the medical sector, where their biocompatibility has been used in the design and production of medical equipment and devices.

Germanium holds the high ground when it comes to transmission range getting that additional coverage from 7-16µm, which silicon lacks. On top of this, germanium has higher electrical conductivity making it a more suitable candidate as an optical component in laser systems.

Another consideration is germanium’s density. At 5.33g/cm3 it does not float like a butterfly and sting like a bee. It’s heavy. Quite heavy and this will need to be considered when designing weight-sensitive systems.

Germanium makes a good electromagnetic interference (EMI) shielding material and can shield IR systems on planes from other nearby signals that would render the system ineffective. This effectively creates an IR Faraday cage or as we like to refer to it, an aerospace tin foil hat. Typical resistance for EMI-grade germanium is approximately 4 Ohm per cm but this depends on the required level of spurious signal suppression. A germanium window made to these specs can effectively short out any errant signals and keep the IR system running well.

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Take the time to research and evaluate potential DLC coating service providers to ensure that you are choosing the right partner for your project.

Another important feature of DLC coatings is their low coefficient of friction. This property is fundamental in applications such as automotive engines, where reducing friction can result in improved fuel efficiency and reduced wear on moving parts.

Choosing an appropriate DLC coating agency can sometimes be tricky, but a few rules of thumb can easily get you on the right track. An important rule of thumb in locating an ideal DLC coating vendor is to seek one with a consistent history of success and positive reviews. Most times, customer feedback is an excellent way of finding a DLC coating service provider with the capability and expertise to meet your coating needs. The more positive feedback, the higher the probability of getting a high-quality job from such a company.

Another maintenance consideration for DLB-coated material is their exposure to excessive moisture, as the coating is more effective when dry. Also, routine and periodic checks to identify any defect, including cracks, dents, and chips, to quickly carry out repair works.

CVD is another popular method for applying DLC coatings. CVD is a method of forming a solid coating that involves reacting a gas-phase precursor with a heated substrate. It produces coating material by decomposing a gas or vapor-phase precursor, which then interacts with the substrate surface to form a solid coating. CVD can provide conformal coatings, which adapt to the substrate’s geometry, making it excellent for coating complicated shapes and geometries.

DLC coatings can also exhibit unique optical and electrical properties. Some DLC coatings, for example, have a high refractive index, making them valuable in optical applications. Other DLC coatings, which can be conductive or semiconductive, are valuable in electrical applications.

Compared to other surface treatments, DLC coatings have a smaller environmental footprint due to their reduced use of harmful chemicals. In addition, eco-friendly DLC coatings are available that use only non-toxic gasses during the coating process, further reducing environmental impact.

One cautionary detail to note is that your germanium window will not appreciate being exposed to high temperatures. In fact, there is an inverse relationship to temperature and transmission when it comes to this material. As your temperature goes up, the transmission properties will drop precipitously, a property known as thermal runaway. Anything over 100ºC is not recommended. By the time it reaches 200ºC it is nearly opaque at all wavelengths. If you need a high temperature window, you’re better suited to stick with a material like MgF2, YAG or our old friend sapphire.

As sustainability and environmental impact become increasingly important factors in manufacturing, it is essential to consider the eco-friendliness of diamond-like coating (DLC) processes. One significant advantage of DLC coatings is their ability to reduce the use of harmful chemicals commonly found in traditional coating methods. However, the DLC process still generates waste, making examining ways to reduce its environmental impact crucial.

Several aspects should be considered when selecting a coating process, including the unique application requirements, the characteristics of the substrate material, the required coating attributes, and the available equipment and expertise. It is critical to thoroughly assess each coating procedure to determine which will best fulfill the demands of the application.