To make moving mechanical systems more durable and sustainable, their moving components should possess a combination of low friction, anti-wear, and anti-corrosion features. Hydrogenated amorphous carbon (a-C:H) is a well-known protective overcoat, commonly grown using plasma-enhanced chemical vapor deposition. However, in ambient to humid environments, a-C:H overcoats do not offer sufficient protection against friction, wear, and corrosion simultaneously. Here, we developed multilayer coatings consisting of alternating layers of a-C:H and copper (Cu). These coatings extraordinarily suppressed the corrosion of mild steel and stainless steel 304 (SS304), reducing corrosion rates by up to 250 times. Despite their anti-corrosion performance, these multilayer coatings failed to significantly reduce the friction and wear on various types of surfaces. To overcome this challenge, further surface engineering of the Cu/a-C:H multilayer coatings was done by introducing a hybrid material of multilayer graphene and multiwall carbon nanotubes. This modification reduced the friction by up to 85% and consequently lowered the wear rate of various substrates, even in humid conditions. This work unlocks how synergy of surface nano-chemistry via multi-material systems can solve broad challenges, which is vital for developing energy-efficient and sustainable futuristic technologies.
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