A series of layered structures based on epoxy-resins coated with diamond-like carbon (DLC) are examined as potential replacements for electroplated chromium in aerospace applications. Diamond-like carbon coatings can offer superior mechanical properties and tribological performance; however, in some applications high internal stresses and poor adhesion limit their practical use. A DLC / epoxy system is developed and studied utilising pin-on-disk testing, analysis with scanning electron microscopy and atomic force microscopy, resulting in an optimum system with characteristics superior to those of chromium plated steel. This new coating system has a great potential in restoring worn or damaged aircraft components, without the health and environmental issues associated with chromium plating. The components can be rebuilt and improved over the original condition thus allowing an extension of service life and eliminating the need for costly replacements.
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