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Abstract

Method of making a composite coated article by the steps of: (a) initiating chemical vapor deposition of separated diamond or diamond-like particles onto a nondiamond or nondiamond-like substrate surface by use of low pressure metastable deposition of carbon in the presence of atomic hydrogen and at a temperature (i.e., 600.degree.-950.degree. C.) that favors the nucleation of such particles, the substrate being selected to retain its strength related properties after said chemical vapor deposition (ie., SiAlON, Si.sub.3 N.sub.4, SiC, Si, Ti, Co cemented WC, TiC, Ni-Mo cemented TiCN); (b) substantially suppressing nucleation of additional particles (heating to above about 1000.degree. C.) before formation of a contiguous film of said particles while permitting the existing particles to grow to a predetermined maximum crystal size consistent with separated crystals; and (c) depositing a mechanically tough, diamond and substrate-wetting metal binding material (i.e., Ti, Ni, Co, Mn, Cr, Mo, Fe) onto and across said separaed particles and exposed substrate surface to form the composite coated article. Chemical vapor deposition comprises thermal decomposition (i.e., microwave plasma, discharge, filament heating) of a hydrocarbon gas containing hydrogen, with or without diamond seeding. The binding material preferably contains a brazing agent (i.e., Cu, Ag, Sn).

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First Claim