Carbon Coatings Research Articles

Tribological properties of dual-freedom sliding roller pairs with a loss of lubrication

Purpose This paper aims to design a novel test device and study the wear properties and the thermal mechanisms of roller pairs in dual-freedom sliding contacts. Design/methodology/approach On the transition process of lubrication regimes, experiments were conducted with various values of running speed and slip ratio obtained by two motorized spindles. Temperature and surviving time would be obtained of GCr15/GCr15 and DLC/GCr15 friction pairs. Micro photography was obtained with a PGI 3D stylus profiler and a confocal microscopy OLS4000-3D. An empirical mode decomposition method was used to eliminate measure errors. Findings Results showed that, even with little initial lubricant, rolling/sliding pairs still rotated for a certain time. With the synthetic actions of the dual-freedom sliding, the loss of lubrication and the tilt, interesting helical grooves appeared. Sliding speeds had remarkable effects on survive time, temperatures and surface topographies. In addition, the equilibrium values of the temperature and the surface roughness were obtained in sufficient oil supply. Extreme wear-out conditions were obtained with starved lubrication. Diamond-like carbon coatings showed better heat resistance and better wear resistance. Originality/value This work would be critical for the life design and the heat treatment of rolling bearings in the full flood lubrication and the starved lubrication. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0164/

Evaluation of Wear Resistance in Tungsten-Doped Diamond-like Carbon Coatings (WC/C) on Coated and Uncoated Surfaces Under Starved Oil Lubrication with R452A Refrigerant

This article assesses the potential of using a diamond-like carbon coating doped with tungsten, a-C:H:W (WC/C), on the sliding pairs of refrigeration compressors. The ability of WC/C coating to provide low wear and a low coefficient of friction was experimentally verified in a specific refrigeration compressor operating environment (lubrication with oil diluted with refrigerant) and under extreme operating conditions (starved lubrication with a small amount of oil). Conditions of starved lubrication with a substance of reduced lubricity promote a temperature increase and high mechanical (friction) stresses on the surface of the sliding pairs. These situations can hinder the effective operation of WC/C coatings. Comparative wear tests were carried out for S235JR steel samples with and without WC/C coating. It was found that the samples with the WC/C coating had the lowest wear values and the lowest friction coefficients (approximately 0.06). A low coefficient of friction suggests that even a small amount of oil (one drop) is likely sufficient to achieve mixed lubrication conditions between the tested sliding surfaces and reduce material loss. The tested WC/C coating can protect sliding friction pairs in refrigeration compressors under extreme operating conditions caused by a lack of oil. Less friction reduces the need for energy to drive the refrigeration compressor. Additionally, the significance of this research is highlighted by the fact that the wear tests were conducted using R452A, a novel, eco-friendly refrigerant.

Waxberry-like TiO2 with Synergistic Surface Modification of Pyrolytic Carbon Coating and Carbon Nanotubes as an Anode for Li-Ion Battery.

Titanium dioxide (TiO2) as an anode material for lithium-ion batteries (LIBs) has the advantages of tiny volume expansion, high operating voltage, and outstanding safety performance. However, due to the low conductivity of TiO2 and the slow diffusion rate of lithium ions (Li+), it is limited in the application of LIBs. Therefore, waxberry-like TiO2 comodified by pyrolytic carbon coating and carbon nanotubes was prepared in this work. The waxberry-like TiO2 with nanorods on its surface shortens the diffusion distance of Li+. Carbon nanotubes and waxberry-like TiO2 are tightly combined through electrostatic assembly and form a cross-linked conductive network to provide more electron transmission paths. A thin layer of pyrolytic carbon wraps carbon nanotubes and waxberry-like TiO2, which enhance the conductivity of the composites and ensure the structural integrity of the materials throughout the cycling process. The experimental data revealed that the discharge-specific capacity of TiO2@CNT@C is 170.5 mAh g-1 after 3000 cycles at a large current density of 5 A g-1, and the discharge-specific capacity is still 143 mAh g-1 at the superhigh rate of 10 A g-1, which provides excellent rate performance and cyclic stability. The efficient dual-carbon modification strategy could potentially be extended to other materials.

Retrieval of refractive index and water content for the coating materials of aged black carbon aerosol based on optical properties: a theoretical analysis

Abstract. Water content in the coatings of aged black carbon (BC) aerosol can be reflected through the complex refractive index. In this study, the retrieval of the refractive index and water content for non-absorbing coatings of BC aerosol during hygroscopic growth (RH = 0 %–95 %) based on scattering and absorption properties is theoretically investigated. Optical properties of morphologically realistic fractal BC aerosols are simulated using the multiple-sphere T-matrix method (MSTM), the optical equivalent refractive index of coating material is retrieved based on the Mie theory, and the water content in coatings is further retrieved using effective medium theory. Results show that the scattering property performs best in retrieving the refractive index and water content. The retrieval errors of the refractive index of heavily aged BC aerosols are less than 10 % at high relative humidities (RHs), while partially coated BC and thinly coated BC have larger errors. The regularity of retrieved water content is similar to that of the refractive index retrieved, and the retrieved water content errors range from 2 % to 63 % for heavily coated BC. This study provides a helpful optical method to obtain the water content of BC coatings.

Biocompatibility and Antibacterial Potential of Tetrahedral Amorphous Carbon (ta-C) Coatings on CoCrMo Alloy for Articulating Implant Surfaces.

Premature implant failure, a critical concern in biomedical applications, is often attributed to poor biocompatibility and vulnerability to bacterial colonization. These issues are addressed by creating an endoprosthetic material with natural biocompatibility and antibacterial properties. In this invitro study, the relaxed and unrelaxed tetrahedral amorphous carbon (ta-C) coatings were examined, both fabricated by the improved patented Pulsed Laser Deposition (PLD) technology. The chemical composition, surface roughness, hardness, topography, and wettability were analyzed. The ta-C surfaces were incubated by MM6 cells, E. coli and S. capitis bacteria for 24 h. PCR assessed the inflammatory response in MM6 cells, while fluorescence microscopy quantified adhering bacteria, and scanning electron microscopy examined local adhesion behavior. The results demonstrate comparable carbon phase composition, wettability properties, and hardness for both relaxed and unrelaxed ta-C. However, relaxed ta-C coating exhibited significantly fewer defects in terms of both quantity and quality, along with an antibacterial effect against E. coli. This suggests that the relaxed ta-C coating could contribute to the development of an endoprosthesis, preventing adverse biological reactions and implant-related infections, thus improving the longevity of the prosthesis.

A multi-method study of femtosecond laser modification and ablation of amorphous hydrogenated carbon coatings

We present a study on femtosecond laser treatment of amorphous hydrogen-containing carbon coatings (a-C:H). The coatings were deposited on silicon wafers by a plasma-assisted chemical vapour deposition (PA-CVD), resulting in two different types of material with distinct properties (referred to as “absorbing” and “semi-transparent” coatings in the following). The samples were laser-treated with single fs-laser pulses (800 nm center wavelength, 35 fs pulse duration) in the ablative regime. Through a multi-method approach using topometry, Raman spectroscopy, and spectroscopic imaging ellipsometry, we can identify zones and thresholds of different fluence dependent effects and have access to the local dielectric function. The two coating materials react significantly different upon laser treatment. We determined the (non-ablative) modification threshold fluence for the absorbing coating as 3.6×10-2\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$3.6\ imes {10}^{-2}$$\\end{document} Jcm−2 and its ablation threshold as 0.22 Jcm−2. The semi-transparent coating does not show such a low-fluence modification but exhibits a characteristic interference-based intra-film ablation mechanism with two distinguishable ablation thresholds at 0.25 and 0.28 Jcm−2, respectively. The combination of tailored layer materials and correlative imaging spectroscopic methods delivers new insights into the behaviour of materials when treated with ultrashort-pulse laser radiation.Graphical abstract

In-Situ Constructing N,S-Codoped Carbon Heterointerface for High-Rate Cathode of Sodium-Ion Batteries.

Na3V2(PO4)3 (NVP) is considered one of the promising choices for cathodes of sodium-ion batteries, but the poor conductivity resulted inferior rate performance limited the practical development of NVP cathodes. In this study, we successfully synthesized N/S dual-atom doped carbon coatings in situ through a simple one-step solid-state sintering method. The uniformly coated carbon layer can inhibit the agglomeration and growth of active materials during the sintering process, shorten the Na+ migration path, and increase the contact area with the electrolyte, thus facilitating rapid Na+ migration. Notably, the doping of N elements can alter the electron distribution of carbon coating, enhancing electron conductivity. Furthermore, the introduction of S elements in the carbon layer can induce the formation of stable C-S-C bonds in the molecular layer, expanding the interlayer spacing, which is beneficial for Na+ transport and storage. Therefore, the modified NVP@NSC composite provides a high specific capacity of 90.3 mAh g-1 at a rate of 20 C, with a capacity retention rate of 94.4% after 8000 cycles, demonstrating excellent stability at high current densities. Moreover, the full cell exhibits remarkable electrochemical performance at 5 C. This research contributes to the practical development of NVP cathodes.

Improve wear resistance of C/C composites as artificial bone using diamond-like carbon coatings

In this study, diamond-like carbon (DLC) coatings and silicon-doped diamond-like (Si-DLC) coatings were prepared on the surface of C/C composites by a combination of plasma-enhanced chemical vapor deposition (PECVD) and magnetron sputtering processes. The film composition, microstructure and atomic bond structure were characterized using X-ray photoelectron spectroscopy, field-emission scanning electron microscopy and Raman spectroscopy. The mechanical properties and friction behavior related to the Si element were investigated using nanoindentation and HT-1000 high temperature friction and wear tester. The biocompatibility of the materials was also evaluated by the MG-63 proliferation test. The results indicate that Si elements were successfully incorporated into the DLC films, bonding with C and O atoms, which altered the thermal stability and microstructure of the coatings, reduced the internal stress of the films, and increased disorder. Compared to C/C composites, all coated layers exhibited lower coefficients of friction, with the formation of transfer layers and graphitization induced by friction contributing to the excellent tribological performance. Both coatings showed no cytotoxicity and demonstrated good biocompatibility. Both coatings are effective in reducing wear and chip losses in C/C composites when used as artificial bones. This work suggests that diamond-like carbon coated C/C composites can be excellent structural materials for human body in biomedical science.

Effect of electrical current on sliding friction and wear mechanisms in a-C and ta-C amorphous Carbon coatings

This study investigated the sliding wear behaviour of amorphous carbon (a-C) and tetrahedral amorphous carbon (ta-C) coatings, two forms of diamond-like carbon (DLC) coatings, against SAE 52100 steel using a modified ball-on-disk tribometer with applied electrical currents ranging from 100 mA to 1800 mA. It focused on the variations in sliding friction and wear characteristics of these coatings as electrical currents increased under constant load and speed conditions. The a-C coatings exhibited lower coefficient of friction (COF) values and reduced volumetric wear losses up to 1500 mA, while ta-C coatings studied displayed higher wear, similar to uncoated M2 steel, at 300 mA with degradation occurring at low currents, resulting in failure due to severe oxidational wear. The a-C coatings showed no significant electrical damage at these currents. Raman spectroscopy revealed structural changes on the wear tracks of sp2-rich a-C coatings, specifically the formation of graphene layers. In comparison, the wear tracks of sp3-rich ta-C coatings did not display such transformation under the conditions studied. The graphene coverage on the surfaces of the a-C coatings increased with the increase in the current as revealed by the Raman intensity maps of 2D peaks and this increase was accompanied by a higher defect density in the graphene. The low COF of graphene-covered a-C surfaces was consistent with the proposed mechanisms of moisture adsorption. However, at currents exceeding 900 mA, surface temperatures of a-C coatings exceeded 100 °C, impairing graphene's ability to maintain low friction, resulting in an increased COF.

Effect of Various Carbon Coating Techniques on the Electrochemical Performance of Li4Ti5O12 Synthesized by Sol-Gel Method

This study aimed to prepare spinel carbon-coated Li4Ti5O12 (LTO/C) via sol-gel reaction and applied as a high-performance lithium-ion battery anode. The LTO powder was coated using various carbon sources, super P (SP), sugar and PVDF-assisted SP. The crystal structure, morphology, conductivity and electrochemical performance of the samples were examined using X-ray diffraction (XRD), Field Emission scanning electron microscopy (FESEM), Fourier Transform Infrared (FTIR) spectroscopy, Electrochemical Impedance Spectroscopy (EIS) and Cyclic Voltammetry/Charge-discharge (CV/CD), respectively. The XRD analysis results showed that the samples contain highly crystalline spinel LTO as the main phase and rutile as impurity. The FESEM image showed that SP covers the entire LTO surface more homogenous than sugar. However, sugar carbon makes roughness on the LTO surface. FTIR spectra showed that the coating using sugar and PVDF still contain hydrocarbon element. Electrochemical performance evaluations showed that SP carbon-coated-LTO possesses higher lithium diffusion and specific capacity than pure LTO, while sugar-coated-LTO shows the lowest specific capacity. Moreover, the SP carbon-coated-LTO sample high-rate capability has improved during full cell evaluation, delivering a discharge capacity of 249, 231, 211, 194, 58, and 23 mAhg-1 at the charge or discharge current density of 0.05, 0.1, 0.5, 1, 5, and 10 C, respectively.

Understanding Selectivity in Product Distributions from Laser Ablation of Organic Liquids.

Pulsed laser ablation in organic solvents is widely used to produce oxide-free metal and metal carbide nanoparticles, often with carbon coatings resulting from laser-induced reactions in the organic solvent. To gain insight into how the molecular structure of the solvent affects these reaction pathways, this work investigates ablation of the C6H14 isomers n-hexane, 2-methylpentane, and 3-methylpentane through characterization of the gas and liquid products with mass spectrometry. Ablation of each C6H14 isomer produces a distinct distribution of product molecular weights and isomers. 2-methylpentane preferentially produces C3 and C9, whereas 3-methylpentane produces C2, C4, C8, and C10 products. These preferential product distributions, along with the lack of such selectivity in n-hexane, arise from differences in the most favorable C-C bond scission pathways in each C6H14 isomer. Moreover, the particular isomers of C8H18, C9H20, C10H22, and C12H26 produced by ablation of each C6H14 isomer indicate that the vast majority of reaction pathways involve addition reactions between a fragment radical and parent C6H14 or between two C6H14 molecules, without molecular rearrangement. This propensity toward direct addition suggests that the chemical reactions induced by ultrashort pulsed laser ablation proceed on faster time scales than those of radical rearrangements.

Surface Engineering of Ti6Al4V: Impact of Rhenium–Carbon Coatings with Molybdenum Anchors on Biocompatibility and Corrosion Behavior

Titanium alloys, particularly Ti6Al4V, are widely used in biomedical applications due to their excellent mechanical properties and inherent biocompatibility. However, enhancing their surface characteristics, such as biocompatibility and corrosion resistance, remains a key challenge for their long-term use in medical implants. In this study, we investigate the effects of rhenium–carbon coatings deposited on Ti6Al4V substrates via magnetron sputtering, incorporating a molybdenum anchoring layer. X-ray diffraction (XRD) and energy dispersive spectroscopy (EDS) analyses confirmed the formation of rhenium carbides, elemental rhenium, and rhenium oxides within the coatings. Despite these successful depositions, scanning electron microscopy (SEM) revealed significant delamination and poor adhesion of the coatings to the Ti6Al4V substrates. Corrosion resistance, evaluated through potentiodynamic polarization tests, showed an increase in corrosion current densities and more negative corrosion potentials, indicating a detrimental effect on the substrate’s corrosion resistance. Biocompatibility assessments using PK15 cells demonstrated a marked decrease in cell viability and metabolic activity, particularly in samples with higher surface roughness. These findings underscore the critical need for the optimization of surface preparation and deposition processes to improve both the adhesion and biocompatibility of rhenium–carbon coatings on Ti6Al4V substrates. Future research should aim to refine coating technique to enhance adhesion, explore the mechanisms of cytotoxicity related to surface roughness, and expand biocompatibility studies across different cell lines and biological environments.

Fluorine containing diamond-like carbon coatings

Fluorine containing diamond-like carbon (DLC) coatings were obtained by CVD deposition using the destruction of gaseous hydrocarbons by a high-energy ion source with an anode layer. The chemical composition, structure, surface energy, mechano-tribological characteristics of the synthesized thin-film material were studied. It has been shown that the fluorine content in the deposited coatings reaches 31 at.%. It has been established that the presence of fluorine in the DLC coating promotes the formation of nanodispersed graphite-like structures. Fluorine containing coatings with a high content of sp2 hybridized carbon atoms and graphite fragments show a decrease in hardness. Such coatings have a very low coefficient of friction at the level of 0.03–0.07 due to the low surface energy, which can be reduced by 1.5 times compared to pure DLC. It has been established that different fluorine contents in thin-film diamond-like carbon material have different effects on the interaction of the DLC coating with polar/non-polar dielectrics. The research results can be used for the technology of producing solid lubricants in friction units of machines and mechanisms, and are also of interest for medicine, the food industry, the production of plastics, and chemical fibers as chemically inert and corrosion-resistant coatings.

PVD Coatings for Lightweight Bipolar Plates

Bipolar plates are one of the main components of proton exchange membrane fuel cells (PEMFCs). Their functions include distributing reactants, supporting the cell, and conducting heat and electricity. They account for a significant proportion of the fuel cell stack’s weight and volume. The main materials currently used for bipolar plates are graphite and stainless steel. Aluminium has a much lower density than steel and is easier to form than both steel and graphite. Its use, therefore, would allow fuel cells with higher power densities but is hindered due to it being prone to corrosion. This work focused on the development of corrosion-resistant and conductive coatings to address this issue. Carbon coatings with Ti and Cr adhesion layers were deposited on aluminium substrates using closed-field unbalanced magnetron sputtering. These coatings were tested for corrosion properties and performance on the cathode side of a single-cell fuel cell. Coated aluminium samples were also tested for their ability to maintain their corrosion protection after being formed. Coating with a Cr adhesion layer outperformed that with a Ti adhesion layer in both forming and fuel cell tests, demonstrating much lower performance degradation after accelerated stress testing.

Nb-doped hydrogenated diamond-like carbon coated biodiesel injectors material: Synthesis, structure and properties

Despite the economic and environmental benefits of biodiesel, it poses significant challenges, including coking on metal surface and increased wear on diesel engine injector nozzles. Therefore, this study investigates the synthesis of niobium-doped diamond-like carbon (Nb-DLC) coatings on two types of injector nozzle materials (viz. H13 steel, AISI 420 stainless steel) using the Closed-Field Unbalanced Magnetron Sputtering (CFUBMS) technique. Comprehensive characterizations, including microstructural analysis, crystal structure evaluation, hardness assessment, and tribological property assessment, were conducted. The Nb-DLC coatings demonstrated a stable friction coefficient, with values four times lower than that of the substrate materials. The present findings demonstrate significant enhancements in terms of structural composition, crystalline phase, hardness, friction coefficients, and adhesion properties due to the Nb-DLC coatings. Therefore, Nb-DLC coated materials could be the promising candidate material for biodiesel engine injector nozzle applications. This emphasizes their potential to contribute significantly to the sustainable consolidation of biodiesel within automotive engine.

Synergistically Boosting Li Storage Performance of MnWO4 Nanorods Anode via Carbon Coating and Additives

Polyanionic structures, (MO4)n−, can be beneficial to the transport of lithium ions by virtue of the open three-dimensional frame structure. However, an unstable interface suppresses the life of the (MO4)n−-based anode. In this study, MnWO4@C nanorods with dense nanocavities have been synthesized through a hydrothermal route, followed by a chemical deposition method. As a result, the MnWO4@C anode exhibits better cycle and rate performance than MnWO4 as a Li-ion battery; the capacity is maintained at 718 mAh g−1 at 1000 mA g−1 after 400 cycles because the transport of lithium ions and the contribution of pseudo-capacitance are increased. Generally, benefiting from the carbon shell and electrolyte additive (e.g., FEC), the cycle performance of the MnWO4@C electrode is also effectively improved for lithium storage.

Deposition of Wear-Resistant Nanocomposite Coatings from Accelerated С<sub>60</sub> Ions

Hard wear-resistant carbon coatings were deposited from accelerated C60 ions at temperatures of 200 and 300°C. It has been established that the mechanical properties of the coatings are determined by the substrate temperature (Ts) and the energy composition of the beam. The hardness of coatings deposited from C+60 ions with an energy of 7 keV exceeds 50 GPa and is virtually independent of Ts. The presence of C602+ and C603+ with an energy of ~14 and 21 keV, respectively, in the beam leads to a result that is not typical for carbon coatings – the hardness increases by more than 1.3 times with an increase in Ts from 200 to 300°C (from 31.6 GPa to 41.6 GPa). In this case, according to Raman spectroscopy data, the size of graphite nanocrystals in the coating increases with temperature up to almost 2 nm. Coatings obtained under conditions of irradiation with C602+ and C603+ ions are characterized by minimal wear (1.5×10–8 mm3/N∙m, Ts = 200°C) and minimal friction coefficient (µ = 0.05 for Ts = 300°C). We attribute the unusual dependence of hardness on Ts and the improvement in the tribological properties of coatings to the formation of a composite structure based on a diamond-like matrix and graphite nanocrystals in this range of Ts.

Planification of amorphous carbon coatings via periodically transitional sp2/sp3 bonds to enhance cavitation erosion resistance

In the marine sector, hydraulic machinery suffers severe damage from cavitation erosion. Although amorphous carbon (a-C) coatings are an effective measure to enhance the cavitation erosion resistance (CER), their widespread application is hindered by their metastable nature characterized by internal stress. In this study, a planification strategy was employed via different sp2/sp3 distributions (including uniform ones with different sp2/sp3 levels and periodically transitional ones with different periods), aiming to construct a pure a-C coating that enhances CER on 316L stainless steel by modulating the bias during magnetron sputtering. The effects of the sp2/sp3 distributions on the microstructure, chemical bonding, adhesion strength, fracture toughness, corrosion resistance and CER was investigated and compared with the coatings featuring uniform sp2/sp3 distributions. The results show that the periodic-mode coatings exhibit much higher CER due to their lower internal stress, excellent adhesion strength, enhanced fracture toughness and high corrosion resistance. After the cavitation erosion test for 4 h, the periodic-mode coatings only show striped structures without any coating delamination, along with less graphitization tendency during cavitation erosion. Hence, the design approach of periodic sp2/sp3 carbon bonds provides a promising new direction for marine equipment with improved CER and potential applications in various other environments.

Influence of the Metallic Sublayer on Corrosion Resistance in Hanks' Solution of 316L Stainless Steel Coated with Diamond-like Carbon.

The purpose of the study was to ascertain the corrosion resistance in Hanks' solution of Cr-Ni-Mo stainless steel (AISI 316L) coated with diamond-like carbon (DLC) coatings to establish its suitability for biomedical applications, e.g., as temporary implants. The influence of the carbon coating thickness as well as the correlated effect of the metallic sublayer type and defects present in DLC films on corrosion propagation were discussed. The results obtained were compared with findings on the adhesion of DLC to the steel substrate. The synthesis of carbon thin films with Cr and Ti adhesive sublayers was performed using a combined DC and a high-power-impulse vacuum-arc process. Evaluation of the corrosion resistance was carried out by means of potentiodynamic polarisation tests and scanning electron microscopy. Adhesive properties of the sublayer/DLC coating systems were measured using a scratch tester. It was found that systems with Ti sublayers were less susceptible to the corrosion processes, particularly to pitting. The best anti-corrosion properties were obtained by merging Ti with a DLC coating with a thickness equal to 0.5 μm. The protective properties of the Cr/DLC systems were independent of the carbon coating thickness. On the other hand, the DLC coatings with the Cr sublayer showed better adhesion to the substrate.

Diatom-Based Artificial Anode-Uniform Coating of Intrinsic Carbon to Enhance Lithium Storage.

Pursuing improved electrode materials is essential for addressing the challenges associated with large-scale Li-ion battery applications. Specifically, silicon oxide (SiOx) has emerged as a promising alternative to graphite anodes, despite issues related to volume expansion and rapid capacity degradation. In this study, we synthesized carbon-coated SiOx using diatom biomass derived from artificially cultured diatoms. However, the inherent carbon content from diatoms poses a significant challenge for the electrochemical performance of diatom-based anodes in large-scale applications. Subsequently, we conducted further research and demonstrated excellent performance with a carbon content of 33 wt.% as anodes. Additionally, real-time characterization of the carbonization process was achieved using thermogravimetry coupled with infrared spectroscopy and gas chromatography mass spectrometry (TG-FTIR-GCMS), revealing the emission of CO and C3O2 during carbonization. Furthermore, electrochemical tests of the processed diatom and carbon (PD@C) anode exhibited outstanding rate capability (~500 mAh g-1 at 2 A g-1), high initial Coulomb efficiency (76.95%), and a DLi+ diffusion rate of 1.03 × 10-12 cm2 s-1. Moreover, structural characterization techniques such as HRTEM-SAED were employed, along with DFT calculations, to demonstrate that the lithium storage process involves not only reversible transport in Li2Si2O5 and Li22Si5, but also physical adsorption between the PD and C layers. Exploring the integration of diatom frustules with the intrinsic carbon content in the fabrication of battery anodes may contribute to a deeper understanding of the mechanisms behind their successful application.