A specific revised HFCVD apparatus and a novel process combining HFCVD and polishing technique were presented to deposit the micro-and nano-crystalline multilayered ultra-smooth diamond (USCD) film on the interior-hole surface of WC-Co drawing dies with aperture ranging from d1.0 mm to 60 mm. Characterization results indicate that the surface roughness values (R-a) in the entry zone, drawing zone and bearing zone of as-fabricated USCD coated drawing die were measured as low as 25.7, 23.3 and 25.5 nm, respectively. Furthermore, the friction properties of USCD films were examined in both dry sliding and water-lubricating conditions, and the results show that the USCD film presents much superior friction properties. Its friction coefficients against ball-bearing steel, copper and silicon nitride balls (d4 mm), is always lower than that of microcrystalline diamond (MCD) or WC-Co sample, regardless of the lubricating condition. Meanwhile, it still presents competitive wear resistance with the MCD films. Finally, the working lifetime and performance of as-fabricated USCD coated drawing dies were examined under producing low-carbon steel pipes in dry-sliding and water-lubricating conditions. Under the water-lubricating drawing condition, its production significantly increases by about 20 times compared with the conventional WC-Co drawing dies.
