The main problem I see is that you first have to understand the bonding in your layer. Why do you want bond two surface layers if within the coating possibly only van der Waals sources exist? The same is valid for the connection between coating and metal. 

I think that "within the coating" the carbon atoms are probably covalently bonded, like in graphite etc.  It's a relatively strong film by itself (doesn't fall apart or crack etc.).  Van der Waals forces don't appear to be strong enough for the metal/carbon bond, as they seem to delaminate pretty easily (eg. when submerged in liquids) - so i need to improve the bond strength, either via a chemical process that bonds the two, or a physical bonding process (eg. heat + pressure).

Hello Demis John,

My suggestion to create a good bond between carbon layers is by vacuum thermal treatment. The medium in the vacuum chamber to be regulated - the temperature of the heating and the carbon electrode being sprayed at a certain rate so as to create a barrier zone condition for the connection between the two graphite layers. Subsequently, it is possible to place the two materials on top of each other by means of a manipulator so as to create the necessary contact.

Wishing for success in scientific research.

Emil Yankov

Thanks Dr. Yankov,

I am trying this tonight, in this Karl Suss wafer bonding tool: https://www.nanotech.ucsb.edu/wiki/index.php/Wafer_Bonder_(SUSS_SB6-8E)

I'm trying it in a nitrogen environment to start.  I'm not sure what temperatures to go to, as I assume Carbon would require very high temps. due to the high C-C bond strength.

What do you mean by "barrier zone condition"? I couldn't find this in literature on wafer bonding. Do you mean in an inert gas environment?  Or do you mean to heat the samples *first* under inert gas, then apply pressure once they are at temperature, and then cool down while still under pressure?