Surface & Coatings Technology最新文献

{"title":"Deposition of high-velocity oxygen-fuel (HVOF) coatings on laser-powder bed fused (L-PBF) parts subjected to in-situ laser remelting treatments","authors":"Maria Francesca Bonilauri ,&nbsp;Matteo Perini ,&nbsp;Sasan Amirabdollahian ,&nbsp;Laura Paglia ,&nbsp;Giovanni Pulci ,&nbsp;Francesco Marra ,&nbsp;Edoardo M. Rossi ,&nbsp;Luca Lusvarghi ,&nbsp;Giovanni Bolelli","doi":"10.1016/j.surfcoat.2025.132250","DOIUrl":"10.1016/j.surfcoat.2025.132250","url":null,"abstract":"<div><div>In this work, we focused on enhancing the adhesion between High Velocity Oxygen-Fuel (HVOF) sprayed coatings and Laser-Powder Bed Fused (L-PBF) substrates by modifying the substrate surface through in-situ laser remelting treatments. Additionally, we investigated whether deposition on laser-treated substrates affected the coating microstructure and performance. Therefore, WC-10%Co-4%Cr coatings were deposited on AISI 316 L stainless steel substrates in as-built conditions and after two different in-situ laser remelting treatments. All substrates were coated both before and after a pickling treatment. Grit-blasted bulk stainless steel samples served as references.</div><div>Laser remelting changed the morphology of the L-PBF surfaces depending on the laser parameters used. The most energetic treatment resulted in more widely spaced grooves and melted the unmelted spherical particles attached to the as-built surface, leading to a more uniform material distribution. These changes influenced the adhesion-cohesion of the coatings. Although all tensile test failures were primarily cohesive, the coatings deposited on the substrates subjected to the most energetic treatment exhibited an increased adhesion-cohesion strength, exceeding 80 MPa, while all other samples showed values around 70 MPa.</div><div>When the substrate was subjected to remelting treatments, however, the corrosion resistance of the coated systems decreased due to faster substrate corrosion in areas exposed to corrosive agents penetrating through coating defects.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"510 ","pages":"Article 132250"},"PeriodicalIF":5.3,"publicationDate":"2025-05-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143921623","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Microstructural evolution and deposition mechanism of cold-sprayed Cr coatings on the Al and Ti substrates","authors":"Wenpeng Wan,&nbsp;Zhe Zhan,&nbsp;Chunjie Huang,&nbsp;Jingwen Yang,&nbsp;Wenya Li","doi":"10.1016/j.surfcoat.2025.132251","DOIUrl":"10.1016/j.surfcoat.2025.132251","url":null,"abstract":"<div><div>Microstructural evolution and nanoindentation analyses were employed to investigate the deposition behavior of Cr particles on the Al and Ti substrates during cold spraying. The results indicate that substrate nanohardness plays an important role in determining both the thickness of the Cr coating and the bonding mechanism between the Cr particles and the substrates. In the initial coating layer, the rigid Cr particles are mechanically embedded into the softer Al substrate with minimal deformation, resulting in a dense and continuous coating composed of a few deformed particles. In contrast, deposition on the harder Ti substrate induces coordinated plastic deformation between the Cr particles and the substrate with mechanical interlocking; however, the resulting coating is discontinuous, exhibiting a thickness equivalent to a single deposited particle. The primary limitation in further increasing coating thickness arises during the stage of interaction between subsequent particles and the pre-deposited coating. Here, the uneven surface of the deposited layer reduces the effective impact velocity of incoming particles and, coupled with continuous work hardening, prevents synergistic plastic deformation with subsequent particles. Based on the observations of microstructural evolution and nanohardness distribution, the hypothesis regarding the formation mechanism of Cr coatings on the Al and Ti substrates is proposed.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"510 ","pages":"Article 132251"},"PeriodicalIF":5.3,"publicationDate":"2025-05-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143921620","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Super-hard yet tough and self-lubricating (TiZrHfNbTa)CxNy high entropy carbonitride films deposited by magnetron sputtering","authors":"Zhiying Lv ,&nbsp;Hongshu Jin ,&nbsp;Fanyong Zhang ,&nbsp;Ruibin Zhao ,&nbsp;Senlong He ,&nbsp;Fuxing Yin","doi":"10.1016/j.surfcoat.2025.132241","DOIUrl":"10.1016/j.surfcoat.2025.132241","url":null,"abstract":"<div><div>Traditional carbide or nitride films possess hardness and wear resistance but lack ideal toughness. C<img>N co-doped high-entropy alloys can achieve a good hardness-toughness combination. In this study, (TiZrHfNbTa)C_xN_y films (HECN) were deposited via reactive magnetron sputtering. With increasing R_N, N content rose to 39 at.%, and C content decreased and stabilized at 25 at.%. At R_N = 6.5 % and 13 %, C/N and Me/(C + N) ratios were approximately 1:1. HECN films transform from amorphous to FCC nano-crystallization with (111) orientation. At R_N = 13 %, super-hardness of 39.9 GPa and excellent fracture toughness (&gt;1.92 MPa·m^1/2) was achieved. Due to tribo-induced C-enrichment, the film showed self-lubrication with a low wear rate (1.3 × 10^-6 mm³/Nm) and a friction coefficient (0.15–0.2).</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"510 ","pages":"Article 132241"},"PeriodicalIF":5.3,"publicationDate":"2025-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143921622","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of substrate variables on the interface fracture energy of thermal spray coatings","authors":"Saim Abbas ,&nbsp;Sanjay Sampath ,&nbsp;Sudhanshu Mallick ,&nbsp;B. Nagamani Jaya","doi":"10.1016/j.surfcoat.2025.132237","DOIUrl":"10.1016/j.surfcoat.2025.132237","url":null,"abstract":"<div><div>The effects of substrate material, substrate roughness and substrate thickness on the interface fracture energy (<em>G</em>_<em>C</em>) of thermal spray coating/metallic substrate interfaces are determined. Air Plasma Sprayed (APS) coatings of Yttria Stabilized Zirconia (YSZ) and Alumina, as well as NiCrAlY are investigated with different substrate materials (stainless steel-SS, mild steel-MS), roughness and thickness. Modified cantilever beam bending with Digital Image Correlation (DIC) based tracking of crack length is used for high-throughput measurements. A 46 % increase in <em>G</em>_<em>C</em> is seen due to an increase of 73 % substrate roughness (<em>R</em>_<em>a</em>) of substrate for YSZ/SS, while a 60 % increase in <em>G</em>_<em>C</em> is seen due to an increase in 166 % <em>R</em>_<em>a</em> of substrate for Alumina/MS system. Interface fracture energy <em>G</em>_<em>C</em> of YSZ/MS is found to be ∼75 <em>J/m</em>^<em>2</em>, compared to ∼50 <em>J/m</em>^<em>2</em> for the Alumina/MS for similar coating/substrate thickness as well as substrate roughness. For the same coating type and thickness of YSZ, <em>G</em>_<em>C</em> decreased to 60 <em>J/m</em>^<em>2</em> when the substrate was changed to SS, even with an increase in <em>R</em>_<em>a</em>. This could be attributed to the significant effect of residual stress, originating from thermal expansion mismatch, with higher compressive residual stresses increasing the propensity for interfacial delamination. There is no effect of substrate thickness on <em>G</em>_<em>C</em>, independent of whether the substrate is machined before or after the deposition. Mechanisms of these changes are discussed in the context of total interface fracture area and crack closure stresses.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"510 ","pages":"Article 132237"},"PeriodicalIF":5.3,"publicationDate":"2025-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143907912","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Microstructure and oxidation behavior of the aluminized coating on K447A nickel-based superalloy prepared by AlF3-activated pack cementation","authors":"Yuhang Zhao ,&nbsp;Kai Zhou ,&nbsp;Xin Xin ,&nbsp;Xijun Zeng ,&nbsp;Xiping Guo ,&nbsp;Yanqiang Qiao","doi":"10.1016/j.surfcoat.2025.132236","DOIUrl":"10.1016/j.surfcoat.2025.132236","url":null,"abstract":"<div><div>The function of AlF₃ activator, the aluminized coating formation mechanism on K447A nickel-based superalloy during the pack cementation process, and their oxidation behaviors have been systematically investigated. Comprehensive characterization by XRD, SEM, TEM and EDS analyses with HSC thermochemical calculation reveals four key findings: AlF₃ demonstrates the optimal aluminizing capability and generates active Al atoms via the disproportionation reaction of AlF gas. The aluminized coating exhibits a multilayer structure, with the outer layer composed of high Al content Ni₂Al₃ or NiAl₃ and the inner layer consisting of NiAl. Precipitated phases such as α-(Cr, W), σ phase, and carbides are distributed in the aluminides, confirming an Al-dominated inward diffusion mechanism characteristic of a “high-activity” process. The coating thickness exhibits linear relationships to the reciprocal of temperature and holding time. Ni₂Al₃ is formed before NiAl, transforms into NiAl, and then is regenerated. After oxidizing at 1150 °C for 100 h, a protective ridged α-Al₂O₃ scale forms on the aluminide coating, effectively shielding the substrate.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"510 ","pages":"Article 132236"},"PeriodicalIF":5.3,"publicationDate":"2025-05-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143921621","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Achieving a self-densified conversion coating architecture by the bath composition design towards a multi-step nucleation pathway","authors":"Siyu Sun ,&nbsp;Yuxin Zhang ,&nbsp;Jiaxi Liu ,&nbsp;Ruoyun Lei ,&nbsp;Peng Zhou ,&nbsp;Fuhui Wang ,&nbsp;Li Xin ,&nbsp;Tao Zhang","doi":"10.1016/j.surfcoat.2025.132225","DOIUrl":"10.1016/j.surfcoat.2025.132225","url":null,"abstract":"<div><div>Achieving a self-densified conversion coating on magnesium alloy is the ultimate goal for a prolonged service life. Such a goal should be achieved by modulating the nucleation process, which poses the greatest challenge. In this work, a new designing rationale for the conversion bath was proposed to facilitate a multi-step nucleation process by thermodynamic calculations, thereby reducing coating defects and improving corrosion resistance. The selection of cation candidates should comply with the following rules: firstly, the solubility product (<em>K</em>_sp) value should be low enough for precipitation; secondary, the <em>K</em>_sp values among different species should not deviate significantly from each other. The phosphate conversion bath was used as an example to validate the idea. Results demonstrate that a self-densified conversion coating architecture when Mn- and Ca-containing salt were simultaneously added. The coating exhibits both excellent protectiveness and durable wet adhesive strength. This work offers a new perspective concerning the design of the conversion bath with optimal protectiveness.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"510 ","pages":"Article 132225"},"PeriodicalIF":5.3,"publicationDate":"2025-05-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143921619","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Cold-sprayed Cu-WC/Cu/Cu-Ni@W multilayer deposits for high-quality repair of Cu alloy electromagnetic rails","authors":"JianYu Liu,&nbsp;Qiao Liu,&nbsp;XiaoTao Luo,&nbsp;ChangJiu Li","doi":"10.1016/j.surfcoat.2025.132233","DOIUrl":"10.1016/j.surfcoat.2025.132233","url":null,"abstract":"<div><div>In electromagnetic launch systems, the harsh service conditions coupling of electrical arc erosion, high temperature friction and high frequency of thermal shock make the surface of the high strength Cu alloy rail easily damaged. The conventional high-strength alloy repair layer faces challenges in balancing electrical conductivity with wear and arc erosion resistance. Addressing this challenge, in the present work, a novel multilayered repairing strategy is introduced by cold spraying pure Cu and Cu-based composite deposits for synergistically improving/balancing the adhesion, electrical conductivity and surface protection performance. The effects of the multilayered deposit structure design, strengthening particle surface modification, and heat treatment on adhesion, electrical conductivity, wear and arc erosion resistance of the deposits are investigated. An optimized multilayered structure composed of a Cu-WC bond coat, a pure Cu middle layer and a composite top layer deposited with Cu-Ni-clad W (Ni@W) powder is achieved. As compared with spraying pure Cu, an increase in adhesion from 14 MPa to 66 MPa is achieved via introducing Cu-WC composite bond coat on the CuCrZr substrate. For the top composite layer, as the Ni@W particles are used to strengthen pure Cu, the friction coefficient and wear rate decreases from 0.37 and 3.2 × 10⁻⁵ mm³·(N·m)⁻¹ to 0.14 and 2.3 × 10⁻⁵ mm³·(N·m)⁻¹, respectively, and the arc erosion depth and area decreased by 31.1 % and 81.0 % with the breakdown intensity improved by 50.6 % relative to the CuCrZr substrate. Meanwhile, a high electrical conductivity of 77.7 %IACS through the thickness direction is detected for the optimized multilayered deposit. Finally, a practical repair demonstration done on V-grooved CuCrZr substrates confirms the structural integrity and machinability of the cold sprayed multilayer composite deposit. The present work is attempted to offer a viable solution for improve the service performance and extending the service life of the metallic structures used in coupled harsh conditions.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"510 ","pages":"Article 132233"},"PeriodicalIF":5.3,"publicationDate":"2025-05-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143907909","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Oxidation and failure mechanisms of CoCrFeNiMo HEA coatings at 1000 °C: Insights into TGO evolution and interface diffusion","authors":"Weilun Deng ,&nbsp;Shengwei Wang ,&nbsp;Tianyi Zhang ,&nbsp;Jianlei Zhang ,&nbsp;Qijie Zhai ,&nbsp;Changsheng Zhai ,&nbsp;Hongxing Zheng","doi":"10.1016/j.surfcoat.2025.132229","DOIUrl":"10.1016/j.surfcoat.2025.132229","url":null,"abstract":"<div><div>This study investigates the oxidation behavior and failure mechanisms of CoCrFeNiMo high-entropy alloy (HEA) coatings fabricated <em>via</em> high-velocity oxygen fuel (HVOF) spraying and high-frequency induction remelting. At 1000 °C, the thermally grown oxide (TGO) developed a dual-layer structure: a dense Cr₂O₃ inner layer, formed by Cr³⁺ and O²⁻ diffusion, and an outer layer of Cr-, Fe-, and Mo-rich composite oxides driven by oxygen ion diffusion. After 5 h of exposure, the TGO reached 30 μm with initial crack formation, while after 200 h, it exceeded 50 μm, showing severe outer-layer degradation due to internal stress, crack propagation, and void formation. Fe/Mo interdiffusion at the coating-steel substrate interface promoted Fe₆₃Mo₃₇ R-phase formation. Electron backscatter diffraction (EBSD) analysis revealed refined grains, twinning, and recrystallization within the coating, enhancing high-temperature stability. These findings offer insights into the oxidation and failure mechanisms of CoCrFeNiMo HEA coatings, supporting their optimization for extreme high-temperature applications.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"509 ","pages":"Article 132229"},"PeriodicalIF":5.3,"publicationDate":"2025-05-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143898924","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Water‑oxygen corrosion and thermal shock behavior of a single-layer Yb-Al-Si-O glass-ceramics environmental barrier coating on SiCf/SiC at 1350 °C","authors":"Xinyu Meng ,&nbsp;Chenxi Liang ,&nbsp;Chun Guo ,&nbsp;Shaobo Yang ,&nbsp;Yujie Ma ,&nbsp;Bo Chen ,&nbsp;Juanli Deng ,&nbsp;Shangwu Fan","doi":"10.1016/j.surfcoat.2025.132228","DOIUrl":"10.1016/j.surfcoat.2025.132228","url":null,"abstract":"<div><div>High-density and high-strength SiC_f/SiC composites were obtained utilizing CaO-Yb₂O₃-Al₂O₃-SiO₂ (CYbAS) glass-ceramics for matrix modification, alongside Yb₂O₃-Al₂O₃-SiO₂ (YbAS) glass-ceramics for environmental barrier coating (EBC). The durability of the single-layer YbAS coating was evaluated by assessing its resistance to water‑oxygen corrosion and thermal shock, in order to ascertain its potential as an advanced EBC. The results indicated that the YbAS coating significantly reduced the growth rate of thermally grown oxide (TGO) in a 50 vol% H₂O-50 vol% O₂ environment at 1350 °C. Additionally, a water-cooled thermal shock test conducted in air at 1350 °C revealed no evidence of penetrative cracks or TGO formation within the coating. These results underscore the potential application of YbAS coating in high-temperature corrosive environments.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"509 ","pages":"Article 132228"},"PeriodicalIF":5.3,"publicationDate":"2025-05-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143902449","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation on the growth mechanism and properties of AO-PEO composite coating on 304 stainless steel prepared by two-step process","authors":"Hongkang Pan ,&nbsp;Hailin Lu ,&nbsp;Zhengwen Zhang ,&nbsp;Zhanshuai Fan ,&nbsp;Zihan Liu ,&nbsp;Shuangshuang Zhi","doi":"10.1016/j.surfcoat.2025.132230","DOIUrl":"10.1016/j.surfcoat.2025.132230","url":null,"abstract":"<div><div>Plasma electrolytic oxidation (PEO) technology is an effective means to improve the surface performance of metal parts, but this method is not suitable for non-valve metal 304 stainless steel. Because 304 stainless steel contains a large amount of Cr element, it will hinder the rise of voltage during the PEO process, thus causing the PEO process to fail. In order to achieve PEO on 304 stainless steel, anodic oxidation (AO) was used as a pretreatment in this study. The experimental outcomes display that compared to 304 stainless steel, after PEO treatment, the hardness of the sample enhanced by 139.32 %, the scratch width under 3 N and 5 N load conditions reduced by 46.47 % and 44.07 % respectively, and the corrosion current density i_corr reduced by two orders of magnitude. This study not only addressed the issue of applying PEO technology on the surface of 304 stainless steel, but also prepared a coating with outstanding friction and corrosion resistance. It provides a new method for improving the performance of 304 stainless steel in the future.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"509 ","pages":"Article 132230"},"PeriodicalIF":5.3,"publicationDate":"2025-05-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143902414","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}