Surface & Coatings Technology最新文献

Strategic PANI/silica surface functionalization of cenospheres for enhanced barrier performance in epoxy composite coatings for metals 战略性聚苯胺/二氧化硅微球表面功能化以增强环氧金属复合涂层的阻隔性能

IF 5.3 2区材料科学

Surface & Coatings Technology Pub Date : 2025-06-23 DOI: 10.1016/j.surfcoat.2025.132429

S.S. Ananthapadmanabhan, Smrutiranjan Parida

{"title":"Strategic PANI/silica surface functionalization of cenospheres for enhanced barrier performance in epoxy composite coatings for metals","authors":"S.S. Ananthapadmanabhan, Smrutiranjan Parida","doi":"10.1016/j.surfcoat.2025.132429","DOIUrl":"10.1016/j.surfcoat.2025.132429","url":null,"abstract":"<div><div>Cenosphere (CNS), a common type of modern industrial waste, which can be used as inorganic fillers to improve weathering and anti-corrosion applications in organic coatings. However, the anti-corrosion applications of CNS have not been very successful due to their high porosity and low interface binding with matrix, leading to poor anti-corrosion performance in coatings. Here we investigate various strategic surface modifications to overcome these limitations in the use of CNS in composite coatings. When CNS was surface modified with polyaniline (pCNS) and silica (sCNS), long-term consistent corrosion performance, high impact and adhesion performance were obtained even at a coating thickness of ∼65 μm. From electrochemical impedance spectroscopy study, thin composite coating with pCNS exhibited a five-order increase in coating resistance (∼10<sup>10</sup> Ω.cm<sup>2</sup>), and very high barrier properties, with ∼62 % less water uptake than the coatings with unmodified CNS. In the accelerated corrosion studies (ASTM <span><span>B117</span><svg><path></path></svg></span>), pCNS and sCNS coatings showed protection efficiencies of >92 % and 73 %, respectively. The epoxy-pCNS composite coating also showed exceptional mechanical properties, with a 62 % increase in adhesion strength and a 66 % increase in impact strength. The surface modifications chosen are strategic in that they can give electrostatic and passive protection along with barrier protection. Results show that these modifications successfully address the CNS limitations reported in literature, yielding an economical coating with sustainable, long-term anticorrosion performance. These strategies also convert the solid waste like CNS into a value-added material in coating formulation for metal corrosion protection.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"512 ","pages":"Article 132429"},"PeriodicalIF":5.3,"publicationDate":"2025-06-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144366108","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}

引用次数: 0

Regulation mechanism of graphene embedding depth on the mecha-nical and tribological properties of high-entropy alloy composite coatings 石墨烯埋深对高熵合金复合涂层力学和摩擦学性能的调控机理

IF 5.3 2区材料科学

Surface & Coatings Technology Pub Date : 2025-06-22 DOI: 10.1016/j.surfcoat.2025.132427

Shaocong Zhou , Yongchao Liang , Yuanwei Pu , Yu Zhou , Xiuzhen Tang , Lili Zhou , Qian Chen

{"title":"Regulation mechanism of graphene embedding depth on the mecha-nical and tribological properties of high-entropy alloy composite coatings","authors":"Shaocong Zhou , Yongchao Liang , Yuanwei Pu , Yu Zhou , Xiuzhen Tang , Lili Zhou , Qian Chen","doi":"10.1016/j.surfcoat.2025.132427","DOIUrl":"10.1016/j.surfcoat.2025.132427","url":null,"abstract":"<div><div>Incorporating graphene (Gr) into metallic matrices can enhance mechanical performance, yet its reinforcement efficiency strongly depends on spatial distribution, which remains insufficiently understood. This study employs molecular dynamics simulations to explore how different embedding depths (d) of Gr affect the nanoindentation and scratching behavior of CoNiCrFeMn high-entropy alloy (HEA) composites. The results show that Gr significantly increases the local hardness in the embedded region and alters the internal stiffness distribution of the alloy, thereby effectively regulating the plastic deformation and promoting rapid load dissipation. As the indentation load increases, the direct load-bearing capacity of Gr becomes the dominant factor contributing to the enhancement of indentation resistance. During scratching process, Gr embedding significantly reduces the friction force and exhibits depth-dependent wear resistance. An optimal depth of 20 Å achieves a 31.2 % reduction in friction coefficient and a 6.27 % decrease in wear atoms due to interfacial lubrication and elastic recovery. At 30 Å, the friction force reaches its minimum, and dislocation annihilation activity at the interface is significantly enhanced, contributing to improved fatigue resistance. These findings provide theoretical insight for designing and optimizing HEA-based composite coatings.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"512 ","pages":"Article 132427"},"PeriodicalIF":5.3,"publicationDate":"2025-06-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144366166","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}

引用次数: 0

Effect of Nb content on microstructure, corrosion and tribology properties of AlCrTiV high entropy alloy films Nb含量对AlCrTiV高熵合金薄膜组织、腐蚀和摩擦学性能的影响

IF 5.3 2区材料科学

Surface & Coatings Technology Pub Date : 2025-06-20 DOI: 10.1016/j.surfcoat.2025.132419

Sikai Mei , Lei Yan , Zhaobing Cai , Ying Liu , Bingxu Wang , Peng Li , Le Gu

{"title":"Effect of Nb content on microstructure, corrosion and tribology properties of AlCrTiV high entropy alloy films","authors":"Sikai Mei , Lei Yan , Zhaobing Cai , Ying Liu , Bingxu Wang , Peng Li , Le Gu","doi":"10.1016/j.surfcoat.2025.132419","DOIUrl":"10.1016/j.surfcoat.2025.132419","url":null,"abstract":"<div><div>The (AlCrTiV)<sub>1-x</sub>Nb<sub>x</sub> HEAF with varying Nb contents were prepared using a co-sputtering method that combined DC magnetron (constant power) and RF magnetron (variable power). This study primarily investigated the effects of different Nb contents on the microstructure, corrosion properties, and friction properties of the films. The results indicated that the films with varying Nb contents exhibited an amorphous structure characterized by a dense surface and uniform elemental distribution. As the Nb content increased, the cross-section displayed a columnar amorphous structure, while the surface roughness of the films initially decreased before increasing with the changing Nb content. The corrosion resistance of the thin film initially increases and then decreases with variations in Nb content, with the sample exhibiting optimal corrosion resistance at the Nb content of 32.1 %. The primary form of corrosion for the thin film is pitting, and passivation occurs on the film surface during the corrosion process. The Nb element influences the corrosion resistance of the thin film by altering the interaction mode of the O element. While the Nb content does not affect the friction coefficient of the thin film, the bonding force between the film and the substrate decreases with the addition of Nb, resulting in the film being worn through during the friction process. This may be attributed to changes in the deposition mode of the thin film caused by the introduction of RF sputtering, which leads to a decrease in the cohesion of the thin film.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"512 ","pages":"Article 132419"},"PeriodicalIF":5.3,"publicationDate":"2025-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144335947","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}

引用次数: 0

Bio-tribo-corrosion behavior of additively manufactured Co-Cr dental implant alloy 增材制造Co-Cr牙种植体合金的生物摩擦腐蚀行为

IF 5.3 2区材料科学

Surface & Coatings Technology Pub Date : 2025-06-20 DOI: 10.1016/j.surfcoat.2025.132422

N. Hashemi, Sh. Yahyavi, M. Moshkbar Bakhshayesh, F. Khodabakhshi, R. Mehdinavaz Aghdam

{"title":"Bio-tribo-corrosion behavior of additively manufactured Co-Cr dental implant alloy","authors":"N. Hashemi, Sh. Yahyavi, M. Moshkbar Bakhshayesh, F. Khodabakhshi, R. Mehdinavaz Aghdam","doi":"10.1016/j.surfcoat.2025.132422","DOIUrl":"10.1016/j.surfcoat.2025.132422","url":null,"abstract":"<div><div>A CoCr-based dental alloy was deposited upon layer built-ups through a laser-assisted directed energy deposition (L-DED) technique. Microstructural studies, including grain morphologies, crystallographic texture formation and nano planar defects were conducted utilizing advanced characterization techniques based on the scanning and transmission electron microscopies. Also, the biocompatibility and cell viability were evaluated with MG-63 cells via MTT assay and cell adhesion test. Additionally, mechanical properties of the deposited alloy, specifically hardness and wear resistance, were assessed through indentation micro-hardness measurements and tribological behavior examinations in simulated oral environments under different loading conditions. Finally, the resistance to corrosion was investigated in Ringer's solution by electrochemical techniques. Microstructural characterization revealed the formation of gradient structure along the building direction due to the combination of columnar/equiaxed dendritic morphologies upon rapid cooling, resulting in the generation of preferred 〈001〉 growth direction with a maximum misalignment of ~25° along scanning direction. In addition, the presence of dense stacking faults interacting with each other and carbides was identified as one of the key factors for strengthening, leading to a high average microhardness of 542 HV<sub>0.2</sub> and excellent wear resistance of around 4.2 × 10<sup>−5</sup> mm<sup>3</sup>/N.m when subjected to a 50 N load. The remarkable viability of ~94.6 % for MG-63 cells cultured on the surface for a week, together with excellent cell spreading and adhesion, indicated the absence of any cytotoxic response. The high polarization resistance of ~650 kΩ.cm<sup>−2</sup> in simulated oral medium owing to the development of a mixed oxide layer suggested that the fabricated CoCr-based alloy was suitable for dental applications.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"512 ","pages":"Article 132422"},"PeriodicalIF":5.3,"publicationDate":"2025-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144330330","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}

引用次数: 0

Self-healing superhydrophilic polyurea composite coating for durable oil/water separation 用于持久油水分离的自修复超亲水性聚脲复合涂层

IF 5.3 2区材料科学

Surface & Coatings Technology Pub Date : 2025-06-20 DOI: 10.1016/j.surfcoat.2025.132416

Jinlong Wu , Peng Wang , Yukun Tian , Shan Liang , Wenbiao Zhang , Xiaoyan He , Qianqian Li , Jianghua Du

{"title":"Self-healing superhydrophilic polyurea composite coating for durable oil/water separation","authors":"Jinlong Wu , Peng Wang , Yukun Tian , Shan Liang , Wenbiao Zhang , Xiaoyan He , Qianqian Li , Jianghua Du","doi":"10.1016/j.surfcoat.2025.132416","DOIUrl":"10.1016/j.surfcoat.2025.132416","url":null,"abstract":"<div><div>Oil/water separation membranes are prone to damage from environment, which limits their application in treating oily wastewater. Improving the durability of these membranes remains challenging. In this study, we incorporated robust polyurea (PU) into a coating. The structure of polyurea was modulated to introduce multiple hydrogen bonds and dynamic disulfide bonds, thus affording a polyurea coating with 90.53 % self-healing efficiency at 80 °C. The disulfide bonds imparted self-healing properties to the coating, while the multiple hydrogen bonds enhanced its stability. Phytic acid (PA), a natural product, and polyethyleneimine (PEI), a positronic compound, were synergistically combined with the polyurea coating to increased hydrophilicity through hydrogen bonding, coordination chelation, and electrostatic interactions. PEI/PA/SHPU@SSM was obtained by applying the composite coating to a stainless steel mesh surface. After 32 oil/water separation cycles, the self-healing group maintained a separation efficiency of 97.6 %, outperforming the non-self-healing group by 1.3 %. After 30 abrasion cycles, the underwater oil contact angle of the self-healing group was 147.1°, which was 6.5° higher than that of the non-self-healing group. The results highlight the effectiveness of the self-healing in enhancing the oil/water separation durability of PEI/PA/SHPU@SSM. This study offers new insights for improving the durability of superhydrophilic coating materials.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"512 ","pages":"Article 132416"},"PeriodicalIF":5.3,"publicationDate":"2025-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144338473","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}

引用次数: 0

Ag-containing refractory metal high-entropy nitride coatings with enhanced hardness, corrosion resistance, and antibacterial performance 含银难熔金属高熵氮化物涂层，具有硬度、耐腐蚀性和抗菌性能

IF 5.3 2区材料科学

Surface & Coatings Technology Pub Date : 2025-06-19 DOI: 10.1016/j.surfcoat.2025.132420

Chuanyao Dong , Zhixuan Mu , Yiwei Li , Linhe Lv , Xinlei Gu , Junhan Yao , Xingfu Bao , Xiaoxi Wei , Kan Zhang

{"title":"Ag-containing refractory metal high-entropy nitride coatings with enhanced hardness, corrosion resistance, and antibacterial performance","authors":"Chuanyao Dong , Zhixuan Mu , Yiwei Li , Linhe Lv , Xinlei Gu , Junhan Yao , Xingfu Bao , Xiaoxi Wei , Kan Zhang","doi":"10.1016/j.surfcoat.2025.132420","DOIUrl":"10.1016/j.surfcoat.2025.132420","url":null,"abstract":"<div><div>Artificial temporomandibular joint (TMJ) replacement surgery effectively restores function and relieves pain in severe joint disorders. However, the complex physiological environment of the TMJ presents significant challenges, including persistent interfacial friction, severe corrosion, and bacterial adhesion, which critically limit implant longevity. This study introduces Ag into refractory metal nitrides based on the concept of high-entropy engineering, successfully synthesizing a stable single-phase solid solution (TiZrNbHfTaAg)N coating with 5.7 at.% Ag. This Ag-containing high-entropy coating exhibits excellent spontaneous oxidation capabilities, significantly enhancing antibacterial performance (antibacterial rate = 90.9 %) compared to both the Ag-free (TiZrNbHfTa)N coating and the Ag-agglomerated (TiZrNbHfTaAg)N/Ag coating. Furthermore, the high-entropy engineering approach mitigates the common issue of Ag agglomeration, which often compromises mechanical integrity and corrosion resistance of coatings. The solution strengthening effect substantially improves the mechanical properties (hardness = 26.06 ± 1.01 GPa) and wear resistance (wear rate = 1.83 × 10<sup>−6</sup> mm<sup>3</sup>/Nm) of the (TiZrNbHfTaAg)N coating. Additionally, the (TiZrNbHfTaAg)N coating also demonstrates excellent corrosion resistance, with a corrosion current density of 1.2 × 10<sup>−7</sup> A/cm<sup>2</sup>. This innovative coating design effectively addresses the inherent limitations of current TMJ implants, providing a balanced enhancement of antibacterial performance, mechanical strength, and longevity, thereby advancing protective strategies for artificial joint implants.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"512 ","pages":"Article 132420"},"PeriodicalIF":5.3,"publicationDate":"2025-06-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144330329","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}

引用次数: 0

Fabrication of nanoporous doped metal oxide coatings via selective infiltration of a block copolymer template: The case of Al-doped zinc oxide 通过选择性渗透嵌段共聚物模板制备纳米多孔掺杂金属氧化物涂层：以掺铝氧化锌为例

IF 5.3 2区材料科学

Surface & Coatings Technology Pub Date : 2025-06-19 DOI: 10.1016/j.surfcoat.2025.132418

Vasanta Gurung , Khalil D. Omotosho , Oluwatosin Obe , Elena Shevchenko , Diana Berman

{"title":"Fabrication of nanoporous doped metal oxide coatings via selective infiltration of a block copolymer template: The case of Al-doped zinc oxide","authors":"Vasanta Gurung , Khalil D. Omotosho , Oluwatosin Obe , Elena Shevchenko , Diana Berman","doi":"10.1016/j.surfcoat.2025.132418","DOIUrl":"10.1016/j.surfcoat.2025.132418","url":null,"abstract":"<div><div>Conductive nanoporous conformal coatings are important for various applications including touchscreens, displays, and electrochromic windows, though design of such coating with controlled porosity and composition remains challenging. We propose a sequential infiltration synthesis (SIS) method for the fabrication of nanoporous conductive aluminum-doped zinc oxide (AZO) films by infiltrating block copolymer (BCP) templates, specifically polystyrene-<em>block</em>-polyvinyl pyridine (PS-b-P4VP), with diethyl zinc and trimethyl aluminum precursors. Tunability of both porosity and electrical conductivity is achieved by precisely controlling the swelling behavior of the polymer templates and adjusting the number of SIS cycles. Our results reveal that porosity levels can reach up to 80 %, with resistivity as low as ~7.83 Ωcm. Using conductive atomic force microscopy (C-AFM) and Hall effect measurements, we show that lower concentrations of aluminum doping relative to zinc (around 1: 17) results in higher conductivity of the AZO films. Additionally, AZO is based on zinc oxide (ZnO) which is cost-efficient, abundant and less toxic than commonly used transparent conductive oxides such as indium tin oxide (ITO) and fluorine-doped tin oxide (FTO). Therefore, this novel approach opens new possibilities for creating highly porous, conformal, conductive AZO coatings with customizable porosity and composition, making them ideal candidates for diverse optoelectronic applications.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"512 ","pages":"Article 132418"},"PeriodicalIF":5.3,"publicationDate":"2025-06-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144366165","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}

引用次数: 0

Microstructure and tribological properties of (AlCrTiV)Nx high-entropy alloy films prepared by magnetron sputtering 磁控溅射制备（AlCrTiV）Nx高熵合金薄膜的显微组织和摩擦学性能

IF 5.3 2区材料科学

Surface & Coatings Technology Pub Date : 2025-06-19 DOI: 10.1016/j.surfcoat.2025.132406

Lei Yan , Sikai Mei , Zhaobing Cai , Ying Liu , Bingxu Wang , Le Gu

{"title":"Microstructure and tribological properties of (AlCrTiV)Nx high-entropy alloy films prepared by magnetron sputtering","authors":"Lei Yan , Sikai Mei , Zhaobing Cai , Ying Liu , Bingxu Wang , Le Gu","doi":"10.1016/j.surfcoat.2025.132406","DOIUrl":"10.1016/j.surfcoat.2025.132406","url":null,"abstract":"<div><div>High-entropy alloy (HEA) films of (AlCrTiV)N<sub>x</sub> with varying N content were deposited on 316 substrates using magnetron sputtering technology. The aim is to examine the influence of N content on the microstructure, mechanical properties, and tribological performance of the films. Results reveal that the introduction of N facilitates the transformation of the films from an amorphous state to a single FCC phase structure. As the N<sub>2</sub> flow rate increases, a columnar crystal structure emerges in the film cross-section, accompanied by a decrease in film thickness and a reduction in grain size. During the experimentation, the four metal elements (Al, Cr, Ti, V) combine with N to form quaternary nitrides (Al, Cr, Ti, V)N, which alter the surface morphology and quality of the films, resulting in increased surface roughness. Following the introduction of N, the hardness and elastic modulus of the films are enhanced; however, both properties exhibit an overall decreasing trend with rising N content. The maximum values, recorded at the N<sub>2</sub> flow rate of 2 sccm, are 14.6 GPa for hardness and 298.5 GPa for elastic modulus. At this flow rate, the friction coefficient is 0.257, while the wear rate reaches its minimum value of 3.5 × 10<sup>−6</sup> mm<sup>3</sup>/N·m, indicating optimal anti-friction and wear resistance performance. As the N<sub>2</sub> flow rate increases, the wear mechanism transitions from oxidative wear to a combination of oxidative and abrasive wear. Notably, Cr<sub>2</sub>O<sub>3</sub> constitutes the largest proportion of the wear debris products, attributable to its strong oxidation properties.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"512 ","pages":"Article 132406"},"PeriodicalIF":5.3,"publicationDate":"2025-06-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144366163","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}

引用次数: 0

High velocity air fuel-sprayed thick composite coatings for sustainable refurbishment of engineering components: A viable alternative to hard chrome plating 用于工程部件可持续翻新的高速空气燃料喷涂厚复合涂层：硬镀铬的可行替代方案

IF 5.3 2区材料科学

Surface & Coatings Technology Pub Date : 2025-06-18 DOI: 10.1016/j.surfcoat.2025.132410

Swarna Madugula , G. Sivakumar , Rahul Jude Alroy , Adepu Kumar , S.M. Shariff

{"title":"High velocity air fuel-sprayed thick composite coatings for sustainable refurbishment of engineering components: A viable alternative to hard chrome plating","authors":"Swarna Madugula , G. Sivakumar , Rahul Jude Alroy , Adepu Kumar , S.M. Shariff","doi":"10.1016/j.surfcoat.2025.132410","DOIUrl":"10.1016/j.surfcoat.2025.132410","url":null,"abstract":"<div><div>Electrolytic hard chrome (EHC) plating has traditionally been the preferred technique for surface modification and dimensional restoration for rotary shafts used in turbines, pumps, bearing assemblies, and couplings, due to its excellent wear, corrosion, and oxidation resistance. However, the generation of toxic hexavalent Cr<sup>6+</sup> ions during the plating process poses significant environmental and health hazards, prompting the need for sustainable alternatives. In this context, thermal spray technologies, particularly the high-velocity air-fuel (HVAF) spray, have gained attention as a viable substitute to EHC, offering dense, low porosity coatings with minimal in-flight oxidation and excellent mechanical performance. The study focuses on depositing four feedstock powders of NiCr, SS316L, NiCrBSiFeC, and Tribaloy-400 on Ni-Cr-Mo alloy steel to produce a 1-mm-thick coating employing the HVAF technique. The coatings were evaluated through ball-on-disc sliding wear tests under varied loads, followed by detailed FE-SEM, XRD, and EDAX analysis. Results revealed that the Tribaloy-400 coating exhibited superior wear resistance, with a wear rate of 3.06338E-6 mm<sup>3</sup>/N · m, outperforming EHC plating (4.19325E-6 mm<sup>3</sup>/N · m) by 1.5 times under accelerated loading conditions. The enhancement is attributed to the presence of hard intermetallic lave phases (Co<sub>x</sub>Mo<sub>y</sub> and Co<sub>x</sub>Mo<sub>y</sub>Si), which reinforce the metal-matrix composite coating, and significantly improve the sliding wear resistance. The findings establish HVAF sprayed Tribaloy-400 as a sustainable alternative to EHC plating for the refurbishment of industrial shafts operating under demanding conditions.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"512 ","pages":"Article 132410"},"PeriodicalIF":5.3,"publicationDate":"2025-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144338370","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}

引用次数: 0

Optimization of laser cladding parameters for Y2O3-reinforced CoCrNi medium-entropy alloy coatings with enhanced high-temperature wear and corrosion resistance y2o3增强CoCrNi中熵合金高温耐磨耐蚀激光熔覆工艺参数优化

IF 5.3 2区材料科学

Surface & Coatings Technology Pub Date : 2025-06-18 DOI: 10.1016/j.surfcoat.2025.132412

Minsheng Hong, Ruifeng Li, Xiaolin Bi, Danlin Shao, Bin Liu

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