Surface & Coatings Technology最新文献

{"title":"Effects of in-situ synthesized carbides on microstructure and properties of FeCoCrNiMo0.2 / graphene composite coatings via laser cladding","authors":"Long Huang ,&nbsp;Tongxin Wang ,&nbsp;Huakai Mao ,&nbsp;Mengzhao Li ,&nbsp;Senao Gao ,&nbsp;Chang Cui ,&nbsp;Guodong Zhang ,&nbsp;Qiang Fu","doi":"10.1016/j.surfcoat.2025.132707","DOIUrl":"10.1016/j.surfcoat.2025.132707","url":null,"abstract":"<div><div>The FeCoCrNiMo_0.2 high-entropy alloy exhibits excellent corrosion resistance due to its ability to suppress the precipitation of σ phase, thus possessing enormous application potential in the field of corrosion-resistant coatings. However, its insufficient mechanical properties limit its application scope. This study reports a method to reinforce FeCoCrNiMo_0.2 high-entropy alloy coatings by in-situ synthesizing M₂C-type carbides through the addition of graphene via laser cladding technology. As the graphene content increases, the microhardness of the composite coating gradually rises. At 0.8 wt% graphene content, the coating achieved a peak microhardness of 254.6 HV_0.5, representing a 21.1 % improvement over the HEA coating without graphene addition. Additionally, the wear resistance of the coating initially enhances, then decreases, and subsequently improves again with increasing graphene content. The optimal wear resistance occurred at 0.2 wt% graphene content, where wear volume decreased by 34.17 % compared with the HEA coating without graphene. However, the introduction of in-situ synthesized carbides compromises the integrity of the passive film and induces galvanic corrosion, leading to a gradual decline in corrosion resistance as graphene content increases. Notably, the coating with 0.2 wt% graphene maintained passive film integrity through repairable secondary passivation due to its fine carbide size. This work provides crucial insights into the mechanisms governing the influence of graphene-induced in-situ carbide synthesis on the microstructure and properties of HEA coatings.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"516 ","pages":"Article 132707"},"PeriodicalIF":6.1,"publicationDate":"2025-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145120078","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":"Fabrication of a super-hydrophobic sealing silane film with anti-corrosion, wear-resistant and self-cleaning properties via electrodeposition on a micro-arc oxidized aluminum alloy","authors":"Tianguan Wang ,&nbsp;Peng Xu ,&nbsp;Xinwei Wang ,&nbsp;Xinyu Zhao ,&nbsp;Chao Zhan ,&nbsp;Fangxin Zou ,&nbsp;Bo Zhang ,&nbsp;Guozhe Meng","doi":"10.1016/j.surfcoat.2025.132693","DOIUrl":"10.1016/j.surfcoat.2025.132693","url":null,"abstract":"<div><div>Micro-arc oxidation (MAO) has gained widespread adoption in aluminum alloy protection due to their remarkable corrosion resistance. Nevertheless, the inherent microporous defects of MAO layer persist in exposing the substrate to corrosive damage during operational conditions. While silane-based sealing techniques have emerged as a promising solution for these defects, their practical implementation still faces critical challenges including insufficient defect-filling capacity and compromised mechanical durability. The present work employs electrochemical-assisted method that selectively generates hydroxyl/hydroxide ions at microporous defect sites within the MAO layer. Such local alkalinization conditions enable the directed assembly of silane hydrolysis products, driving interfacial adhesion-condensation reactions to achieve in situ silane film deposition with spatial selectivity. The optimized sealing system demonstrates a 50 % improvement in long-term corrosion resistance (150 MΩ·cm²) compared to conventional impregnation methods, accompanied by significantly enhanced self-cleaning, wear-resistant property. This provides a solution for the multifunctional anti-corrosion, wear-resistant, self-cleaning of aluminum alloy surfaces.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"516 ","pages":"Article 132693"},"PeriodicalIF":6.1,"publicationDate":"2025-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145099092","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":"Optimizing the anti-erosion performance of ZrAlSiN coatings by adjusting nitrogen flow rate","authors":"Honghong Zhang ,&nbsp;Binyang Zhang ,&nbsp;Zeqing Li ,&nbsp;Luqing Cui ,&nbsp;Yonghua Chen ,&nbsp;Xin Cao ,&nbsp;Weifeng He","doi":"10.1016/j.surfcoat.2025.132699","DOIUrl":"10.1016/j.surfcoat.2025.132699","url":null,"abstract":"<div><div>To optimize the anti-erosion performance of ZrAlSiN coatings, a series of ZrAlSiN coatings were fabricated at different nitrogen flow rates by the means of magnetic filtered cathode vacuum arc technology. The effects of the nitrogen flow rate on the microstructure and mechanical properties of ZrAlSiN coatings were systematically investigated. Their sand erosion resistance and corresponding damage mechanisms were elaborately explored as well. The results showed that the increased nitrogen content in ZrAlSiN coatings promoted the crystallinity and the formation of metal nitrides. With increasing nitrogen flow rate, the hardness and residual stress of coatings increased initially and then decreased, while the adhesion strength displayed an opposite variation trend. Therein, the ZrAlSiN coating prepared at 100 sccm nitrogen flow rate exhibited the best sand erosion resistance due to the optimal combination of high hardness and adhesion strength, as well as appropriate residual stress. As the nitrogen flow rate increased, the erosion damage mechanism of ZrAlSiN coatings transformed from ductile to brittle characteristics. The N25 coating predominantly displayed ductile damage characteristics, including deformation, cutting and plough, while the N50, N75 and N100 coatings were more prone to brittle spalling as a result of the initiation and propagation of cracks.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"516 ","pages":"Article 132699"},"PeriodicalIF":6.1,"publicationDate":"2025-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145159394","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":"Study on the effect of electrolytic surface roughening of a stainless steel plate on the interfacial bonding strength of the stainless steel/aluminum clad plates by the cold roll bonding","authors":"Qingsong Bian ,&nbsp;Jun Liao ,&nbsp;Shijian Fa ,&nbsp;Weiming Liu ,&nbsp;Hongbo Pan ,&nbsp;Fabin Cao","doi":"10.1016/j.surfcoat.2025.132703","DOIUrl":"10.1016/j.surfcoat.2025.132703","url":null,"abstract":"<div><div>Traditional mechanical polishing, widely used for preparing stainless steel (SS)/aluminum clad plates, has long been plagued by uneven coarsening effect and inadequate interfacial adhesion, thereby failing to meet the demands of modern industrial development for high-performance SS/Al clad plates. To address this, electrolytic surface roughening was used as a substitute for conventional brush roughening in the pretreatment of stainless steel. The SS samples treated by electrolytic surface treatment were bonded to aluminum alloy through cold rolling under various cold rolling and annealing conditions. Stripping experiments, hardness testing, and microanalysis techniques were employed to investigate the characteristics of the interface traits of different samples. Results showed that electrolytic treatment combined with rolling preheating induced the formation of a brittle Face-hardened and carbon diffusion layer on the SS surface. The bond strength of the specimens initially increases and then decrease with increasing reduction ratio, peaking at a 20 % reduction. This trend was attributed to the combined effects of work hardening from rolling deformation and the embedding/fragmentation of brittle carbides into the aluminum alloy surface. Increasing the annealing temperature and time causes the bonding strength to firstly increase and then decrease, which is related to the combined effects of enhanced atomic interdiffusion and the formation of an intermetallic compound (IMC) layer. The optimal processing technique for SS/ Al clad plates produced by cold rolling is annealing at 500 °C for 2 h, followed by a single cold rolling pass with 20 % reduction. This process yields a bonding peel strength of up to 225 N/mm at the clad plate interface, which is 5 to 6 times higher values reported for SS/Al clad plates to date. Microstructural analysis confirms a dense, well-bonded interface with minimal cracks or fractures. Furthermore, the fracture surface exhibits abundant dimples of varying sizes, accompanied by only sparse IMC formation, further confirming the superior interfacial integrity of the optimized clad plates.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"516 ","pages":"Article 132703"},"PeriodicalIF":6.1,"publicationDate":"2025-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145269492","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":"A novel antioxidant strategy for low Al-containing Ni-Al alloys by deposition of a Cr precursor film","authors":"Hang Ding ,&nbsp;Jun Ye ,&nbsp;Xun He ,&nbsp;Song Tang ,&nbsp;Yun Xie ,&nbsp;Xiaoyong Shu ,&nbsp;Xiao Peng","doi":"10.1016/j.surfcoat.2025.132689","DOIUrl":"10.1016/j.surfcoat.2025.132689","url":null,"abstract":"<div><div>Based on classical Wagner's criteria, Ni-Al alloys are unable to establish a protective alumina scale if their Al concentration is lower than the critical value required (<span><math><msubsup><mi>N</mi><mi>Al</mi><mfenced><mn>1</mn></mfenced></msubsup></math></span>) for external alumina scale formation. However, this study presented that depositing a thin metallic Cr film on Ni-16Al alloy with a subcritical Al concentration promoted the transition from internal to external Al₂O₃ oxidation, converting the alloy from a NiO-former to an Al₂O₃-former and reducing oxidation rate by 80 %. More importantly, the newly grown Al₂O₃ layer was in stable alpha phase, providing better protection than the predominant metastable-Al₂O₃ layer formed by bare Ni-22Al alloy. This provides a novel strategy for designing advanced structural alloys with good combination of oxidation resistance and mechanical properties.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"516 ","pages":"Article 132689"},"PeriodicalIF":6.1,"publicationDate":"2025-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145120075","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 high-temperature molten oxides within in-flight droplet on the bonding formation mechanism between NiCrAlY splat and substrate","authors":"Yong-Sheng Zhu,&nbsp;Xin-Yuan Dong,&nbsp;Xiao-Tao Luo,&nbsp;Yan Wang,&nbsp;Chang-Jiu Li","doi":"10.1016/j.surfcoat.2025.132702","DOIUrl":"10.1016/j.surfcoat.2025.132702","url":null,"abstract":"<div><div>During metallic coating deposition by atmospheric plasma spraying (APS), air entrainment into the plasma jet inevitably leads to oxidation of the molten metallic droplets. The oxides formed in-flight accumulate within the metallic coating, which significantly degrades the performance of the coating compared to the bulk counterpart. It is widely believed that the in-flight oxidation behavior of metal droplets and the state of oxides on their surfaces are critical factors affecting the subsequent spreading behavior and bonding formation of the metal droplet on the substrate surface. In the present work, individual in-flight droplets were collected with liquid N₂ to investigate their in-flight oxidation and the oxide state on the droplet surfaces. The effect of in-flight oxidation on the bonding formation of NiCrAlY splats with the superalloy substrate was examined by the focus ion beam (FIB) technique and high-resolution transmission electron microscopy (TEM). Results reveal that the oxides formed during flight within the plasma jet primarily exist in two forms, including small-sized oxide nodules inside the particles and an oxide cap covering the particle surface. SEM examination of splat morphology shows that the high-temperature molten oxide cap is located in the tail of the NiCrAlY metal droplet when the droplet travels through the plasma jet. This oxide distribution pattern results in the metal droplet impacting the substrate first, followed by the deposition of the oxide on the metal splat surface. FIB analysis reveals that the molten oxides deposit on the NiCrAlY splat surfaces without affecting the interfacial bonding at the impact center between splats and substrate. However, these oxides cause entrapment at the periphery of the splats and hinder the bonding between the splats and the substrate. TEM evidence confirms that metallurgical bonding forms at the impact center of the particle due to the absence of oxide film. Chemical bonding is locally achieved at oxide-containing interfaces, whereas delamination dominates most interfacial regions. The effect of high-temperature molten oxides on the bonding mechanism between NiCrAlY splat and substrate is addressed.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"516 ","pages":"Article 132702"},"PeriodicalIF":6.1,"publicationDate":"2025-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145120073","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":"Hybrid cavitation erosion resistance mechanisms of 42CrMo modified by ultrasonic surface rolling process","authors":"Jianxiong Wu ,&nbsp;Yilei Zhao ,&nbsp;Hongbin Lin ,&nbsp;Xuelei Fu ,&nbsp;Shuangjia Liu ,&nbsp;Yiman Duan ,&nbsp;Yu Fang ,&nbsp;Junhui Zhang ,&nbsp;Bing Xu ,&nbsp;Chao Zhang","doi":"10.1016/j.surfcoat.2025.132705","DOIUrl":"10.1016/j.surfcoat.2025.132705","url":null,"abstract":"<div><div>Ultrasonic surface rolling process (USRP) can effectively improve the surface quality, contributing to the cavitation erosion resistance capability of the metal surface. However, there is a lack of detailed mechanisms about the synergistic effects of surface morphology and microstructure on the cavitation erosion resistance of metals. This study reveals the hybrid cavitation erosion resistance mechanisms of 42CrMo modified by USRP, including surface degradation-induced corrosion erosion acceleration mechanism and grain refinement-induced corrosion erosion resistance mechanism. The details are as follows: the increase of rolling plastic deformation causes obvious grain refinement and surface defect removal, resulting in the improvement of cavitation erosion resistance performance. As the rolling plastic deformation exceeds a certain degree, the effect of grain refinement weakens and surface rolling fatigue defects are generated, causing a sharp decline in the cavitation corrosion resistance. This study offers a compressive understanding of hybrid cavitation erosion resistance mechanisms of 42CrMo modified by USRP.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"516 ","pages":"Article 132705"},"PeriodicalIF":6.1,"publicationDate":"2025-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145120112","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":"Effects of pulse parameters on the reactive high-power impulse magnetron sputtering of ternary C–Cr–Zr thin films with Zr/Cr/Zr tri-cathodes in ethyne/argon mixing atmospheres","authors":"Chin-Chiuan Kuo,&nbsp;Yu-Tang Yin","doi":"10.1016/j.surfcoat.2025.132695","DOIUrl":"10.1016/j.surfcoat.2025.132695","url":null,"abstract":"<div><div>To develop new coating properties, reactive high-power impulse magnetron sputtering is continuously being studied to understand its complex mechanisms and overcome existing challenges. In this study, the effects of deposition parameters on C–Cr–Zr ternary films obtained using a Cr/Zr/Zr tri-cathode reactive high-power impulse magnetron sputtering system under various ethyne/argon mixing atmospheres were investigated by comparing the film composition and film deposition rate, and discharge waveforms of the cathodes. The C content of the films was proportional to the C₂H₂/Ar mixing ratio, and intensifying the substrate bias moderately decreased the C and Zr contents of the obtained films. The fractional deposition rate of Zr decreased more significantly with an increase in the C₂H₂/Ar ratio, reduction in the pulse width, and pulse duty than that of the Cr cathode because of the severe poisoning of the Zr cathode. This resulted in changes in the Cr/Zr ratios of the films under these deposition parameters. These findings revealed that the Zr ratio in the films can be adjusted by controlling the poisoning of the Zr cathode by tuning the pulse width and duty cycle.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"516 ","pages":"Article 132695"},"PeriodicalIF":6.1,"publicationDate":"2025-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145222555","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":"Research on the strengthening mechanism of QPQ coupled ultrasonic rolling post-treatment process","authors":"Pengju Fan ,&nbsp;Xiufang Cui ,&nbsp;Jian Li ,&nbsp;Hao Wu ,&nbsp;Liang Li ,&nbsp;Chunlei Teng ,&nbsp;Jinna Liu ,&nbsp;Guo Jin","doi":"10.1016/j.surfcoat.2025.132690","DOIUrl":"10.1016/j.surfcoat.2025.132690","url":null,"abstract":"<div><div>This study investigated the effects of ultrasonic surface rolling processing (USRP) on quench–polish–quench (QPQ)-nitrided 32Cr3MoVE steel. USRP was employed to eliminate the porous structure of the QPQ-nitrided layer and enhance the overall material performance. The results indicate that USRP eliminated defects such as pores in the QPQ-nitrided layer and reduced grain size. Furthermore, USRP not only increased the proportion of low-angle grain boundaries but also introduced a residual stress field with a depth of 250 μm at the surface of the sample owing to its work-hardening effect. As a result, USRP improved the surface hardness of the nitrided layer by approximately 22 % and reduced the wear rate by up to 64 %. The effects of USRP on the material—elimination of the loose interlayer structure and introduction of compressive stress—changed the corrosion mechanism of the material, enhancing its corrosion resistance. Additionally, the strengthening effect of USRP increased with increasing applied static pressure.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"516 ","pages":"Article 132690"},"PeriodicalIF":6.1,"publicationDate":"2025-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145120113","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":"Interface-reinforced ceramic films via Type-B2 discharge in micro-arc oxidation: A dual-stage strategy for enhancing wear-corrosion resistance of bearing steel","authors":"Fengyuan Bao ,&nbsp;Yanhui Liu ,&nbsp;Zhiyuan Wang ,&nbsp;Feng Li ,&nbsp;Oleg Bashkov","doi":"10.1016/j.surfcoat.2025.132692","DOIUrl":"10.1016/j.surfcoat.2025.132692","url":null,"abstract":"<div><div>Bearing steel suffers from wear and corrosion failures in service. To enhance its surface performance, the ceramic film was fabricated via magnetron sputtering combined with micro-arc oxidation. Real-time optical-acoustic analysis revealed a novel non-valve-metal based strong discharge mechanism (Type-B₂). This mechanism generated interface-reinforced cavities with Fe-Ti-O crystalline phases at the film-substrate interface. Mechanical and electrochemical tests under varying oxidation durations demonstrated that Type-B₂ discharged films exhibited an 18.58 % increase in hardness (469 HV vs. 395 HV), 14.29 % longer wear life, and superior corrosion resistance (E_corr: −0.60563 V vs. -0.64306 V). The enhanced performance was attributed to (1) porosity reduction (18 % decrease in cross-sectional porosity) densifying the structure to inhibit crack propagation; (2) interlocking Fe-Ti-O phases at the interface enhancing adhesion through chemical bonding; and (3) capacitive closed-pore networks blocking ionic transport. This work elucidates the micro-arc oxidation growth mechanism of composite films and demonstrates a surface-protection strategy for bearing steel applications.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"515 ","pages":"Article 132692"},"PeriodicalIF":6.1,"publicationDate":"2025-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145105156","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}