Applied Surface Science最新文献

{"title":"Carbon quantum dots implanted sulfonated 2D-MoS2 for hydrogen evolution","authors":"Akash Sarkar ,&nbsp;Gayathry Ganesh ,&nbsp;Ummiya Qamar ,&nbsp;Vivek Kumar Singh ,&nbsp;Ruchi Sharma ,&nbsp;Ankur Srivastava ,&nbsp;Gunasekaran Venugopal ,&nbsp;Rajan Jose ,&nbsp;Santanu Das","doi":"10.1016/j.apsusc.2025.163315","DOIUrl":"10.1016/j.apsusc.2025.163315","url":null,"abstract":"<div><div>We report the enhancement of electrocatalytic activity in sulfonate (−SO₃H) group functionalized two-dimensional molybdenum disulfide (2D-s-MoS₂) nanosheets for their use in hydrogen evolution reaction (HER). These as-developed nanosheets have been decorated with sustainable biomass-derived carbon quantum dots (CQDs) via a sonochemical method, creating a s-MoS₂-CQD composite material. This innovative composite demonstrates significantly improved electrocatalytic performance for the hydrogen evolution reaction (HER) via water splitting. In particular, incorporating CQDs on 2D-s-MoS₂ overcomes many limitations, as observed in pristine 2D-MoS₂ and 2D-s-MoS₂, especially regarding low electrical conductivity and restricted electrocatalytic activity on the basal plane. Incorporating CQDs enhances electron transfer efficiency, increases the availability of active sites, and enhances overall conductivity. As a result, the s-MoS₂-CQD achieves remarkable HER performance, featuring a lower overpotential of ∼ 273 mV and a reduced Tafel slope of 67 mV/dec compared to s-MoS₂. These enhancements signify faster reaction kinetics, accelerated <em>H*</em> adsorption–desorption, and greater catalytic efficiency. Furthermore, using sustainably synthesized CQDs positions this approach as a cost-effective, scalable, and environmentally friendly alternative to traditional noble-metal catalysts. This research highlights the potential of functionalized two-dimensional materials, such as s-MoS₂, implanted with zero-dimensional materials, such as CQDs, to advance sustainable hydrogen production technologies, thereby contributing to the global shift towards clean energy solutions.</div></div>","PeriodicalId":247,"journal":{"name":"Applied Surface Science","volume":"702 ","pages":"Article 163315"},"PeriodicalIF":6.3,"publicationDate":"2025-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143853235","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 thermal oxidation temperature for enhanced structural and electrical properties of Ho2O3 ultrathin-film gate dielectric on Ge semiconductor substrate","authors":"Tahsin Ahmed Mozaffor Onik ,&nbsp;Chia Ching Kee ,&nbsp;Yung Cheng Wong ,&nbsp;Ahmad Hafiz Jafarul Tarek ,&nbsp;Prastika Krisma Jiwanti ,&nbsp;Yew Hoong Wong","doi":"10.1016/j.apsusc.2025.163224","DOIUrl":"10.1016/j.apsusc.2025.163224","url":null,"abstract":"<div><div>This study systematically characterized the structural, morphological and electrical properties of sputtered Ho/Ge interface after subsequent thermal oxidation in O₂ ambient varying deposition temperature from 450 °C–550 °C for metal oxide semiconductor capacitor (MOSCAP) device. The XRD analysis confirmed presence of cubic c-Ho₂O₃ and tetragonal and cubic GeO₂ while the effect of crystallite size and micro-strain on electrical performance has been reported. As observed in XPS, 500 °C thermal oxidation condition has been conducive for exhibiting more stoichiometric phase of Ho₂O₃. This condition helped to limit irregular O diffusion toward substrate facilitating more controlled Ge activation and minimized uneven intermixing. Thereby, inhibited unstable interfacial (IL) layer sub-oxides, GeO_x resulting more stable and compact interface Ho₂O₃/ IL (GeO₂ + GeO_x). However, thermal budget of 550 °C led thicker interfacial layer due to over-oxidation corresponding severely defected Ho₂O₃/(GeO₂ + GeO_x) interface degrading device operation. HRTEM further confirmed double stacked amorphous Ho₂O₃/IL structure ranging physical thickness from 7.04–10 nm. The reduction of structural defect at optimum oxidation condition 500 °C imposed a conduction band offset of 1.77 eV which impeded uneven electron transportation from Ge CB edge into the interface of Ho₂O₃/IL leading enhanced electrical breakdown at <span><math><mrow><msub><mi>J</mi><mi>g</mi></msub><mspace></mspace></mrow></math></span> 10^-6 Acm⁻² withstanding electrical breakdown field, <span><math><mrow><msub><mi>E</mi><mrow><mi>BD</mi></mrow></msub><mspace></mspace></mrow></math></span> 7.93 MVcm⁻¹. Therefore, controlling the temperature set up for oxidized Ho/Ge could offer thinner GeO_x layer improving the <span><math><mi>k</mi></math></span> 12.54 corresponding EOT 2.65 nm while reducing <span><math><msub><mi>Q</mi><mrow><mi>eff</mi></mrow></msub></math></span> and <span><math><msub><mi>Q</mi><mrow><mi>it</mi></mrow></msub></math></span> and <span><math><msub><mi>D</mi><mrow><mi>it</mi></mrow></msub></math></span> 10¹² eV⁻¹ cm⁻². In outline, Ho₂O₃ is projected to be a potential candidate as dielectric insulator for Ge-based MOSCAP devices.</div></div>","PeriodicalId":247,"journal":{"name":"Applied Surface Science","volume":"701 ","pages":"Article 163224"},"PeriodicalIF":6.3,"publicationDate":"2025-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143853705","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":"Twins and dark features in MPCVD diamond films","authors":"Lijun Li ,&nbsp;Kang An ,&nbsp;Guangyu Xu ,&nbsp;Haiping Wu ,&nbsp;Zhiliang Yang ,&nbsp;Zuoshuai Xi ,&nbsp;Peng Liu ,&nbsp;Yongkang Zhang ,&nbsp;Yachen Zhang ,&nbsp;Xufang Zhang ,&nbsp;Hong Li ,&nbsp;Xiongbo Yan ,&nbsp;Fengbin Liu ,&nbsp;Chengming Li","doi":"10.1016/j.apsusc.2025.163222","DOIUrl":"10.1016/j.apsusc.2025.163222","url":null,"abstract":"<div><div>In this study, diamond films were prepared by Microwave Plasma Chemical Vapor Deposition (MPCVD). The twins, dark features, pores, and their surface relationships were investigated, with a focus on the crystallographic transition within fivefold twins, the growth characteristics of distinct film regions and dark features, and the mechanisms of pore formation. The samples were characterized using SEM, XRD, Raman spectroscopy, EBSD, Optical microscopy, and Laser confocal microscopy, complemented by first-principles calculations and molecular dynamics simulations.</div><div>It is demonstrated that Σ3 twins, fivefold twins, and parallel twins all constitute Σ3 twin boundaries, among other types of twin boundaries, and ∑3 twins, fivefold twins and parallel twins are contact twins. It is revealed that the transformation of the crystal planes is due to energy fluctuations, and the results show that the dark features are mainly composed of growth pores, and the regions with more dark features are often accompanied by a greater number of pores. In addition, it is revealed that the growth pores are mainly formed under the influence of twins, which may lead to different growth rates of crystal planes and atomic misalignment, both of which may promote the formation of growth pores, but the first formation mechanism is predominant.</div></div>","PeriodicalId":247,"journal":{"name":"Applied Surface Science","volume":"701 ","pages":"Article 163222"},"PeriodicalIF":6.3,"publicationDate":"2025-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143849748","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":"Functionalization of a clay mineral with Sn species for anti-inflammatory removal","authors":"Lucilane Gomes Oliveira ,&nbsp;Denise Brito França ,&nbsp;Luis Humberto Oliveira ,&nbsp;Josy Anteveli Osajima ,&nbsp;Edson Cavalcanti da Silva-Filho ,&nbsp;Ignacio Sainz-Díaz ,&nbsp;Santiago Medina-Carrasco ,&nbsp;Maria del Mar Orta Cuevas ,&nbsp;Maria Gardênnia Fonseca","doi":"10.1016/j.apsusc.2025.163313","DOIUrl":"10.1016/j.apsusc.2025.163313","url":null,"abstract":"<div><div>Diclofenac is one of the most detected drugs in aquatic environments, however, it can be removed through adsorption. In the present study, sodium bentonite (Na-Bent) was functionalized with an Sn species by reaction between the clay and aqueous SnCl₂ solutions (0.01, 0.05 and 0.10 mol L^-1), and used as new adsorbents for diclofenac. X-ray diffraction patterns with Rietveld refinement analysis indicated the presence of hydrated SnO₂ or Sn(OH)₄ nanoparticles in the samples. SnO₂ content in the samples were 12.8, 32.4, and 45.0 % for Sn0.01-, Sn0.05- and Sn0.10-Bent, respectively. The specific surface area of the samples increased, reaching 194 m² g⁻¹ for Sn0.1-Bent. X-ray photoelectron spectroscopy (XPS) suggested the presence of Sn(IV) species in Sn-Bent. The adsorption isotherms indicated high drug adsorption, reaching 106.1 and 105.5 mg g⁻¹ for Sn0.05- and Sn0.10-Bent samples, respectively. Fourier transform infrared (FT-IR) spectroscopy and XPS analyses showed an interaction between the carboxylate group of diclofenac sodium and the Sn species in the Sn-Bent samples. <em>Artemia salina</em> tests indicated that Sn0.10-Bent was not toxic, and all samples showed good stability during diclofenac adsorption at pH 6. Therefore, Sn-Bent samples behaved as environmentally friendly adsorbents for the removal of diclofenac.</div></div>","PeriodicalId":247,"journal":{"name":"Applied Surface Science","volume":"702 ","pages":"Article 163313"},"PeriodicalIF":6.3,"publicationDate":"2025-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143853728","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":"Surface oxygen vacancy regulation via Li-doped in MOF-derived mesoporous TiO2 for printable mesoscopic perovskite solar cells","authors":"Hang Yang,&nbsp;Zhongge Luo,&nbsp;Boxue Wang,&nbsp;Ke Wang,&nbsp;Jianhong Zhao,&nbsp;Jin Zhang,&nbsp;Yuming Zhang,&nbsp;Qingju Liu","doi":"10.1016/j.apsusc.2025.163316","DOIUrl":"10.1016/j.apsusc.2025.163316","url":null,"abstract":"<div><div>The mesoporous TiO₂ displays low conductivity and abundant oxygen vacancies (OVs) defects, leading to reduced carrier extraction and affecting the power conversion efficiency (PCE) of perovskite solar cells (PSCs). In this study, we investigate the electron transport layer of mesoporous TiO₂ derived from Ti-MOFs with Li-doped, employing a strategy to regulate the OVs on the TiO₂ surface to enhance device performance. Experimental results demonstrate that Li doping increases the conductivity of TiO₂, improves the energy level alignment between the TiO₂ and perovskite interfaces, and alleviates the residual stress in the perovskite. Theoretical calculations indicate that Li doping can inhibit the formation of OVs, reduce the band gap of TiO₂, and decrease the surface energy of the interface, thereby enhancing carrier extraction. Ultimately, carbon-based printable mesoscopic PSC by Li-doped achieved a champion PCE of 18.07 % and improved long-term stability.</div></div>","PeriodicalId":247,"journal":{"name":"Applied Surface Science","volume":"702 ","pages":"Article 163316"},"PeriodicalIF":6.3,"publicationDate":"2025-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143853726","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 interlayer and interphase multiple coordination deformation mechanism of Fe-20.4Cr-4.7Mn-0.27N duplex stainless steel with gradient heterostructure","authors":"Lingxiao Li ,&nbsp;Tingsong Yang ,&nbsp;Zhilei Liu ,&nbsp;Yanfeng Feng ,&nbsp;Xinjun Zhang ,&nbsp;Miao Jin ,&nbsp;Lei Chen ,&nbsp;Kun Yang ,&nbsp;Shuo Hao","doi":"10.1016/j.apsusc.2025.163309","DOIUrl":"10.1016/j.apsusc.2025.163309","url":null,"abstract":"<div><div>In this work, ultrasonic rolling treatment was conducted on the surface (USRT) of the Fe-20.4Cr-4.7Mn-0.27N duplex stainless steel plate for 6 passes, its influences on the tensile deformation and damage behaviors were clarified by means of XRD, EBSD, TEM, SEM, etc. The results show that the USRT introduced gradient heterostructure layers with a total volume ratio of about 27 % in the Fe-20.4Cr-4.7Mn-0.27N steel, the α’_bcc-martensite proportion increases from 0 % in the base-material core to 5 % on the USRT surface. This leaded to an improvement in yield strength of 125 MPa, an increase in ultimate tensile strength of 17 MPa and a decrease in total elongation of 20 %. Besides, a further increase in α’_bcc-martensite proportion of 35 %–38 % was shown in austenite throughout the USRT specimen after tensile fracture. While in ferrite, the dislocation activity in the USRT layer was obviously weaker than that in the base-material core during tensile deformation. The complex coordination deformation behavior is closely associated with the plasticity partitioning difference between the heterogeneous phases and between the heterogeneous layers. This finally leaded to different damage characteristics on the USRT surface from that in the as-annealed specimen.</div></div>","PeriodicalId":247,"journal":{"name":"Applied Surface Science","volume":"701 ","pages":"Article 163309"},"PeriodicalIF":6.3,"publicationDate":"2025-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143849747","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":"Electrochemical deposition of graphene-doped polyaniline films for enhanced zinc corrosion resistance","authors":"A. Messabhia ,&nbsp;H. Boudellioua ,&nbsp;Y. Hamlaoui ,&nbsp;F. Pedraza","doi":"10.1016/j.apsusc.2025.163311","DOIUrl":"10.1016/j.apsusc.2025.163311","url":null,"abstract":"<div><div>Pure polyaniline (PANI), graphene-doped PANI (PANI-GR), and graphene nanoplatelet-doped PANI (PANI-GRNPs) coatings were electrodeposited galvanostatically from an aqueous solution of sodium salicylate and aniline onto zinc substrates. Graphene was obtained via the electrochemical exfoliation of graphite in an acidic medium. Prior to incorporation into the composites, both forms of graphene were dispersed in the surfactant SDS. The electrochemical behaviour of the bare and coated substrates was evaluated in 1 M NaCl. The study demonstrates that electrodeposition via galvanostatic mode is an effective method for coating zinc substrates with polyaniline (PANI) and PANI-graphene composites. Structural analyses using X-ray diffraction (XRD) and Raman spectroscopy confirmed the successful integration of graphene into the PANI matrix. The incorporation of graphene significantly improved the coating quality, enhancing surface homogeneity and minimizing the formation of surface cracks. Mechanical testing revealed that PANI-GR composite coatings exhibited superior microhardness compared to pure PANI and PANI-GRNPs coatings. The PANI-GR coatings outperformed the corrosion resistance of both bare zinc and pure PANI coatings. This enhanced corrosion resistance is attributed to the improved barrier properties, more noble corrosion potential, decreased anodic and cathodic branches and enhanced charge transfer mechanisms facilitated by graphene incorporation.</div></div>","PeriodicalId":247,"journal":{"name":"Applied Surface Science","volume":"701 ","pages":"Article 163311"},"PeriodicalIF":6.3,"publicationDate":"2025-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143846916","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":"Degradation of pollutants by electrically activated peroxydisulfate with Cu-FeOCl/MWCNTs-COOH/PTFE electrochemical membranes","authors":"Shuaiqi Lv ,&nbsp;Zheyi Ni ,&nbsp;Leyi Liu ,&nbsp;Sihao Jiang ,&nbsp;Mengru Shan ,&nbsp;Yanqing Cong ,&nbsp;Shiwen Lv ,&nbsp;Guoqing Wang ,&nbsp;Jing Xu ,&nbsp;Yi Zhang","doi":"10.1016/j.apsusc.2025.163312","DOIUrl":"10.1016/j.apsusc.2025.163312","url":null,"abstract":"<div><div>Cu-FeOCl catalyst loaded onto Carboxylated multiwalled carbon nanotubes-polytetrafluoroethylene membranes (MWCNTs-COOH/PTFE) by high temperature pyrolysis to form Cu-FeOCl/MWCNTs-COOH/PTFE electrode. The Scanning Electron Microscope results show that the surface of the material shows a layered structure with large specific surface area. And it can be observed by X-Ray Diffraction, X-ray photoelectron spectroscopy and Fourier Transform Infrared Spectrometer that the doping of Cu affects the energy bands and crystallographic changes among other elements. Degradation of 98 % was achieved by electrically activating peroxydisulfate and sequestering sulfamethoxazole (SMX) in the flow system, and 92 % within 60 min in the immobility reaction. The flux of the membrane against bovine serum albumin and the recovery of the degradation rate after cyclic flux testing were also explored. In addition, the electrode is applied to the degradation of pollutants in the muddy water. Through the synergistic action of anodic oxidation and cathodic activation of PDS, active species such as hydroxyl radical (^<img>OH), sulfate radicals (SO₄^<img>−), and superoxide radicals (O₂^<img>−) are generated in the reaction system, accompanied by the generation of high valence metals in the anode. Fe-Cu bimetallic catalysts for electrochemical activation of PDS for pollutant degradation is a feasible and efficient material.</div></div>","PeriodicalId":247,"journal":{"name":"Applied Surface Science","volume":"701 ","pages":"Article 163312"},"PeriodicalIF":6.3,"publicationDate":"2025-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143849767","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":"Unveiling the heterogeneous structure of FeCoNiPdCu High-Entropy Alloy: A case study on electrochemical nitrate reduction","authors":"Hao Zhang ,&nbsp;Tianze Ren ,&nbsp;Xiuming Bu ,&nbsp;Chuqian Xiao ,&nbsp;Shaoyan Wang ,&nbsp;Di Yin ,&nbsp;Xiulan Hu ,&nbsp;Johnny C. Ho ,&nbsp;Xianying Wang","doi":"10.1016/j.apsusc.2025.163269","DOIUrl":"10.1016/j.apsusc.2025.163269","url":null,"abstract":"<div><div>Recently, high-entropy nanoalloys (HEA) had attracted significant interest in various potential catalytic applications due to their unique high-entropy effect. However, in most previous studies, the successful preparation of single-phase HEA has been identified primarily through X-ray diffraction (XRD) and inductively coupled plasma mass spectrometry, often neglecting the presence of minor secondary phases owing to the spatially averaged information provided by XRD. In this work, using FeCoNiPdCu HEA applied to an electrochemical nitrate reduction reaction (NO₃RR) as an example, we confirmed that trace amounts of oxygen induced the formation of a FeCoNiPdCu high-entropy oxide/FeCo oxide@NiPdCu alloy/FeCoNiPdCu HEA three-layer heterogeneous structure, achieving a Faradaic efficiency of 95.16% at an applied potential of −0.7 V vs. RHE. Moreover, by modifying the oxygen content, the element distribution across the entire HEA can be tuned owing to differences in oxide formation enthalpy, further affecting catalytic activity and selectivity. Our work deepens the understanding of HEA structures and provides insights into the active sites and corresponding catalytic mechanisms.</div></div>","PeriodicalId":247,"journal":{"name":"Applied Surface Science","volume":"702 ","pages":"Article 163269"},"PeriodicalIF":6.3,"publicationDate":"2025-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143846914","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":"Environmentally-friendly preparation nanometer Fe-Al solid solution alloy coatings on mild steel by electrodeposition in AlCl3-BMIC ionic liquid","authors":"Anan Song,&nbsp;Cunying Xu,&nbsp;Tongjiang Tian,&nbsp;Xiuling Yan,&nbsp;Yixin Hua,&nbsp;Qibo Zhang","doi":"10.1016/j.apsusc.2025.163296","DOIUrl":"10.1016/j.apsusc.2025.163296","url":null,"abstract":"<div><div>The formation of Fe-Al solid solutions can significantly enhance their corrosion resistance owing to the homogeneous microstructure. However, preparation high-iron-content alloys with solid solutions remains a considerable challenge. In this study, Fe-Al alloy solid solutions with high Fe content were successfully prepared via electrodeposition from an acidic 1-butyl-3-methylimidazolium chloroaluminate (AlCl₃-BMIC) ionic liquid (IL) containing ferrous chloride (FeCl₂). FeCl₂ was dissolved in the acidic AlCl₃-BMIC IL to form complex [Fe(AlCl₄)₄]^2-, alongside the well-known [Al₂Cl₇]⁻ species, facilitating the co-deposition of Fe-Al alloy. The electrodeposition process of Al-Fe alloys was observed to be a normal co-deposition, where the presence of Fe(II) inhibits the reduction of [Al₂Cl₇]⁻, resulting in Fe content consistently exceeding 50 at%. During electrodeposition, increasing temperature and decreasing current density resulted in higher Fe content in the Fe-Al alloy. By adjusting the current density and temperature, Fe-Al alloys with diverse microstructures, including microspheres, staghorn coral, and pagoda-like structures, were successfully fabricated. The resultant Fe-Al alloys with Fe content between 39.2 at% and 76.3 at%, exhibit solid solutions, and they evolves from a dual-phase mixture of Fe(Al) and Al(Fe) solid solutions to a single-phase Fe(Al) solid solution as the Fe is up to 76.3 at%. Notably, the alloy coatings containing 61.6 at% Fe, composed of polycrystalline particles with an average grain size of 10.75 nm, demonstrated superior anti-corrosion performance compared to pure Al coatings. The enhanced anti-corrosion properties of the Fe-Al alloy coatings on mild steel can be attributed to several factors: the absence of intermetallic compounds, the extended solubility of Fe and Al within the Al-based and Fe-based solid solutions, and the compact structure made of nanoparticles. Accordingly, the combination of electrodeposition techniques with solid-solution alloy offers a promising approach for effective chemical protection on iron-based material surfaces.</div></div>","PeriodicalId":247,"journal":{"name":"Applied Surface Science","volume":"701 ","pages":"Article 163296"},"PeriodicalIF":6.3,"publicationDate":"2025-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143846950","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}