Porosity Of Coatings Research Articles

Terahertz Non-Destructive Testing of Porosity in Multi-Layer Thermal Barrier Coatings Based on Small-Sample Data

Accurately characterizing the internal porosity rate of thermal barrier coatings (TBCs) was essential for prolonging their service life. This work concentrated on atmospheric plasma spray (APS)-prepared TBCs and proposed the utilization of terahertz non-destructive detection technology to evaluate their internal porosity rate. The internal porosity rates were ascertained through a metallographic analysis and scanning electron microscopy (SEM), followed by the reconstruction of the TBC model using a four-parameter method. Terahertz time-domain simulation data corresponding to various porosity rates were generated employing the time-domain finite difference method. In simulating actual test signals, white noise with a signal-to-noise ratio of 10 dB was introduced, and various wavelet transforms were utilized for denoising purposes. The effectiveness of different signal processing techniques in mitigating noise was compared to extract key features associated with porosity. To address dimensionality challenges and further enhance model performance, kernel principal component analysis (kPCA) was employed for data processing. To tackle issues related to limited sample sizes, this work proposed to use the Siamese neural network (SNN) and generative adversarial network (GAN) algorithms to solve this challenge in order to improve the generalization ability and detection accuracy of the model. The efficacy of the constructed model was assessed using multiple evaluation metrics; the results indicate that the novel hybrid WT-kPCA-GAN model achieves a prediction accuracy exceeding 0.9 while demonstrating lower error rates and superior predictive performance overall. Ultimately, this work presented an innovative, convenient, non-destructive online approach that was safe and highly precise for measuring the porosity rate of TBCs, particularly in scenarios involving small sample sizes facilitating assessments regarding their service life.

Tailored micro-arc oxidation coatings to match with parylene for enhanced tribological performance of Ta-12W alloys

To improve the tribological properties of tantalum-tungsten alloys, dual-layer composite coatings are designed using micro-arc oxidation (MAO) and chemical vapor deposition (CVD) techniques. By adjusting the concentrations of NaOH and NaF additives as well as the oxidation mode (constant current/voltage) of MAO process, the microstructure and properties of underlying MAO layers are tailored for better matching with the top parylene layer, aiming to develop composite coatings capable of service under heavy loads. A comprehensive study is conducted to evaluate the effect of these parameters on the growth, microstructure, bond strength, and mechanical properties of MAO coatings, along with their subsequent impact on the friction and wear behavior under various loads for composite coatings. The findings reveal that increasing the concentration of either NaOH or NaF significantly increases the coating thickness, surface porosity, crystallinity, and hardness of MAO coatings, by promoting the spark discharge activities. However, distinct interfacial growth behavior is observed due to anionic effects caused by OH− and F−. The oxidation mode plays a crucial role in determining the mechanical quality of coatings; the constant voltage mode facilitates dense coatings with high adhesion due to its self-repairing mechanism. Furthermore, wear tests confirm that the enhanced mechanical properties and open-porosity of the MAO coatings markedly improve the tribological performance of composite coatings. This improvement is attributed to the excellent load-bearing capacity provided by hard MAO layers, as well as the anchoring and storage capabilities of the textural porous surfaces. The optimized composite coating demonstrates long-lasting low friction even under heavy loads up to 80 N.

Microstructure and corrosion properties of CrMnFeCoNi high entropy alloy coating by temperature field-assisted laser cladding

The CrMnFeCoNi high entropy alloy coatings were prepared on the surface of Q345 steel using a temperature field-assisted laser cladding process, and the effects of the applied temperature field on the cladding coatings were studied. The microstructures and corrosion morphologies of the coatings were observed, and the elemental distribution, hardness, effective elastic modulus, electrochemical corrosion performance, and corrosion products of different coatings were analyzed. The results show that the porosity of the HEA coatings prepared with a temperature field is reduced to below 50 % of the initial level. The microstructure of the coating changed, with the nanoindentation hardness of the coating increasing by up to 0.55 GPa, enhancing the mechanical properties. Among all the coatings, the coating prepared at 250 °C temperature field exhibited the best corrosion resistance, with corrosion potential and current density of −0.27 V and 0.15 μA/cm2, respectively, improving the corrosion potential by 0.1 V and reducing the current density by 1.08 μA/cm2 compared to the sample prepared at room temperature. After incorporating the temperature field, the stability of the passive film on the coating during corrosion improved, and the nucleation rate of pitting decreased. Therefore, incorporating an appropriate temperature field during laser cladding can effectively enhance the overall performance of the CrMnFeCoNi HEA coating.

High-performance porous 3D Ni skeleton electrodes for the oxygen evolution reaction

A key component of green hydrogen production technologies is the fabrication of large-scale porous transport layer (PTL) for use in anion electrolyte membrane water electrolysers (AEMWEs). One strategy to achieve that goal is to manufacture Ni-based 3D electrode skeletons that can be further catalyzed to achieve high current densities at low overpotentials. In the present work, shock-wave induced spray (SWIS) and cold spray (CS) deposition techniques were used to prepare 20 cm2 Ni-based electrode skeletons. In our experimental conditions, the porosity of coatings prepared using the SWIS deposition system and Ni powders with particle sizes D50 = 32 and 75 μm never exceeded 28%. Higher porosity could only be achieved using the CS deposition system and a spheroidal Ni–Al powder, whose particles consist of an aluminum core encapsulated in a nickel shell. After Al leaching in an alkaline solution, the resulting electrodes showed good mechanical and structural integrity with up to 41% porosity. The electrochemical active surface area of the most porous electrodes is a factor of 2100 larger than a polished Ni plate, and it has superaerophobic properties with a captive air bubble contact angle of 151°. During 1 h of electrolysis, the overpotential at 100 mA cm−2 of the most active leached Ni–Al cold spray deposited electrode was 330 mV, compared to 380 mV for a Ni foam electrode.

Microstructure and wear resistance of cold sprayed CoCrFeNi HEA coatings: Influence of powder particle size and spraying temperature

This study focuses on the successful fabrication of three distinct types of CoCrFeNi high entropy alloy (HEA) coatings through cold spray (CS) technology, with an emphasis on analyzing the impact of varying crucial CS parameters (spraying temperature and the range of powder particle size), on the coating's microstructure and tribological properties. Contrasted with conventional thermal spraying techniques, lower operational temperature in CS safeguards the materials from undergoing oxidation or phase transitions that are typically induced by high-temperature conditions. Additionally, the high-velocity impact of particles onto the substrate within CS process triggers plastic deformation, resulting in the creation of coatings that are characterized by heightened hardness, and greater density. Such coatings exhibit significantly enhanced performance and durability. The cocktail effect observed in CoCrFeNi HEA is reflected in a suite of exceptional properties that markedly surpass those exhibited by traditional alloys. Chiefly, this phenomenon is manifested through the alloy's exceptionally high hardness and dense structure, positioning CoCrFeNi HEA as a promising candidate for applications in high-wear scenarios. Experimental outcomes indicate that when smaller powder particles and higher spraying temperatures are employed, the porosity of CSed CoCrFeNi HEA coatings was observed to decrease by nearly an order of magnitude, concomitant with a 22.46% enhancement in microhardness. This improvement in microhardness translates into a significant reduction of over 72% in the wear rate, underscoring the positive correlation between enhanced microstructural integrity and wear resistance properties. By meticulously tuning spraying temperature and powder particle size, the resulting microstructure can be rendered increasingly dense and refined.

Tribological properties of atmospheric plasma sprayed Cr3C2–NiCr/20% nickel-coated graphite self-lubricating coatings

Using atmospheric plasma spraying technology, Cr3C2–NiCr (CN)and Cr3C2–NiCr/20 % Nickel-coated graphite (CG) composite coatings were successfully deposited on 304 stainless steel substrates, with three different spraying distance parameters designed to optimize the experiment. The study investigated the influence of nickel-coated graphite on the structure, hardness, porosity, and friction-wear performance of the composite coatings. Wear mechanisms were investigated based on analyses of morphologies and chemical states of the worn surfaces of the CG composite coatings. Our results demonstrate that the CG coating exhibits lower friction coefficients, ranging from 0.24 to 0.28, than that of the CN coating. The incorporation of nickel-coated graphite leads to formation of a solid-lubricating film at friction interface, lowering friction and wear. What's more, presence of nickel-coated graphite mitigates brittleness of the CN coating, as is deemed important for improving abrasion resistance of the coatings.

Influence of non-valve metal phase on growth behavior and performance of PEO coating on Mg–Zn–Mn alloys with high Mn content

The influence of pure metal phases (precipitation or reinforcement phases) on the PEO discharge and coating growth in Mg alloys remains underexplored. This study investigated the effects of the α-Mn phase on voltage evolution, coating morphology, phase composition, and corrosion resistance by subjecting Mg–4Zn-xMn (x = 0, 0.6, 1.2, 2.4 wt%) alloys to PEO treatment in alkaline silicate-based electrolyte. Results indicate that the presence of α-Mn does not prevent spark discharge. However, an increase in α-Mn content leads to a downward shift in the voltage-time curve. The α-Mn phase significantly slows down the voltage ascent rate and prolongs the duration of Stages I to III of PEO process. Electrochemical oxidation of the surrounding Mg matrix by the α-Mn phase induces the formation of pits and porous local morphologies, exacerbating coating unevenness. With the increasing in Mn content, the thickness and porosity of PEO coatings gradually decrease for the same treatment time. The coated Mg–4Zn-1.2Mn alloy exhibits the highest corrosion resistance. The differences in oxidizability between the α-Mn phase and the Mg matrix, as well as the stability and dielectric properties of the oxide products may be the underlying reasons for these effects. Despite Mn oxides' instability under alkaline conditions at high potentials, reaction products with the electrolyte offset this drawback. This study enhances understanding of pure metal phases' influence on Mg alloy PEO and contributes to research on PEO processes for Mg-based materials containing pure metal phases.

Multi-parameter coupled optimization of Al6061 coating porosity based on the response surface method

The objective of this study is to study the multi-particle deposition process of cold spray through numerical simulation methods and to use multi-factor coupling to optimize the porosity of Al6061 coating to more accurately characterize the real cold spray deposition process. This study aimed to predict and optimize the porosity of Al6061 coatings using numerical simulation methods. The tasks to be solved are: to nest the multi-particle model established by the Python script in the CEL deposition model to simulate the cold spray deposition process. A multi-parameter function with particle temperature, substrate temperature, and particle velocity as independent variables and Al6061 coating porosity as dependent variables was established. The response surface analysis method was used to predict the optimal spraying parameters and coating porosity of Al6061 coating. The methods used are as follows: optimize the porosity of the coating through multi-factor coupling through response surface analysis; use a multi-particle model established through a Python script to be nested in the CEL deposition model to simulate the deposition process of cold-sprayed Al6061 multi-particles. To characterize the coating porosity more accurately, the average value of multiple groups of samples was taken as the final coating porosity value. Conclusions. the porosity value of Al6061 coating obtained by the prediction model is 1.969%; Under the influence of multi-factor coupling, particle velocity has the greatest impact on the porosity of the Al6061 coating, and the substrate temperature has the least impact. Optimum spraying parameters: particle temperature 649.692K, substrate temperature 536.437K, and particle velocity 672.385m/s. Under the optimal spraying parameters, the porosity value of the Al6061 coating is 1.91875%; The error between the predicted value and the actual value obtained by numerical simulation is only 2.55%.

Preparation of zwitterionically charged chitin nanofibers through one step chemical modification and their application for antireflective coatings

Chitin nanofibers are widely used in many fields because of their biocompatibility, renewability and excellent mechanical properties. Herein, zwitterionically charged chitin nanofibers (ZC-ChNFs) were prepared from chitin via one step chemical modification (oxalic acid pretreatment) and subsequent ultrasound treatment. Effects of pretreatment time on size of the ZC-ChNFs and pH of ZC-ChNF suspensions on the thickness, porosity, refractive index and antireflective capacity of ZC-ChNF coatings were investigated. It was found that, by adjusting pH of the ZC-ChNF suspension, porosity and refractive index of the ZC-ChNF coatings could be controlled. The ZC-ChNF coatings fabricated with smaller ZC-ChNFs had higher antireflective performance and the transmittance gain of a glass with a ZC-ChNF coating was about 3.5 % at a wavelength of 550 nm compared to the bare glass. The results of this work provide a promising pathway to fabricate antireflective coating with ZC-ChNFs just by controlling the pH of ZC-ChNF suspensions.

The effect of laser post-treatment on the microstructure and properties of Al coating on the PEEK substrate

To improve the bonding strength and electrical conductivity(σ) of cold-sprayed Al coatings on polyetheretherketone(PEEK) substrates, laser post-treatment was employed as an effective strengthening method without decomposition of the polymer substrates. Optical and electron microscopy observations were used to examine the microstructures and tensile fracture surfaces of the Al coatings fabricated with various laser powers. X-ray diffraction and electron backscatter diffraction were employed to investigate the phase composition and grain information of each coating. Hardness, pull-out adhesion, and electrical conductivity tests were performed to investigate the effect of laser power on the mechanical and physical properties of cold-sprayed Al coatings. The results revealed that despite the formation of several hundred micrometer-sized pores on the PEEK side, the porosity of the laser post-treated Al coatings significantly decreased, and the particle–particle interfaces were greatly healed with increasing laser power. The heat input induced large-scale recrystallization and significantly reduced the dislocation density in the samples. The XRD pattern revealed that no oxidation phase appeared following the laser treatment under the protection of Ar. The electrical conductivity and bonding strength of the Al coatings increased by up to 40 % and 167.4 %, respectively, after the laser post-treatment.

REVIEW: MATERIALS FOR IMPREGNATION OF POROUS METALLIZATION THERMAL SPRAYED ANTICORROSIVE COATINGS OF SUBMERSIBLEOILFIELD EQUIPMENT. Part 1

Submersible oilfield equipment undergoes aggressive corrosive effects of petroleum fluid, abrasive effects of mechanical impurities during operation, and also operates at elevated temperatures in the bottom. The most effective way to protect the outer surface of oilfield equipment is the use of metallization thermal sprayed coatings, and therefore the application of thermal spraying technology is becoming more and more in demand.However, the formation of a coating structure from many particles of molten material, due to their spraying, incomplete melting and loose packaging, leads to the formation of porosity, and porosity is one of the main disadvantages of thermal sprayed coatings. To eliminate this disadvantage, it is possible to use impregnation of porous coatings with various compositions, in which case the coating becomes composite. Depending on the operating environment, temperature conditions and operating conditions, metal, organic and inorganic impregnating compositions are used,but their use in the oil environment has been little studied, therefore the development of composite impregnated coatings is relevant for the protection of submersible oilfield equipment. The article highlights the influence of technological modes of its application on the porosity of thermal sprayed coating and the quality of substrate surface preparation. The main methods of sealing the porosity of thermal sprayed coatings by impregnation are described. The mechanism of impregnation (infiltration) of porous coatings, used methods of application and their classification are described, the determining role of wetting the coating with an impregnating material is emphasized. The effect of the rough surface of a thermal sprayed coating is shown, which consists in enhancing the wetting properties of the impregnating composition, the influence of roughness on the formation of adhesive bonds between the coating and the impregnating composition.The review presents traditional impregnating materials used in industry and their application modes.The application of metal and non-polymer inorganic impregnating compounds, represented mainly by salts of inorganic acids (nitrates, phosphates, silicates), is described. Specific test results are presented, including for the corrosion and abrasive resistance of thermal sprayed coatings after the application of impregnating compounds.

Nanostructured Yb2SiO5/mullite-SiC/Si environmental barrier coating with long-term stability at 1250 °C

In this work, nanostructured Yb2SiO5/mullite-SiC/Si environmental barrier coatings (EBCs) were prepared to investigate the effect of heat treatment on the microstructure and phase transition of nanostructured Yb2SiO5/mullite-SiC/Si coatings. The Yb2SiO5 content and microstructure evolution in the coatings were thoroughly analyzed before and after heat treatment. The results demonstrate a slight decrease in the porosities of nanostructured Yb2SiO5 and mullite-SiC coatings, accompanied by a gradual growth in grain sizes with increasing heat treatment time, indicating the nanostructured EBCs show good resistance to sintering. Moreover, the thickness of thermal growth oxidation layer is only 200 nm at 1250 °C for 500 h of heat treatment. In particular, the presence of the Yb2O3 phase has been observed to exert a favorable influence on the thermal stability of nanostructured EBCs. This work provides an innovative strategy for designing advanced EBCs with excellent high-temperature thermal stability.

Structural evolution and enhanced thermal cycling life of HVAF-sprayed NiCrAlY bond coat modified by YSZ

Thermal barrier coatings with varied bond coat structures were deposited using high-velocity air fuel spraying. Highly hard YSZ particles are introduced into the NiCrAlY bond layer by accelerating to supersonic speeds at low temperatures to change the porous structure of the bond coat. We systematically increased the YSZ content in NiCrAlY bond coats and extensively investigated microstructure, oxidation behavior, thermal cycling life, and residual stress variation of the bond coats suing a combination of scanning electron microscopy, optical microscope, confocal Raman microprobe. Introduction of YSZ particles reduced the porosity of NiCrAlY bond coat from 2.69% to 0.45%, and altered the oxidation behavior of the bond layer. The NiCrAlY mixed YSZ composite structure induced the formation of a complex and thin thermal growth oxide layer on the bond coat during oxidation process, greatly alleviating and reducing the thermal stress generated of the coating and during the thermal cycling test. And the thermal cycling life of the NiCrAlY mixed YSZ composite structure coating is 2.8 times longer than that of the ordinary NiCrAlY coating. This finding highlights the significance of the bond coat structure in enhancing the service life of thermal barrier coatings.

High-velocity oxy-fuel and high-velocity air fuel sprayed WC-Co-Cr coatings on solution-treated 21-4N steel for slurry and corrosion resistance

This study aims to fabricate WC-Co-Cr coatings on the solution-treated 21-4N steel utilizing high-velocity oxy-fuel (HVOF) and high-velocity air fuel (HVAF) techniques. The microstructure, hardness, surface quality, porosity, slurry erosion, and corrosion resistance of HVOF and HVAF coatings on solution-treated 21-4N steel were investigated and compared. The HVAF sprayed WC-Co-Cr coating exhibited dense structure, more hardness (1582 HV), greater fracture toughness (5.69 MPa m1/2), less decarburization, and lower porosity (0.97 %) as compared to HVOF sprayed coating. Further, slurry jet erosion tests and electrochemical corrosion tests provide a comprehensive evaluation of the coating’s performance under erosive and corrosive conditions. Eventually, the conclusive results of the study affirm the exceptional performance of the high-velocity air fuel sprayed WC-Co-Cr coating, demonstrating its superiority in both erosion and corrosion resistance compared to the high-velocity oxygen fuel sprayed coating.

Load-dependent wear behavior of novel Fe-based amorphous APS coating derived from compositionally modified high-P pig iron

This study examines the wear resistance of a new amorphous coating fabricated by APS thermal spraying using industrial grade pig iron. The coating's performance is evaluated under varying plasma power conditions at three distinct loads of 40, 50, and 60 N. Scanning electron microscope (SEM) micrographs are analyzed to measure the porosity and thickness of each coating. The average porosities (%) of S1-S4 and S5-S8 coatings are 07 ± 03 and 14 ± 04, respectively. The rates of wear between reference mild steel and among all coatings at three different loads are evaluated, compared, and correlated with plasma powers to arrive at optimal level of plasma power. The plasma power of 30–35 kW corresponding to the least wear rate is found to be optimal at three different loads. Further, the generated debris particles are subjected to morphological and phase analysis by scanning electron microscopy and Fourier-transformed infrared spectroscopy. Detailed microstructural analysis of worn surfaces indicates that the wear modes include delamination, abrasion, and oxidation

INFLUENCE OF SPRAY DISTANCE ON THE POROSITY OF Ni-BASED AMORPHOUS COATINGS: NUMERICAL SIMULATION AND EXPERIMENT

The influence of injection distance on the porosity of Ni-based amorphous coatings (AMCs) prepared with a high-velocity air fuel (HVAF) process is discussed based on a numerical analysis and experimental methods. A computational fluid dynamics model was established to demonstrate the gas flow field and behavior of particles in flight at different spraying distances during HVAF spraying. When analyzing the changes in the particle velocity and temperature, the spraying distance is less than 30 µm. The velocity and temperature changes of small particles have a significant impact, and the optimal spray distance (350 mm) for obtaining a low porosity coating is predicted. The calculation was validated experimentally by producing a Ni-based AMC with a low porosity (1.87 %) that was manufactured using the predicted HVAF optimal spraying distance.

In-situ synthesis and oxidation behaviors of Ti-xAl coatings by high-frequency induction heated combustion

Ti-xAl coatings (x=25, 33.3, 50, 66.7, and 75 at%) were fabricated in situ using high-frequency induction heating synthesis (HFIHCS). The process parameters for preparing Ti-Al coatings via HFIHCS were orthogonally optimized employing the finite element method. The effect of the aluminum content on the microstructures and phase compositions of Ti-Al coatings fabricated by HFIHCS, as well as their oxidation behaviors at 900℃ for 100 h was investigated. The results showed that the distribution of interfacial temperature difference was influenced by induced current (62.11%), relative density of compact (9.86%), and indenter material (28.03%). The minimum interfacial temperature difference was achieved with an induced current of 300 A, a graphite indenter material, and a compact density of 82.9%. The Ti-xAl coatings exhibited a core (Ti)-shell (TixAly) ring structure. The rise in aluminum content in the Ti-xAl coatings led to a gradual reduction in the titanium-rich phase, accompanied by a progressive increase in the aluminum-rich phase and the interface thickness of zones Ⅰ and Ⅱ. The porosities of Ti-xAl coatings containing over 50 at% aluminum exhibited an order of magnitude higher than those of Ti-xAl coatings with 50% aluminum or lower. The mechanisms of reaction, pore-forming, and interfacial diffusion for Ti-xAl coatings were predominantly controlled by dissolution-precipitation, thermal expansion of intrinsic pores within the cold-pressed compact and voids formed after molten aluminum flow, and liquid-solid co-diffusion, respectively. The increase in aluminum content in the Ti-xAl coatings led to in a gradual decrease in its oxidative weight gain, a shift in the oxidation kinetics from a linear-parabolic to a parabolic law, and an enhancement in preservation of internal core-shell characteristics and the likelihood of forming a protective layer of thin Al2O3. The oxidation behaviors of Ti-xAl coatings with a core-shell structure were co-controlled by the aluminum content and the porosity affected by the aluminum content.

The hardfacing properties of the nickel-based coating deposited by the PTA process with the addition of wc nano-particles: Wear investigation

The impact of the addition of tungsten carbide (1 to 7 wt%) on the microstructure and wear characteristics of the nickel–tungsten carbide composite layer fabricated by the plasma transferred arc (PTA) process was studied. With the addition of nanoparticles, the degree of segregation becomes lower while heterogeneous nucleation increases and refining of the microstructure enhances. Wear rate and coefficient of friction for all samples with increasing the load from 1 to 5 N decrease and wear mechanism changes from abrasive to adhesive. The higher wear resistance for samples with 3%wt is due to a decrease in the porosity of the composite coatings, strong interfacial bonding, and promotion in the deposition efficiency at the same time.

Effect of laser remelting on the microstructure and corrosion behavior of high-velocity arc-sprayed FeNiCrBSiNbW amorphous coating

Fe-based amorphous coating was produced using high-velocity arc-spraying (HVAS), and then laser remelting (LR) technology was used to treat the as-sprayed coatings (ASC) to prepare the laser remelted coatings (LRC). The morphology, phase composition, microhardness, porosity, and corrosion property of the Fe-based amorphous coatings before and after LR were investigated. The outcomes demonstrated that the internal defects of the ASC were eliminated and the porosity was significantly reduced after LR, which was significant in dramatically enhancing corrosion resistance. After the LR procedure, the ASC's free corrosion potential (Ecorr) in 3.5 wt% NaCl solution increased, and the corrosion current density (Icorr) almost reduced by a factor of ten. Therefore, LR helped to strengthen the corrosion characteristics of Fe-based amorphous coating and improve its microstructure.

Cold spraying of Al-5Si/Al2O3 composite coatings on AZ31 Mg alloy: Microstructure, adhesion strength, and tribological properties

To improve the wear resistance of commercial AZ31 Mg alloy, two types of dense and thick composite coatings were prepared on AZ31 Mg alloy by means of cold-spray technology. For this purpose, Al2O3 particles with different morphology (round and irregular) were separately added to the Al5Si feedstock. The morphological effects of Al2O3 on the microstructure, adhesion strength, hardness, and tribological properties of the coatings were comprehensively studied. Microstructural features of the coatings were examined by means of optical microscopy (OM), X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and electron backscatter diffraction (EBSD). The analysis reveals that most of the grains in both coatings are ultrafine, and approximately half of the total grain boundary length is composed of low-angle grain boundaries. Wear, hardness, and pull-off tests showed that both types of Al2O3 particles have a positive impact on porosity, adhesion, hardness, and wear resistance of the composite coatings. Compared to round Al2O3, irregular Al2O3 particles exhibit better retention in the coating, thereby resulting in a higher hardness and wear resistance.