Properties Of Coatings Research Articles

The Influence of Adding B4C and CeO2 on the Mechanical Properties of Laser Cladding Nickel-Based Coatings on the Surface of TC4 Titanium Alloy.

The development of titanium alloys is limited by issues such as low hardness, poor wear resistance, and sensitivity to adhesive wear. Using laser cladding technology to create high-hardness wear-resistant coatings on the surface of titanium alloys is an economical and efficient method that can enhance their surface hardness and wear resistance. This paper presents the preparation of two types of nickel-based composite coatings, Ni60-Ti-Cu-xB4C and Ni60-Ti-Cu-B4C-xCeO2, on the surface of TC4 titanium alloy using laser cladding. When the B4C addition was 8 wt.%, the hardness of the cladding layer was the highest, with an average microhardness of 1078 HV, which was 3.37 times that of the TC4 substrate. The friction coefficient was reduced by 24.7% compared to the TC4 substrate, and the wear volume was only 2.7% of that of the substrate material. When the CeO2 content was 3 wt.%, the hardness of the cladding layer was the highest, with an average microhardness of 1105 HV, which was 3.45 times that of the TC4 substrate. The friction coefficient was reduced by 33.7% compared to the substrate material, and the wear volume was only 1.8% of that of the substrate material.

The Challenges and Advances in Recycling/Re-Using Powder for Metal 3D Printing: A Comprehensive Review

This review explores the critical role of powder quality in metal 3D printing and the importance of effective powder recycling strategies. It covers various metal 3D printing technologies, in particular Selective Laser Melting, Electron Beam Melting, Direct Energy Deposition, and Binder Jetting, and analyzes the impact of powder characteristics on the final part properties. This review highlights key challenges associated with powder recycling, including maintaining consistent particle size and shape, managing contamination, and mitigating degradation effects from repeated use, such as wear, fragmentation, and oxidation. Furthermore, it explores various recycling techniques, such as sieving, blending, plasma spheroidization, and powder conditioning, emphasizing their role in restoring powder quality and enabling reuse.

Vat photopolymerization of silica reinforced styrene-butadiene rubber elastomeric nanocomposites

Compared to their unfilled counterparts, elastomeric nanocomposites offer tailorable combinations of properties, including improved mechanical properties, increased durability, and enhanced thermal and electrical conductivity. However, the high viscosity caused by the presence of both the high molecular weight elastomer and the inclusion of fillers complicates additive manufacturing (AM) of elastomeric nanocomposites. This is especially challenging in vat photopolymerization (VP) AM, which requires resins that possess low viscosity (< 10 Pa·s) and exhibit sufficient storage modulus (∼ 104 Pa) when photocured. To address this process limitation, the authors have previously demonstrated decoupling the relationship between viscosity and molecular weight via VP of a photocurable composite latex resin. In this approach, a photocurable matrix is photocured as a scaffold around the latex particles, which provides sufficient modulus for the printed "green" part. Following a dehydration post-processing step, the latex particles coalesce to provide the final elastomeric mechanical properties without compromising feature resolution.In this work, the authors explore the effects of the addition of silica nanoparticles (10, 15, and 20 wt.%) on (i) the printability of photocurable styrene-butadiene rubber (SBR) latex resin and (ii) the mechanical properties of the resultant printed composites. The printable photocurable silica-SBR colloidal resin is realized by balancing the viscosity of the resin, the modulus of the cured green body, the silica nanoparticles content for reinforcement, and the high SBR content for elastomeric behavior. Specifically, the photocurable colloidal resin's viscosity is controlled by formulation design, while high silica nanoparticle content in the final part is achieved through evaporation of unreactive diluent. Characterization of the printed SBR nanocomposites with 20 wt.% silica reinforcement elucidated significant enhancements in the tensile strength (53 % increase), Young's modulus (671 % increase), and Shore A hardness (108 % increase) compared to printed SBR without filler reinforcement. To the authors' knowledge, this is the first report of 3D printing rubber nanocomposite using VP.

Mechanical and Fatigue Properties of Ti-6Al-4V Alloy Fabricated Using Binder Jetting Process and Subjected to Hot Isostatic Pressing.

Binder jetting 3D printing is an additive manufacturing technique based on the creation of a part through the selective bonding of powder with an adhesive, followed by a sintering process at high temperature to densify the material and produce parts with acceptable properties. Due to the high initial porosity in the material after sintering, which is typically around 5%, post-sintering treatments are often required to increase the material density and enhance the mechanical and fatigue properties of the final component. This paper focuses on the study of the benefits of hot isostatic pressing (HIP) after sintering on the mechanical and fatigue properties of a binder jetting Ti-6Al-4V alloy. Two different HIP processes were considered in this study: one at 920 °C/100 MPa for 4 h, and a second at a higher pressure but lower temperature (HIP-HPLT) at 850 °C/200 MPa for 2 h. The effects of the HIP on the densification, microstructure, mechanical behavior, and fatigue properties were investigated. The results show that the HIP-HPLT process produced a significant increase in the mechanical and fatigue properties of the material compared with the as-sintered parts and even with the conventional HIP process. However, the fatigue and fracture micromechanisms suggest that the oxygen content, which resulted from the decomposition of the binder during the sintering process, played a critical role in the final mechanical properties. Oxygen could reduce the ductility and fatigue life, which deviated from the behavior observed in other additive manufacturing techniques, such as powder bed fusion (PBF).

Effects of spraying parameters and heat treatment temperature on microstructure and properties of single-pass and single-layer cold-sprayed Cu coatings on Al alloy substrate

Exploring the deposition of single-pass and single-layer pure Cu coatings on Al alloy substrate through high-pressure cold spray technology is a crucial endeavor with significant implications for advancing the utilization of such coatings. Regrettably, research in this specific area remains scarce, highlighting the need for further investigation and understanding. This study examined the characteristics of cold-sprayed Cu coatings deposited on a 6061 T6 aluminum alloy substrate under varying gas temperatures and pressures, and explored the effects of subsequent heat treatment on the microstructure and mechanical properties of the Cu coatings. The morphology, phase composition, surface roughness, thickness, porosity, microstructure, shear strength, and microhardness of the cold-sprayed Cu coatings were systematically analyzed. The findings indicated that the spraying parameters had a substantial impact on the properties of the Cu coatings. Specifically, increased gas pressure led to rougher surfaces and lower porosity, whereas higher gas temperature produced smoother surfaces and also reduced porosity. At 800 °C and 4.0 MPa, the Cu coatings exhibited the lowest surface roughness, measuring 8.03 μm. Conversely, at 800 °C and 5.5 MPa, the Cu coatings demonstrated the lowest porosity, at 0.26 %. Moreover, the microstructure analysis showed evidence of dynamic recrystallization in the deposited Cu particles, contributing to enhanced mechanical properties. Following this, the influence of heat treatment on the microstructure and properties of the cold-sprayed Cu coatings was examined. The results demonstrated that annealing at different temperatures induced changes in the interfacial microstructure, with the formation of intermetallic compounds between the Cu coating and Al alloy substrate. This interdiffusion phenomenon led to improved bonding strength and mechanical properties of the Cu coatings, as evidenced by increased shear strength. After undergoing heat treatment at 400 °C, the Cu coatings exhibited the highest shear strength, measuring 49.89 MPa. However, excessive heat treatment temperatures resulted in the formation of cracks and a decrease in mechanical properties.

Enhanced mechanical, corrosion, and tribological properties of hydroxyapatite coatings for orthopedic and dental applications

Biomedical coatings were elaborated by pulsed electrodeposition with hydrogen peroxide (H2O2) into electrolytes on Ti6Al4V substrates, and the effect of H2O2 concentration on the electrolyte and the heat treatment was studied. The experimental procedures employed in this study produce a consistent hydroxyapatite coating. This coating is well-suited for use in bio-implants, as it enhances the integration of the implant with surrounding bone tissue and improves the mechanical performance. The coatings' surface morphology and chemical composition were assessed using scanning electron microscopy (SEM) in conjunction with energy-dispersive X-ray spectroscopy (EDXS) for x-ray microanalysis. X-ray diffraction (XRD) was also utilized to identify the phases and composition of the coatings. Nanoindentation and scratch tests were conducted to analyze the nanomechanical properties and adhesion behavior. Potentiodynamic polarization was employed in the Ringer solution to evaluate the corrosion resistance and replicate the conditions of the human body environment. The results of our thorough investigation revealed that employing pulsed electrodeposition with 9 % H2O2 in the electrolyte, combined with subsequent heat treatment, facilitated the creation of coatings comprising two distinct phases: stoichiometric hydroxyapatite (HAP) and β-tricalcium phosphate (β-TCP). Our meticulous research underscores the significance of this process in achieving these specific coating compositions. Under these tests listed above, this composite demonstrated favorable mechanical properties (E = 30.45 GPa and H = 72.2 MPa). It also exhibited superior scratch adhesion and a critical load of 23 MPa and 12 N, respectively. Additionally, an improvement in tribological comportment was observed, and the wear volume decreased from 4.15 106 μm3 to 2.44 106 μm3. The HAP coating heat treated with 9 % H2O2 exhibited the highest corrosion resistance, with Ecorr at −0.189 V/SCE and icorr at −1.11 μA cm−2

Enhanced bioactivity and mechanical properties of silicon-infused titanium oxide coatings formed by micro-arc oxidation on selective laser melted Ti13Nb13Zr alloy

The titanium scaffolds and surface-porous implants are manufactured by fast and cheap additive methods such as selective laser melting (SLM). The obtained irregularity and relative biological inertness of the titanium need proper surface modification. This research is aimed at forming bioactive multicomponent oxide coatings by micro-arc oxidation (MAO) at different process parameters on the selective laser-melted Ti13Zr13Nb alloy. The MAO process was carried out in a base solution containing 0.15 mol/L Ca and 0.1 mol/L GP, with different amounts of metasilicate added under two different applied voltages. Scanning electron microscopy, atomic force microscopy, X-ray electron diffraction spectroscopy, nanomechanical and nano scratch tests, water contact angle measurements, phosphate deposition observed in long-term immersion tests, and biological LDH and MTT assays were performed. The results showed that the coating microstructure, morphology, and properties were significantly dependent on process parameters. In particular, the metasilicate addition and its rising content in the electrolyte resulted in the higher development of the surface followed by better viability of osteoblasts at no necrosis, with no negative change in the other parameters, usually close to those obtained on silicon-free coatings. The obtained results prove that the addition of silicon to the electrolyte at the partial expense of calcium can be favorable for long-term titanium implants made by selective laser melting.

Rate-Dependent Tensile Properties of Aluminum-Hydroxide-Enhanced Ethylene Propylene Diene Monomer Coatings for Solid Rocket Motors.

Quasi-static and dynamic tensile tests on aluminum-hydroxide-enhanced ethylene propylene diene monomer (EPDM) coatings were conducted using a universal testing machine and a Split Hopkinson Tension Bar (SHTB) over a strain rate range of 10-3 to 103 s-1. This comprehensive study explored the tensile performance of enhanced EPDM coatings in solid rocket motors. The results demonstrated a significant impact of strain rate on the mechanical properties of EPDM coatings. To capture the hyperelastic and viscoelastic characteristics of EPDM coatings at large strains, the Ogden hyperelastic model was used to replace the standard elastic component to develop an enhanced Zhu-Wang-Tang (ZWT) nonlinear viscoelastic constitutive model. The model parameters were fitted using a particle swarm optimization (PSO) algorithm. The improved constitutive model's predictions closely matched the experimental data, accurately capturing stress-strain responses and inflection points. It effectively predicts the tensile behavior of aluminum-hydroxide-enhanced EPDM coatings within a 20% strain range and a wide strain rate range.

Study on microstructure and wear resistance of laser cladding TiAlZrVNiX high entropy alloy coating based on Laves phase modulation

The incorporation of Laves phase into HEAs coating represents a novel approach to enhance wear resistance, building upon the innovative background of titanium alloy surface protection. The TiAlZrVNiX (X = 1, 1.5, 2) HEAs coatings were prepared in this study using laser cladding advantages to achieve dependable wear-resistant coatings. The microstructure, phase composition, microhardness, and tribological properties of the HEA coatings were simultaneously investigated. TiAlZrVNiX coatings were composed of V-rich HCP solid solution phases, C14-Laves phases, and NiTi2 phases. The microhardness of the 1.5Ni coating measured 708.75HV0.3 and wear rate of 1.12 × 10−13m3N−1 m−1. The primary wear mechanism was abrasive wear, and it had been confirmed that the 1.5Ni coating exhibited best wear resistance. The Laves phase with high space utilization would produce precipitation strengthening and dispersion strengthening, effectively reducing the stress-induced microcrack diffusion. Additionally, the introduction of Ni elements induced the growth of the NiTi2 phase in order to enhance the strength while mitigating brittleness, thereby enhancing the wear resistance of the coatings.

Influence of Cu addition on the microstructure and tribological properties of Ti-based laser cladded composite coatings on TC4

Ti-based composite coatings using TC4/Ni60/Cu mixed powders with of 0, 5, and 10 wt% Cu additions were prepared on TC4 by coaxial powder feeding laser cladding to investigate the effects of the addition of Cu on their microstructure and tribological properties. Multiple technical methods were performed for characterization, and the results revealed that TiC, TiB, Ti2Ni, and α-Ti precipitated in all coatings. As Cu added, the coating microstructure was gradually refined, and quasi-nanometer Ti3Cu was synthesized in the 5 and 10 wt%-Cu coatings where the Ti3Cu-Ti2Ni and Ti3Cu-α-Ti composite structure phase were formed. The microhardness and wear resistance of the three coatings were higher than that of the TC4 substrate and presented a gradual decrease with the Cu additions. The friction coefficients of the above coatings were higher than those of TC4 and generally consistent. The study found that the appropriate Cu addition could enhance the forming quality of the coating, effectively refine the microstructure, improve the uniformity of the microstructure distribution, and reduce fluctuations in microhardness and tribological properties.

Crystal and band structures of N-doped Ti3O5 coatings: Experiments and first-principles calculations

N-doped α-phase Ti3O5 has received limited attention in both theoretical and experimental studies compared to N-doped TiO2. This work focuses on the production and analysis of N-doped Ti3O5 coatings, which can be facilely produced using air-based sputtering. First-principles calculations were employed to investigate the crystal and band structures of N-doped Ti3O5. The results revealed that substitutional nitrogen doping within the investigated range preserved the orthorhombic structure of Ti3O5. As the N-doping concentrations increased, Ti3O5 exhibited a transition from metallic to semiconducting characteristics, confirmed by the density of states and refined band calculations. The calculated bandgaps in the semiconductor regime aligned well with the limited experimental results, demonstrating the pronounced narrowing effect of nitrogen doping. Integrating these calculations with experimental findings enhances the understanding of the crystalline and physical properties of N-doped Ti3O5 coatings.

Microstructure, mechanical performance, thermal stability, and oxidation resistance of AlCrN/AlCrBN nano-multilayer coating

This study synthesized three different coatings using multi-arc ion coating technology: AlCrN, AlCrBN monolayer, and AlCrN/AlCrBN nano-multilayer coatings. A comparative investigation was conducted on the microstructure, mechanical performance, thermal stability, and oxidation properties of coatings. The results indicate the AlCrN, AlCrBN, and AlCrN/AlCrBN nano-multilayer coatings consist of face-centered cubic solid solution fcc-(Cr, Al)N phase. AlCrN/AlCrBN nano-multilayer coatings also exhibit better thermal stability and oxidation resistance than AlCrN and AlCrBN monolayer coatings. The AlCrN/AlCrBN nano-multilayer coatings have a dense, protective, Al2O3 layer formed during high-temperature oxidation. During high-temperature oxidation, the AM (amplitude modulation) decomposition of the AlCrN and AlCrBN monolayers in the AlCrN/AlCrBN nanolayers is inhibited by the structure of the multilayer coatings. The formation of dense oxides on the surface prevents the diffusion of Al and Cr atoms to the outside and prevents the diffusion of oxygen from the outside to the inside of the AlCrN/AlCrBN nanolayers.

Microstructure evolution and property regulation of CoCrNiNbx laser cladding coatings

The influence of different Nb on the microstructure evolution, properties of the CoCrNi laser cladding coatings was investigated. With the increase of Nb addition, the eutectic structures showed a transition from planar crystals to cellular crystals to dendritic crystals. Besides, the eutectic lamellae gradually became dense. A large amount of Ni3Nb-HCP structure precipitates were precipitated in the coatings with excessive Nb. The introduction of Nb brought about an increase in heterogeneous nucleation cores, which in turn significantly refined the grain size in the secondary remelting zone of the cladding coating. As the Nb content increased, the hardness of coatings gradually increased, but both wear resistance and corrosion resistance showed a trend of first increasing and then decreasing.

Modeling and Laboratory Investigation of Tack Coats as Bituminous Pavement Interlayer

The adhesive properties of tack coats between asphalt pavement layers are crucial for the pavement’s structural behavior. This study first involved numerical analyses to compare stress patterns, deformations, and displacements in the pavement structure under various geometric and mechanical conditions. A rational calculation method based on the theory of elastic multilayer systems was used to quantify the impact of layer properties such as thickness, stiffness modulus, and Poisson’s ratio on interlayer bonding. Three bonding conditions—Full Friction, Partial Bonding, and Full Debonding—were analyzed to understand the tack coat’s effect between the top two layers. The second phase involved characterizing the mechanical behavior of the interface through shear strength tests (Leutner shear test) on both laboratory-prepared specimens and samples from a 10-year-old highway. Specimens were prepared using a Roller Compactor and tested under different interface conditions: hot-on-hot (H/H), residual bitumen 200 g/m2 (RB 200), and residual bitumen 400 g/m2 (RB 400). The tests examined the bonding effects in terms of tangential force and shear displacement at failure, as well as the impact of vehicular traffic on rutting and fatigue failure. Finally, this study investigated the long-term aging effects of the binder on interlayer bonding and sought to correlate the results of numerical calculations with those of the laboratory tests.

Transparent self-cleaning coating prepared from SiO2/B4C and SiO2/B4C/TiO2 for the solar cell

Transparent self-cleaning coatings based on photocatalytic activity have attracted great attention in recent years owing to their promising applications in many fields, such as solar cell cover glass. This study reports a simple method to prepare transparent self-cleaning silicon dioxide (SiO2) coatings filled by boron carbide (B4C) and titanium dioxide (TiO2) nanoparticles. A sol-gel technique was used to synthesize a SiO2 solution containing B4C and TiO2 nanoparticles, and a dip-coating technique was followed to coat the composite solution on glass slides. The SiO2 coating was successfully obtained in the presence of both semiconductor nanoparticles as confirmed by FTIR and XRD measurements. Both the photocatalytic activity and self-cleaning property of the composite coatings were evaluated by photocatalytic degradation of a model dye, methylene blue, under visible light irradiation. The SiO2 coating containing both B4C and TiO2 nanoparticles exhibited an improved photocatalytic activity compared to the SiO2 coating including only B4C. In particular, a 46% degradation rate of the model dye methylene blue was achieved for the SiO2 coating containing 15 wt% B4C and 5 wt% TiO2 nanoparticles. Highly transparent composite coatings on glass slides were prepared. The SiO2 coating containing both B4C and TiO2 nanoparticles was found to exhibit ~8% reduction in the optical transmission of the glass slide and ~1% reduction in the efficiency of a solar cell containing the coated glass slide. These findings demonstrated that the SiO2 composite coatings have potential for self-cleaning applications in removing contaminants from the glass cover of the solar cell under visible light irradiation.Graphical

Investigations on the Structure, Mechanical Property, Wear and Oxidation Resistances of TiAlSiN Coatings by Tailoring Al/(Al + Ti) Ratios

Previous studies have broadly dealt with TiAlSiN coatings that exhibit promising characteristics as surface protective layers for antiwear and antioxidation applications. In this regard, revealing the correlations among coating composition, structure, and properties is vitally important for developing advanced TiAlSiN coatings. The present work addresses the issue by studying the structure and properties of TiAlSiN coatings by tailoring Al/(Al + Ti) ratios. To this end, TiAlSiN coatings are produced by arc deposition with the Al/(Al + Ti) ratios of 0.31, 0.42, 0.51, and 0.62, respectively. The results show that, when the Al/(Al + Ti) ratio ranges from 0.31 to 0.51, the phase structure is mainly TiN phase, and the hardness, wear resistance and oxidation resistance of the films are increased with the rise in the Al/(Al + Ti) ratio. When the Al/(Al + Ti) ratio reaches 0.62, the oxidation resistance of the coating does not improve significantly, while the mechanical and wear properties of the coating are deceased due to the formation of w‐AlN phase. Therefore, the appropriate Al/(Al + Ti) ratio at 0.51 provides overall improvements including mechanical properties, and wear and oxidation resistances under operation conditions. These findings show that optimizing the Al/(Al + Ti) ratio is a promising way to develop TiAlSiN coatings with advanced structure and properties.

Effects of Cr and Mo content on the microstructure and properties of Fe-based amorphous composite coatings by laser cladding

In this study, we successfully produced Fe-based amorphous composite coatings on the surface of 45 steel using laser cladding technology, and the impact of the relative content of Cr and Mo elements on the microstructure, hardness, and wear resistance of composite coatings has been investigated. The results show that the microstructure of the coating changes from dendrite to amorphous nanocrystalline when the content of Cr and Mo is 20 and 15 wt. %, respectively. However, when the Mo element continues to be added, elemental segregation will be caused, resulting in a large number of brittle Fe–Cr–Mo intermetallic compounds and MoSi2 ceramic phases in the coating. Therefore, the appropriate element ratio can not only increase the amorphous phase content in the coating but also prevent elemental segregation. Among the three types of amorphous composite coatings studied, the Fe45Cr20Mo15B10Si10 (wt. %) composite coating exhibited the most favorable performance, primarily due to its highest amorphous content (43.33%). Through the interaction of the amorphous phase, α-Fe, Fe–Cr solid solution, and a small proportion of intermetallic compounds, this coating achieved a hardness of 1282.8 HV0.2, approximately five times that of the 45 steel substrate, and demonstrated superior wear resistance.

Machine learning based prediction of Young's modulus of stainless steel coated with high entropy alloys

The High Entropy Alloy (HEA) coatings exhibit diverse properties contingent upon their composition and microstructure, addressing current industrial requirements. Machine Learning (ML) regression emerges as a proficient solution for predicting the properties of HEA coatings, offering a significant reduction in experimental work. The ML regressions including Support Vector Regression (SVR), Gaussian Process Regression (GPR), Ridge Regression (RR), and Polynomial Regression (PR), are effectively employed to predict Young's modulus of HEA coated Stainless Steel (SS) through a significant database. The statistical responses of the developed regression models are analyzed through evaluation indices of Coefficient of determination (R2), Mean Absolute Error (MAE), and Root Mean Square Error (RMSE). Among the regression models, the 2-degree PR model stands alone with a high prediction accuracy of R2-0.95, MAE-16.12, and RMSE-21.53. The 2-degree PR model demonstrates a significant correlation between the predicted and experimental Young's modulus, contributing to the accurate prediction of unknown Young's modulus of the HEA-coated SS. The prediction of Young's modulus by the PR model is more reliable, as proved by an error percentile of ±4.76 %, compared to the experimental values of Young's modulus.

Effect of ZrB2 on the wear resistance and corrosion properties of nanocrystalline Ni-Cu coatings fabricated by electrodeposition

In this study, a pulsed electrodeposition approach was used to create a Ni-Cu/ZrB2 composite coating on the surface of J55 steel. Ni-Cu/ZrB2 composite coatings with different material additions were prepared, and the surface morphology, grain size, microhardness and wear and corrosion resistance were investigated. The results confirmed that the embedding of ZrB2 in the Ni-Cu coating can refine the grains and make the coating surface denser. Furthermore, ZrB2 can effectively increase the wear resistance and corrosion resistance of the coating; the Ni-Cu/ZrB2 (1.0 g/L) composite coating reflects this by having the shallowest and narrowest wear cross-section as well as the lowest average friction coefficient (0.537). Additionally, the composite coating has the highest impedance modulus, reaching 83.60 kΩ/cm2. The composite coating improved corrosion resistance by 63.1 % compared to the pure sample. The enhancement in the coating's corrosion resistance can be attributed to three factors. Firstly, the addition of zirconium diborate refines the coating grain and changes the corrosion type from pitting corrosion to homogeneous corrosion. Secondly, zirconium diborate forms a physical barrier against corrosive ions. Lastly, the formation of the oxide layer on the coating during the process of corrosion, also enhances the material's resistance to corrosion.

Investigation of Optical Properties of Complex Cr-Based Hard Coatings Deposited through Unbalanced Magnetron Sputtering Intended for Real Industrial Applications

Investigation of Optical Properties of Complex Cr-Based Hard Coatings Deposited through Unbalanced Magnetron Sputtering Intended for Real Industrial Applications