Composite Coatings Research Articles

Influence of ultrasonic assistance on the microstructure and friction properties of laser cladded Ni60/WC composite coatings

The effects of different ultrasonic vibration powers on the distribution, phase structure, friction and wear properties of WC reinforced particles in laser melted Ni60/WC composite coatings are investigated. The effects of ultrasonic vibration on the microstructure, elemental distribution, crystal orientation, friction and wear properties of the fused coatings are analyzed. The experimental results show that the deposition of WC particles in the lower and middle parts of the coating is significantly improved after the introduction of ultrasonic vibration during the fusion cladding process. In particular, at 600 W ultrasonic power, not only the distribution uniformity of tungsten carbide particles in the coating is optimal, but also the composite coating shows better wear resistance. However, too much ultrasonic power increases the possibility of particle agglomeration. In addition, although the phase pattern of the coating does not change after ultrasonic vibration, the width of the columnar crystalline region of the coating is reduced, and the coating is covered by a homogeneous lamellar nanoscale eutectic structure with the phase compositions of the γ-(Fe, Ni) and M23C6 phases. The ultrasonic vibration improves elemental segregation of the coating, reduces the large number of precipitated phases in the coating, weakens the grain growth orientation, and relieves the local stress concentration in the coating. In addition, the mechanism of the influence of WC particles on the microstructure evolution and wear resistance of the composite coatings is discussed.

Research Progress on Polysaccharide Composite Films and Coatings with Antioxidant and Antibacterial Ingredients to Extend the Shelf Life of Animal-Derived Meat

Animal-derived meat is rich in proteins and other nutrients, but is prone to spoilage during storage, including microbial contamination and fat oxidation. Therefore, there is an urgent need to find effective solutions to extend the shelf life of animal-derived meat. Polysaccharides are natural macromolecules containing multi-hydroxyl structures and functional groups, which have good solubility, film-forming properties, etc., and can form edible films. Polysaccharide films can be combined with biopolymers, nanoparticles, and natural active agents to improve their properties and enhance the antioxidant and antimicrobial activities of the films. This review summarizes the various sources of polysaccharides, such as chitosan, hyaluronic acid, sodium alginate, carrageenan, starch, and pullulan polysaccharides and their combination with different substances to extend the shelf life of animal-derived meat. This review may serve as a reference for further development of polysaccharides in animal-derived meat preservation.

Tribological and Corrosion Properties of Al2O3@Y2O3-Reinforced Ni60A Composite Coatings Deposited Using Laser Cladding

Since rare earth oxides and hard ceramic particles improve coating quality, a novel Al2O3@Y2O3 core–shell structure was prepared. Then, Ni60A coatings with different amounts (2~6 wt.%) of Al2O3@Y2O3 core–shell structures were prepared using laser cladding technology on an H13 steel surface. To demonstrate the unique effect of the core–shell structure on the performance of the coatings, a set of controlled experiments was also conducted with different proportions of Al2O3-Y2O3 mechanically mixed powders. The effect of Al2O3@Y2O3 addition on the phase composition, element distribution, microstructure, wear, and corrosion resistance of the coatings was characterized and tested thoroughly. By comparing the forming quality, hardness, wear, and corrosion resistance of the different coatings, 2 wt.% was confirmed as the optimal concentration of Al2O3@Y2O3, and its corresponding friction coefficient was about 0.44. The wear rate was approximately 4.15 × 10−3 mm3·(N·m)−1, the self-corrosion potential was around −0.3659 V, and the self-corrosion current density was about 1.248 × 10−6 A·cm−2.

Study on the Microstructure and Performance of the Multi-Field Composite-Assisted Laser Cladding of Nickel-Based Tungsten Carbide Coatings

Improving the hardness and wear resistance of die cutting tools is an important issue in the study of the service life of die cutting equipment. Using laser cladding technology, nickel-based composite coatings with varying BiFeO3 contents were prepared on a 45 steel substrate, because BiFeO3 can have an effect on the dilution rate and microstructure of the sample; morover BiFeO3 is a new type of multiferroic material with certain magneto-electric coupling effects which can be prepared for the study of added magnetic fields. The microstructure and morphology were characterized to determine the optimal BiFeO3 content. Based on the optimal addition of BiFeO3, a comparative analysis was conducted to investigate the effect of different magnetic field strengths under a composite energy field on the microstructure, hardness, and wear resistance of Ni-based WC cladding layers. The results show that the optimal addition of BiFeO3 was 5 wt%. At this concentration, there were no significant porosity defects in the coating, and the dilution rate was appropriate (4.77%). Additionally, the interface bonding strength was also increased. With optimal BiFeO3 addition, stirring with different magnetic field strengths was applied to the cladding layer, and the results show that the aspect ratio of the cladding layer gradually increased with increasing the alternating magnetic field strength. When the magnetic field strength in the composite energy field was 40 mT, the microstructure was fine and uniform, the hardness of the cladding layer reached the highest level, about 925.2 HV1.0, the wear resistance was also the best, the friction coefficient of the cladding layer was about 0.54, and the width of the wear mark was about 0.53 mm.

Experimental analysis on tribological behavior of Co/TiC/CaF2/Y2O3 composite coating developed by plasma transferred arc (PTA) cladding technique on AZ91D Mg alloy substrate

Abstract In this study, Co/TiC/CaF2/Y2O3 composite coating was fabricated on AZ91D Mg alloy by plasma transferred arc cladding (PTA) technique. The composite coating was fabricated with parameters as PTA current of 40 A and scan speed of 150 mm/min. The coating powders consisted of Co (60 wt. %) and Y2O3 (1 wt. %), with varying amounts of TiC (ranging from 34 wt. % to 19 wt. %) and CaF2 (ranging from 5 wt. % to 20 wt. %). An investigation on the effect of TiC and CaF2 content on the mechanical and wear performance of Co/TiC/CaF2/Y2O3 composite coatings has been conducted. Characterization of the coatings such as microstructure, elemental analysis, and phase analysis were investigated by scanning electron microscopic (SEM) with energy dispersive x-ray spectroscopic (EDX), and x-ray diffraction (XRD) respectively. Results showed that the phase constituents in the coatings were TiC, CoO, CoTi, Co2Y3, YTiO3, CoYC, TiO2, and CaF2. The maximum average microhardness of the clad layer was about 1162HV0.05, while the average microhardness of AZ91D Mg alloy substrate was about 68HV0.05. Based on this study, it has been found that the coating has 17 times more hardness than the AZ91D Mg substrate. Also, it can be concluded that the coating has nearly 37 times higher wear resistance than the AZ91D Mg alloy substrate.

Ceramic–Polymer–Carbon Composite Coating on the Truncated Octahedron-Shaped LNMO Cathode for High Capacity and Extended Cycling in High-Voltage Lithium-Ion Batteries

Ceramic–Polymer–Carbon Composite Coating on the Truncated Octahedron-Shaped LNMO Cathode for High Capacity and Extended Cycling in High-Voltage Lithium-Ion Batteries

Transparent Photochromic Coatings for Smart Windows and Information Storage

AbstractOrganic–inorganic composite photochromic coatings receive significant attention in energy utilization and conservation due to their easy application and rapid photoresponse. However, their high sensitivity to moisture limits practical applications. This study fabricates organic–inorganic composite functional coatings using a simple one‐pot method, producing materials with excellent photoresponsive, water resistance, and thermal insulation. Unmodified phosphotungstic acid serves as the inorganic photochromic filler, while methacrylate derivatives act as the polymer matrix, resulting in coatings with high initial transparency (over 85%). After 5 min of UV exposure, the samples shift to nearly non‐transmittable states in the visible range and maintain color depth through 14 coloring‐erasing cycles. Unlike polyvinylpyrrolidone substrates, which absorb moisture and soften quickly, this coating has a static water contact angle of up to 91.7°, showing excellent water resistance. Additionally, the composite material provides effective heat insulation in simulated chamber experiments, lowering the temperature by 15 °C compared to untreated chambers. In summary, this composite coating, with its excellent thermal insulation, rapid light responsiveness, stable cycling performance, and outstanding waterproof capabilities, proves highly suitable for applications such as smart windows, information storage, and building energy efficiency.

Effect of nano-Cu-loaded graphene fillers on tribological properties of PTFE based composite coatings

The Polytetrafluoroethylene(PTFE)-based composite coating has been widely used in the tribology field due to the high strength of graphene(GNS) and the self-lubricating property of PTFE. However, the weak interfacial bonding between GNS and PTFE inhibits the tribological performance of PTFE-based composite coatings. In this study, the composite coating is in situ fabricated by loading Cu nanoparticles on the GNS surface, and the microstructure, bonding, friction, and wear properties of the composite coating were investigated. The results showed that the interfacial bond strength, friction, and wear properties of Cu@GNS-PTFE coating are higher than those of pure PTFE and GNS-PTFE coating. Compared with the PTFE coating, the Cu@GNS-PTFE coating with the optimal ratio(5%) can increase the bond strength by 24.6% and reduce the wear rate by 42.2%. The lubrication mechanism of the Cu@GNS-PTFE coating is the Cu nanoparticle can increase the interfacial bonding property of GNS and PTFE from both mechanical interlocking and chemical activity, which can promote the synergistic lubrication of GNS and PTFE, and provide a theoretical basis for the further application of PTFE and GNS.

The SCC behavior of MAO/EPD biocomposite coatings on Ti-6Al-4V alloy

Aseptic loosening and inadequate osseointegration are significant issues associated with titanium alloy implants in complex body fluid environments. Surface coatings techniques are often employed to enhance the bioactivity and osseointegration capabilities. In this research, biocomposite coatings were fabricated on Ti-6Al-4V alloy employing micro-arc oxidation (MAO) and the integration of micro-arc oxidation/electrophoretic deposition (MAO/EPD) technology. Microstructure, bioactivity, and corrosion resistance of the coatings were studied. To investigate the effect of the coatings on the stress corrosion cracking (SCC) behavior of Ti-6Al-4V alloy, slow strain rate tension (SSRT) tests were conducted in simulated body fluid (SBF). Results show that the adhesive strength of the MAO/EPD composite coatings is around 28.41N, with an average contact angle of 19.05 °, indicating excellent wettability and biocompatibility. The corrosion rate of biocomposite coatings is 3.43 μm·a−1 and the biocomposite coatings exhibit excellent SCC resistance, with a SCC sensitivity of 9.21%, which is significantly lower than the 18.39% of Ti-6Al-4V alloy. This can be attributed to the lower porosity of the coatings, which can provide excellent protection for the alloy.

Study of corrosion resistance of cold sprayed Al + B4C composite coatings

Study of corrosion resistance of cold sprayed Al + B4C composite coatings

Corrosion resistance and biocompatibility of magnesium alloy with bioactive glass-reinforced hydrogel composite coatings

Magnesium (Mg) alloy is a promising candidate for biodegradable implants; however, its rapid degradation can create an unstable physiological environment that hampers tissue regeneration. To address this challenge, a polyvinyl alcohol (PVA) hydrogel composite reinforced with bioactive glass (BG) particles was developed as a coating for Mg alloy pellets, which underwent laser surface texturing (LST) and salting-out processes. results demonstrate that these treatments significantly enhance both the adhesiveness and swelling of the hydrogel coating. Notably, electrochemical corrosion assessments reveal a marked improvement in corrosion resistance, with the Mg–B1-L-S specimen exhibiting the highest performance after salting-out treatment. Electrochemical corrosion assessments revealed a significant enhancement in corrosion resistance for Mg alloy with the hydrogel coating, with the Mg–B1-L-S specimen showing superior performance following salting-out treatment. Immersion tests in simulated body fluid (SBF) confirmed the protective effect of the coatings, indicating that the addition of BG particles and salting-out treatment reduced mass loss and maintained pH stability. Biocompatibility evaluations through in vitro viability tests and osteogenic differentiation assays indicate that the Mg–B1-L and Mg–B1-L-S specimens exhibit superior cell activity, surface adhesion, and osteogenic potential. These findings highlight the effectiveness of PVA-BG hydrogel composite coatings in enhancing the corrosion resistance and biocompatibility of Mg alloy implants, positioning this approach as a significant advancement in the development of biodegradable materials for biomedical applications.

Improvement of the microstructure and corrosion behavior of Ni-TiO2 composite coatings electrodeposited at various amounts of TiO2 powder

The purpose of this study was to produce efficient Ni-TiO2 composite coatings at different concentrations of TiO2 particles to enhance BS2 microstructure and corrosion resistance in 3.5 wt. % NaCl. % NaCl solution. EDS analysis shows that the Ti and O content increases by increasing the amount of TiO2. XRD results reveal that the preferential growth plane of pure Ni is (100), which corresponds to the (111) and (100) planes for Ni-TiO2 composite coatings. SEM shows that the substrates are coated homogeneously. In addition to the microstructural improvements, the corrosion resistance efficiency was enhanced significantly with the inclusion of TiO2 particles. Specifically, the study showed that 10 g/L of TiO2 provided the optimal balance, achieving a corrosion resistance efficiency of 74.6%, along with a marked reduction in porosity. Furthermore, the surface morphology confirmed a uniform and defect-free distribution of the TiO2 particles, contributing to the overall anti-corrosion properties. These findings suggest that Ni-TiO2 composite coatings are a promising candidate for industrial applications, particularly in environments where materials are exposed to harsh conditions, such as marine environments. The outcomes of this research have the potential to inform the development of advanced anti-corrosion strategies for various industries.

PTFE layer formation during brush electroplating of nickel

Brush electrodeposition of Ni/PTFE composite coatings was explored using a nickel high speed solution and polytetrafluoroethylene (PTFE) particles 6–9 μm in diameter. A novel bilayer-like, partially intercalated structure was produced, consisting of a rough nickel sublayer covered by an outer, compact, smooth PTFE layer. The study of the coating growth revealed that the PTFE particles bind together on the nickel coating valleys and grow until all the surface is covered by a polymer layer without the need of a baking stage. The resulting coating presents a hydrophobic surface with a low coefficient of friction (0.10) and higher corrosion resistance to salt spray testing than the nodular nickel coating. The coatings were produced using an aqueous nickel plating solution, where the hydrophobic PTFE particles were suspended using different substances: cetrimonium bromide (CTAB) cationic surfactant, isopropyl alcohol premixed with the particles, and ethanol premixed with the particles. High concentrations of the suspending products were detrimental for the deposition process, but optimal values of 0.1 g/l, 3 ml/l and 3 ml/l respectively were found. All compounds successfully suspended the PTFE particles and both alcohols produced the Ni/PTFE coating described before, but the CTAB failed to co-deposit the polymer.

Investigation of the effect of current density and ZrO2 bath concentration on electrodeposited Ni-P/ZrO2 composite coatings

In this study, Ni-P/ZrO2 nanocomposite coatings were deposited on St-37 steel substrates using the electroplating method with varying ZrO2 concentrations and current densities. To investigate the effects of electrolyte components and current density on coating properties, analyses were performed regarding microhardness, wear performance, and surface morphology. As a result of the analyses, it is observed that different bath concentrations and current densities significantly affect properties such as morphology, hardness, and wear performance. It is seen that the surface morphologies of the obtained coatings are generally smooth, but it is understood from the optical images that the surfaces of all nanocomposite coatings are rougher. While adding ZrO2 nanoparticles to the main matrix increases microhardness by approximately 40% compared to pure nickel, a similar but higher hardness value was obtained with the increase in current density. When examined in terms of wear performance, an average friction coefficient value of 3.15 times higher than that of pure nickel nanocomposite coatings was obtained.

Oxidation Behaviour of TiC/TiN Coatings Deposited by Chemical Vapor Deposition (CVD): Mechanisms, Structures, and Properties

This review explores the oxidation behavior of Titanium Carbide (TiC) and Titanium Nitride (TiN) coatings deposited by Chemical Vapor Deposition (CVD), with a focus on their industrial applications as wear-resistant coatings for cutting tools. It examines effect of process parameters—such as temperature, pressure, precursor composition, and substrate preparation—on formation and performance of TiC/TiN coatings. The review evaluates the microstructural characteristics of these coatings, including crystal structure, using X-ray diffraction analysis. Also, estimates the mechanical properties such as hardness, wear resistance, and adhesion strength. Additionally, the review covers the thermal stability of TiC/TiN coatings, emphasizing their ability to maintain structural integrity at high temperatures, which is essential for the performance of cutting tools and other industrial components. A major focus is the oxidation behavior of TiC/TiN coatings, including the impact of coating composition, deposition methods, and environmental conditions. The review details oxidation kinetics and mechanisms, revealing various stages of oxidation at different temperatures. It also examines oxide scale morphology and its effect on coating properties. Finally, this review reveals the importance of alloying elements, like silicon, in improving oxidation resistance. Composite coatings such as TiSiN and TiSiCN are shown to offer better high-temperature stability compared to traditional TiN coatings. The effects of coating thickness and the benefits of multilayer coatings for enhanced oxidation resistance are also discussed.

Synergism of h-BN and La2O3 in improving the tribological performance of Al2O3 coatings

Wear is a significant cause of material loss, contributing to surface degradation of crucial components, notably within engineering sectors. This article is dedicated to enhancing tribological properties through the implementation of Al2O3-based ceramic coatings, specifically targeting situations where reciprocating sliding wear predominates. This study introduces lanthanum oxide (La2O3), a rare earth oxide, as a reinforcing material in Al2O3 coatings in varying weight percentages of 1.2%, 1.6%, and 1.8% respectively along with 3% hexagonal boron nitride (h-BN). The coatings were developed by the high-velocity oxy-fuel (HVOF) surface modification technique, with SS304 serving as the substrate. The porosity, hardness, and chemical composition of the developed coatings were examined. Additionally, reciprocating tribological testing of the coatings was conducted at two loads (5 N and 15 N) under dry sliding conditions. Results indicated that coating containing 95.4% Al2O3–3% h-BN–1.6% La2O3 reduced the porosity up to 50% and improved hardness by 46% compared to the 97% Al2O3–3% h-BN coating. The formation of the α-Al2O3 phase leads to an increase in coating hardness and a reduction in porosity. Notably, the coating comprising 97% Al2O3–3% h-BN exhibited the lowest coefficient of friction among all developed coatings under both loads. Furthermore, an increase in load led to a decrease in the coefficient of friction for all developed coatings. Furthermore, the addition of La2O3 (1.6 wt%) to the coating with 3 wt% h-BN exhibited the lowest wear at both loads. The findings also revealed increased wear at high loads for all developed coatings. SEM, EDS, and XRD analysis of the worn surfaces revealed the contribution of h-BN and La2O3 in enhancing friction behavior through the formation of oxides such as α-Al2O3, B2O3, Al8B2O15, and Al11La0.497O17, along with alterations in wear mechanism and the size of wear debris. The composite coatings developed in this study shall be helpful in advanced engineering applications.

Bio‐inspired graphene oxide/epoxy coating with ordered stacking for anticorrosion/wear protection of Mg alloy

AbstractThe random arrangement of graphene oxide (GO) nanosheets within the organic coating forms a conductive network, thereby accelerating galvanic corrosion and exacerbating metal deterioration. Inspired by ordered layered structure of natural nacre, this study has successfully fabricated a biomimetic GO/epoxy coating on Mg alloy to prevent corrosion and reduce wear. By polymerizing polyaniline (PANI) and dopamine (PDA) on the GO, GO/PANI/PDA sheets with good dispersibility and impermeability are obtained. Subsequently, the bio‐inspired coating (I‐GO/PANI/PDA‐WEP) with “nacre‐like” structure is prepared via alternately spraying GO/PANI/PDA layers with epoxy layers. The anisotropic electrical conductivity of the coating is derived from the ordered distribution of GO/PANI/PDA layers to the Mg substrate, which can conduct electricity more efficiently in‐plane while suppressing longitudinal electron transport. The enhanced physical barrier effect by the “nacre‐like” structure and the electron suppression effect can improve anticorrosion performance. The coating reduces the corrosion rate by 6.3 × 105 times in comparison to Mg alloy. Moreover, this coating shows excellent wear resistance, which protects Mg alloy from friction and wear with a reduction in wear rate by approximately 96%. This bio‐inspired approach offers a unique strategy for fabricating GO composite coatings with exceptional performance.Highlights The corrosion/wear resistance of I‐GO/PANI/PDA has greatly improved. GO/PANI/PDA coating exhibits excellent anisotropic conductivity. Galvanic corrosion is inhibited due to the addition of GO/PANI/PDA. “Nacre‐like” structure shows high labyrinth effect. The ordered orientation of GO/PANI/PDA suppresses out‐plane electron transport.

Corrosion resistance analysis of Al2O3-TiO2 composite ceramic coatings on carbon steel pipe surfaces

This study investigates the corrosion resistance of Al2O3-TiO2 composite coatings reinforced with multi-walled carbon nanotubes (MWCNTs) on carbon steel pipe surfaces. Coatings were deposited using atmospheric plasma spraying (APS) and high velocity oxy-fuel (HVOF) techniques. Microstructural analysis revealed that HVOF-sprayed coatings exhibited denser and more homogeneous structures compared to APS-sprayed coatings. Electrochemical tests in 3.5 wt% NaCl solution showed that the HVOF-sprayed Al2O3-13 wt% TiO2-1.5 wt% MWCNT coating demonstrated the lowest corrosion current density of 7.6 × 10−9 A/cm2 and the most positive corrosion potential. Hot corrosion tests in a simulated boiler environment (500°C, 1000 h) revealed that this coating also exhibited minimal weight gain (0.9 mg/cm2) and thickness loss (2 μm). The corrosion rate of the optimal coating was 0.05 mm/year, significantly lower than the bare carbon steel (2.45 mm/year). XRD analysis of corroded samples showed that HVOF-sprayed coatings maintained their original phase composition without detectable substrate corrosion products. The superior corrosion resistance of the HVOF-sprayed Al2O3-13 wt% TiO2-1.5 wt% MWCNT coating is attributed to its optimized composition, dense microstructure, and the reinforcing effect of MWCNTs. These findings provide valuable insights for developing advanced coating solutions to mitigate corrosion-related challenges in the oil and gas industry and other harsh industrial environments.

Plasma electrolytic oxidation deposited HAp-Ta2O5 composite coatings on Ti6Al4V for biomedical applications: The importance of Ta2O5 reinforcing phase

In this research, the focus was placed on enhancing the properties of hydroxyapatite (HAp) coating by the addition of various concentrations of tantalum pentoxide (Ta2O5) nanoparticles, ranging from 0 to 1.5 g/L, to its electrolyte solution. The HAp-Ta2O5 composite coatings were deposited on the Ti6Al4V metallic implant using the plasma electrolytic oxidation technique. The results of the X-ray diffraction test indicated that the increased concentration of Ta2O5 nanoparticles has no significant effect on the phase composition of the coatings. The denser and rougher coatings were fabricated when 1.5 g/L of Ta2O5 nanoparticles were added to the solution. The favorable microstructural properties of the HAp-1.5 g/L Ta2O5 composite coating resulted in a notable improvement in the mechanical properties, i.e., >40% increase in both microhardness and bonding strength compared to HAp. The corrosion resistance of the coated implants was evaluated through electrochemical impedance spectroscopy and potentiodynamic polarization tests. The inclusion of Ta2O5 nanoparticles in HAp coating led to a 72% reduction in the corrosion current density of HAp, indicating the constructive contribution of the nanoparticles to improved corrosion protection. The samples were incubated in simulated body fluid for 7 days to assess their in vitro immersion performance. All of the PEO-derived coatings stimulated the nucleation and growth of apatite grains, showing their superior biomineralization ability. An obvious decrease in the level of harmful ions such as Al3+ and V5+ released from the surface of composite coatings was obtained. These findings suggest that the developed system has potential for dental and orthopedic applications.

Composite electrochemical coatings of Ni-CrB2 from sulfuric acid and sulfamate electrolytes: formation, structure and properties

Electrodeposited coatings are in demand in many industries: due to the high adhesive strength to the base metal, they can be applied to complex-shaped products, and the thickness of the deposited coating can be controlled. However, standard electrolytic coatings do not always meet the necessary operating requirements. In this case, the formation of composite electrolytic coatings, which consist in the modification of electrolytes by various dispersed particles, becomes an urgent task. These particles are introduced into the electrolyte and deposited together with the precipitate metals, which leads to changes in the coating properties. In this article, the structure, adhesive and corrosion properties of nickel-chromium diboride composite coatings obtained in the electrodeposition process are studied. Precipitation was carried out in sulfuric acid and sulfamate electrolytes with a concentration of dispersed chromium diboride particles of 10-40 g/l. The coatings consist of nickel and CrB2 phases. The adhesive strength of the coating with a steel base is satisfactory; chipping and peeling were not observed. The corrosion resistance of sulfamate electrolyte coatings is higher than that of the coatings obtained from sulfuric acid electrolyte due to the compactness of nickel precipitates. Chromium diboride in the coating provides 1.5-2 times greater corrosion resistance.