Thick Coatings Research Articles

Quantitative analysis of commercial coating penetration into Fagus crenata wood using X-ray microtomography

Recent advances in wood treatment include the use of eco-friendly coatings to improve the wood’s dimensional stability and appearance. Assessing coating performance during its service life is critical for establishing a knowledge base for product optimization. Numerous approaches, including microimaging, are available for analyzing coating behavior. In addition to conventional microscopic techniques, high-resolution X-ray microtomography is a tool that provides nondestructive imaging of coatings and their substrates. In this study, we performed two-dimensional (2D) and three-dimensional (3D) visualization of tomographic reconstruction images of two coating types, spray and brush, to observe and assess the distribution of several commercial Japanese coating materials in Fagus crenata. X-ray images and plot profiles were used to determine the penetration depths and thicknesses of coatings. Each coated sample was scanned using X-ray microtomography, which allowed successful visualization and quantification of the coating penetration depth. Chemical content and concentration of the coating materials influenced penetration depth and amount.

Rationale Design for Anchoring Pendant Groups of Zwitterionic Polymeric Medical Coatings.

A biocompatible and antifouling polymeric medical coating was developed through rational design for anchoring pendant groups for the modification of stainless steel. Zwitterionic 2-methacryloyloxyethyl phosphorylcholine (MPC) was copolymerized individually with three anchoring monomers of carboxyl acrylamides with different alkyl spacers, including acryloylglycine (2-AE), 6-acrylamidohexanoic acid (6-AH), and 11-acrylamidoundecanoic acid (11-AU). The carboxylic acid groups are responsible for the stable grafting of copolymers onto stainless steel via a coordinative interaction with metal oxides. Due to hydrophobic interaction and hydrogen bonding, the anchoring monomers enable the formation of self-assembling structures in solution and at a metallic interface, which can play an important role in the thin film formation and functionality of the coatings. Therefore, surface characterizations of anchoring monomers on stainless steel were conducted to analyze the packing density and strength of the intermolecular hydrogen bonds. The corresponding copolymers were synthesized, and their aggregate structures were assessed, showing micelle aggregation for copolymers with higher hydrophobic compositions. The synergistic effects of inter/intramolecular interactions and hydrophobicity of the anchoring monomers result in the diversity of the thickness, surface coverage, wettability, and friction of the polymeric coatings on stainless steel. More importantly, the antifouling properties of the coatings against bacteria and proteins were strongly correlated to thin film formation. Ultimately, the key lies in deciphering the molecular structure of the anchoring pendants in thin film formation and assessing the effectiveness of the coatings, which led to the development of medical coatings through the graft-onto approach.

In-situ synthesis of BN/Al18B4O33 heterogeneous core-shell nanowires with different BN shell thicknesses and the microstructure evolution mechanism

A simple method was developed for the controllable synthesis of novel BN-coated aluminum borate (Al18B4O33) heterogeneous core-shell nanowires using Al4B2O9 nanowhiskers as rigid templates. This method allows the fabrication of Al18B4O33 nanowires with BN coatings of different thicknesses. The phases, microstructures, and chemical compositions of the samples were investigated using X-ray diffraction (XRD), scanning electron microscopy (SEM), Fourier transform infrared spectroscopy (FT-IR), transmission electron microscopy (TEM), and other characterization techniques. The heterogeneous core-shell nanowires of BN/Al18B4O33 had diameters and tube lengths of 35–60 nm and 400–600 nm, respectively, and the thickness of the BN cladding shell was between 2 and 7 nm. The concentration of B* volatilized on the whisker surface could be controlled by varying the ammonia flow rate, which in turn regulated the thickness of the BN cladding layer. The thickness of the BN cladding changed more significantly when the ammonia flow rate was varied at the Al4B2O9 nanowhisker's decomposition temperature. The experimental results show that the BN on the BN/Al18B4O33 heterogeneous core-shell structured nanowires conforms to the vapor–solid (VS) growth mechanism.

Coupled Monte Carlo density functional theory calculations of cold and laser-assisted electron field emission from graphene-coated copper cathode

Field emission is an important process with a variety of applications. Quantitative predictions of such electron emission need to include details of the internal potentials that shape the electronic wavefunctions (and hence the tunneling probability), predictive analysis of the work function barrier (ΦB), and knowledge of the electron distribution at the surface that constitutes the supply function. Here, these various factors were all collectively considered based on a combined Monte Carlo-density functional theory approach. Results were obtained for both the field-dependent cold electron emission current density as well as photoemission from a short laser pulse. The method also allows for calculations of field-dependent emittance. The technique is general and could be extended to include plasmon–polariton modes, different thicknesses of coatings, and role of surface adsorbates and defects.

VACUUM SYSTEM FOR COATING PARTS OF ROCKET AND SPACE EQUIPMENT

A vertical type vacuum plant was created for applying coatings using the ion-plasma deposition method to the inner surface of hollow products with a diameter of up to 200 mm and a length of up to 1000 mm. The plant includes: a vacuum chamber with a vacuum system, an evaporator with a magnetic system, a power supply and control system, a cooling system. Radial evaporation cathode of tubular shape with controlled arc is used. Inside the cathode is a magnetic system that controls the movement of cathode spots on its surface. Permanent magnets create arched magnetic fields that hold the position of the discharge track in the tangential direction. The trajectory of the movement of the cathode spots has the form of an ellipse stretched along the cathode. For uniform spraying of the cathode surface, the track moves in two directions: around the circumference of the cathode surface and along its length. A mechanism for moving the magnetic system is mounted on the cover of the vacuum chamber. The product to be coated is mounted inside the vacuum chamber in a vertical position thanks to the removable top cover. The necessary rarefaction of the atmosphere (vacuum) is achieved with the help of two vacuum pumps. Coating materials are traditional Сr and Ni-Cr alloys. A feature of the coating structure is presented: the formation of a combination of solid condensed and soft droplet phases. The droplet phase is a part of the evaporator material with several times lower hardness compared to the nitrided condensed phase. The distribution of the soft phase in a strong coating prevents its brittleness, which is important for thick coatings. The disadvantage of the vacuum-arc deposition process is the heating of the part to a temperature of 380-450 °C. To exclude the softening of the main metal of the combustion chamber and nozzle, it is recommended to use bronze alloys with a recrystallization temperature of at least 500 °C.

Production of Cu/Diamond Composite Coatings and Their Selected Properties.

This article presents Cu/diamond composite coatings produced by electrochemical reduction on steel substrates and a comparison of these coatings with a copper coating without diamond nanoparticles (<10 nm). Deposition was carried out using multicomponent electrolyte solutions at a current density of 3 A/dm2 and magnetic stirring speed of 100 rpm. Composite coatings were deposited from baths with different diamond concentrations (4, 6, 8, 10 g/dm3). This study presents the surface morphology and structure of the produced coatings. The surface roughness, coating thickness (XRF), mechanical properties (DSI), and adhesion of coatings to substrates (scratch tests) were also characterized. The coatings were also tested to assess their solderability, including their spreadability, wettability of the solder, durability of solder-coating bonds, and a microstructure study.

Exploring the Impact of Spray Process Parameters on Graphite Coatings: Morphology, Thickness, and Tribological Properties

This study explores, through a full factorial experimental design, the effects of graphite concentration and spray flow rate on the morphology, thickness, and tribological performance of graphite coatings for potential tribological applications. Coatings were applied to rough substrates using varying concentrations and flow rates, followed by analysis of their morphological characteristics, roughness, thickness, coefficient of friction (COF), and wear behavior. The results revealed distinct differences in the coating morphology based on flow rate, with low-flow-rate coatings exhibiting a porous structure and higher roughness, while high-flow-rate coatings displayed denser structures with lower roughness. A COF as low as 0.09 was achieved, which represented an 86% reduction compared to uncoated steel. COF and wear track measurements showed that thickness was influential in determining friction and the extent of wear. Flow rate dictated the coating structure, quantity of transfer film on the ball, and the extent of graphite compaction in the wear track to provide a protective layer. SEM and elemental analysis further revealed that graphite coatings provided effective protection against wear, with graphite remaining embedded in the innermost crevices of the wear track. Low flow rates may be preferable for applications requiring higher roughness and porosity, while high flow rates offer advantages in achieving denser coatings and better wear resistance. Overall, this study highlights the importance of optimizing graphite concentration and spray flow rate to tailor coating morphology, thickness, and tribological performance for practical applications.

Pulsed Laser Ablation Characteristics of Light-Absorbing Mask Layer Based on Coating Thicknesses under Laser Lift-Off Patterning Process.

Thin transparent oxide layers are typically patterned for use in electronic products including semiconductors, displays, and solar cells for applications such as transparent electrodes, insulating films, and encapsulation films. Conventional patterning methods have traditionally been used in photolithography and lift-off processes. Photolithography employs the wet development process, which has disadvantages such as potential undercut effects, swelling, chemical contamination, and high process costs. On the other hand, laser ablation, which has the advantages of high accuracy, high speed, a noncontact nature, and selective processing, can be used to pattern thin films. However, absorption in transparent oxide films is usually low. In this study, experiments were conducted to determine the ablation characteristics of mask layers. The factors affecting ablation, including beam radii, fluences, overlap ratios, and coating thicknesses, were examined; and the parameters characteristic of residue-free ablation, namely the ablation threshold, minimum fluence, and minimum ablation linewidth, were also examined. The experimental results revealed that the beam radius was an important parameter in determining the resolutions of transparent films and substrates.

Investigate the Effect of Coating Concentration and Coating Thickness on the Anti-microbial Properties of Polycarbonate Sheet

This paper investigates the effect of coating concentration (ppm), and coating thickness (µm) on the anti-microbial properties of polycarbonate sheets using a variety of anti-microbial agents (Cu-infused Mg(OH)2, Mg(OH)2, Cu(OH)2, MgO, CuCl2.2H2O, and ZnO). In addition, a complete analysis was performed for all agents to rank the best agent in terms of the highest anti-microbial performance against E. coli K-12 MG1655 in two time intervals (4 and 24 hours). The coating concentration (ppm) was found to be a significant factor in the anti-microbial characteristics for Cu-infused Mg(OH)2, Mg(OH)2, Cu(OH)2, MgO, CuCl2.2H2O, and ZnO (p = 0.004, p &lt; 0.0001, p &lt; 0.0001, p = 0.0297, p = 0.0011, and p = 0.0130 respectively). The coating thickness (µm), on the other hand, was found to be a major contributor to the anti-microbial properties of Cu-infused Mg(OH)2, Mg(OH)2, Cu(OH)2, MgO, and CuCl2.2H2O (p &lt; 0.0001, p = 0.0004, p = 0.0011, p = 0.0310, and p &lt; 0.0001 respectively). The analysis determined that the coating did not influence the anti-microbial properties of ZnO. The interaction between the coating concentration (ppm), and the coating thickness (µm) was found to be a significant factor for Cu-infused Mg(OH)2, Cu(OH)2, MgO, CuCl2.2H2O, and ZnO (p &lt; 0.0001, p = 0.0001, p = 0.0004, p &lt; 0.0001, and p &lt; 0.0001 respectively), however, this was not a significant factor for Mg(OH)2. Highlights • The anti-microbial activity of the inorganic material is dependent on the particle shape and size. • Particles with sharp edges will provide additional physical injuries to the microorganisms. • Smaller particle size will provide higher surface area therefore better interaction with microorganisms. • The coating concentration and coating thickness will be crucial to the anti-microbial activity. • The thermal embossing techniques demonstrate good adhesion to the surface.

Rapid preparation of nanocrystalline high-entropy alloy coating with extremely low dilution rate and excellent corrosion resistance via ultra-high-speed laser cladding

Ultra-high-speed laser cladding (UHSLC) not only offers an efficient solution to the limitations of conventional laser cladding but also aligns with the contemporary objectives of material conservation and efficiency enhancement in metal protective coatings. This study investigates the fabrication of CrFeCoNiMo0.2 high-entropy alloy (HEA) coatings using UHSLC and traditional laser cladding (TLC) methods. Key aspects such as macroscopic forming quality, element distribution, dilution rate, grain morphology, hardness, and electrochemical corrosion properties of both UHSLC and TLC coatings are thoroughly examined. Notably, UHSLC-produced coatings, with their significantly reduced thickness ranging from 100 to 300 μm, demonstrate an impressively low substrate dilution rate compared to the 2–3 mm thickness of TLC coatings. The rapid solidification inherent in UHSLC leads to smaller grain sizes in the coating, resulting in enhanced hardness. Moreover, the UHSLC coating exhibits superior corrosion resistance, characterized by a lower maintaining-passivity current density in 1 mol/L H2SO4 and a higher self-corrosion potential relative to TLC coatings. This work presents a novel approach, employing high-efficiency and low-cost laser-cladding technology, to minimize dilution in the matrix and improve the coating properties of HEAs.

Revealing and Overcoming Unfavorable Electrochemical Behaviors of Thick LiNbO3-Coated NCM523 for All-Solid-State Lithium Batteries

All-solid-state batteries (ASSBs) are very promising for next-generation energy storage technologies owing to several key advantages including higher power density, better thermal and electrochemical stability, and improved safety for electric vehicles. In this work, bulk-type ASSB cells were prepared with 0–25 nm thick LiNbO3 coatings, and their electrochemical behaviors at different upper cutoff voltages (upper cutoff potential ≥ 4.40 V) were systematically compared. A thicker coating caused three unfavorable electrochemical behaviors in the first three cycles: (1) a higher overpotential, (2) sluggish discharge kinetics, and (3) capacity fading. The measured electronic conductivity decreased drastically with increasing coating thickness, suggesting that this may have caused behaviors (1–3). To overcome this, a carbon additive was used to improve electronic transport in the composite cathode and successfully suppressed the aforementioned behaviors. Our findings indicate that the combination of a thick LiNbO3 coating on NCM523 and carbon additive can achieve synergistic effects to improve both the electrochemical properties and durability of ASSB cells.

Thickness Variation of Conductive Polymer Coatings on Si Anodes for the Improved Cycling Stability in Full Pouch Cells.

Si-dominant anodes for Li-ion batteries provide very high gravimetric and volumetric capacity but suffer from low cycling stability due to an unstable solid electrolyte interphase (SEI). In this work, we improved the cycling performance of Si/NCM pouch cells by coating the Si anodes with the conductive polymer poly(3,4-ethylenedioxythiophene) (PEDOT) prior to cell assembly via an electropolymerization process. The thicknesses of the PEDOT coatings could be adjusted by a facile process parameter variation. Glow-discharge optical emission spectroscopy was used to determine the coating thicknesses on the electrodes prior to the cell assembly. During electrochemical testing, improvements were observed closely linked to the PEDOT coating thickness. Specifically, thinner PEDOT coatings exhibited a higher capacity retention and lower internal resistance in the corresponding pouch cells. For the thinnest coatings, the cell lifetime was 18% higher compared to that of uncoated Si anodes. Postmortem analyses via X-ray photoelectron spectroscopy and cross-sectional scanning electron microscopy revealed a better-maintained microstructure and a chemically different SEI for the PEDOT-coated anodes.

Failure mechanisms for Gd2O3–Yb2O3 co-doped YSZ thermal barrier coatings under high-temperature gradient

In this study, Gd2O3–Yb2O3 co-doped YSZ thermal barrier coatings with a top coat thickness of 400 μm were prepared on a nickel-based superalloy by atmospheric plasma spraying. The samples underwent multiple short-term and single long-term thermal exposures through burner rig tests under high-temperature gradients. The short-term thermal exposure duration of the coating was 25 s and the long-term thermal exposure duration was 1200 s. The microstructures and phase compositions of the samples were characterized, and their failure mechanism was discussed. The results demonstrate that during the burner rig tests, the coating surface temperature reached 2600K, resulting in coating sintering and sintered zone formation comprising coarse equiaxed grains. The short-term thermal exposure life of the coating is 3 cycles, and the long-term life is more than 1200s. After the single 1200s thermal exposure, the coating exhibited a stable cubic phase. However, under multiple 25s thermal exposures, the depth of the sintered zone increased with increasing number of cycles, leading to the formation of various vertical and transverse cracks within the coating. Coating failure was due to a combination of sintering and thermal-mismatch-induced stress.The early-stage coating delamination was attributed to sintering-induced transverse cracks, while the overall spallation was primarily ascribed to thermal-mismatch-induced transverse cracks.

SYNTHESIS OF COPOLYMERS FOR PROTECTIVE COATINGS

Copolymers were obtained in this work and the methodology for their synthesis was worked out. Various fillers were selected for the polymer coating. Resulting copolymers have good adhesion required for composite protective coatings. An experiment was conducted to determine the corrosion resistance of metals coated with copolymers when exposed to aggressive environments, as well as to determine the hardness and thickness of the polymer coatings obtained. It was found that the polymer coating filled with bronze powder, despite the small thickness of 43.4 μm, hasthe best adhesion and corrosion properties, as well as having the highest hardness values of 80.5 HB. Such physical and mechanical properties of polymer coatings allow them to be used as protective coatings for metal products working under the influence of aggressive media.

Impact of Alpha Rays on the Optoelectronic Properties of Epoxy Resin Thick Films

Irradiated epoxy thick films are important for optical properties and may be used in many optical applications. This study aims to evaluate the effect of alpha irradiation on the optical and structural properties of epoxy thick films. Epoxy resin films were prepared by mixing epoxy resin (A) with hardener (B) at a mixing ratio of 3:1. Thus, specific thick films with thicknesses of 0.7 mm,0.8 mm and 1 mm were manufactured. Using visible and ultraviolet spectroscopy is one of the most important methods for studying polymers band gaps and electrical properties. The absorbance and transmittance spectra were used to investigate the optical properties of epoxy coatings of different thicknesses over a wavelength range of 300 nm–900 nm. Optical properties, such as absorption coefficient, refractive index, extinction coefficient, real dielectric constant, imaginary dielectric and optical band gap, were measured. The results show that the epoxy thick films have good optical transparency in the low-wavelength region. The results showed that increasing the thickness of the resin films decreased the optical energy gap and refractive index while increasing the absorption and extinction coefficients. In comparison, the effect of irradiation on an epoxy film of thickness 1 mm leads to an increase in the transmittance spectrum and energy gap and a decrease in the optical constants. The Fourier-transform infrared (FTIR) spectrum of the films was examined and showed the types of chemical bonds of the epoxy films before and after irradiation.

Numerical analysis and structural optimization of a DLC coated capacitance wire-mesh sensor for measuring liquid metal-gas two-phase distribution

The detection of liquid metal-gas two-phase distribution in lead-cooled fast reactor once steam generator tube rupture occurs is vital to the security assessment of the reactor core. In this paper, considering the high temperature, corrosiveness and high conductivity of the liquid metal, a diamond-like carbon coated capacitance wire-mesh sensor is proposed to detect the two-phase distribution in liquid metal. Based on the software COMSOL, a numerical model is firstly established that is quantificationally verified by experiment to study and optimize the performance of the coated WMS. The measurement accuracy of the sensor is investigated by ranging the AC excitation frequency and structure parameters of the system. The results show that the liquid metal has blocking effect on the small bubbles and the sensor has great measurement accuracy when the transverse and vertical interval are 2 mm while the exitation frequecy, coat thickness and electrode diameter show little effect. This research could guide the measurement in liquid metal-gas two-phase flow.

Suppression of cracking in drying colloidal suspensions with chain-like particles.

The prevention of drying-induced cracking is crucial in maintaining the mechanical integrity and functionality of colloidal deposits and coatings. Despite exploring various approaches, controlling drying-induced cracking remains a subject of great scientific interest and practical importance. By introducing chain-like particles composed of the same material and with comparable size into commonly used colloidal suspensions of spherical silica nanoparticles, we can significantly reduce the cracks formed in dried particle deposits and achieve a fivefold increase in the critical cracking thickness of colloidal silica coatings. The mechanism underlying the crack suppression is attributed to the increased porosity and pore sizes in dried particle deposits containing chain-like particle, which essentially leads to reduction in internal stresses developed during the drying process. Meanwhile, the nanoindentation measurements reveal that colloidal deposits with chain-like particles exhibit a smaller reduction in hardness compared to those reported using other cracking suppression approaches. This work demonstrates a promising technique for preparing colloidal coatings with enhanced crack resistance while maintaining desirable mechanical properties.

Large amplitude voltage oscillations during plasma electrolytic oxidation (PEO) of niobium and their correlation with the porous morphology

Plasma electrolytic oxidation (PEO) is a technique that has been widely studied to obtain thick anodic oxide coatings based on aluminum, titanium, niobium, and other valve metals. In the case of niobium oxides, they are attractive because of their properties as semiconductors, biocompatibility, and high corrosion resistance. The electrochemical behavior during this process can vary according to the PEO parameters and influence characteristics such as coating thickness, adherence, morphology, and crystalline structure of the oxide film. In this study, unusual voltage oscillation transients are observed during the anodization of niobium under a galvanostatic PEO regime. The niobium substrates were anodized in three different electrolytic solutions (H3PO4, KOH, and C2H2O4), and the influence of temperature on the oscillation aspects in each one was investigated. In addition, three different current densities were tested to check the effect of this parameter on voltage oscillations. Scanning Electron Microscope (SEM), Energy Dispersive Spectrometer (EDS), and X-ray Diffraction (XRD) are used to characterize the samples. The results indicate a relationship between the exposed surface area and the pore morphology during the film growth in the oscillatory regime. A simultaneous process of oxide dissolution/pore filling and the micro-discharges observed during the PEO process is proposed.

Solid lubrication performance of multi-layered V2CTx coatings

MXenes induce excellent wear resistance under solid lubrication due to their distinctive surface chemistry, easy-to-shear ability, and capability to form low-friction and wear-resistant tribofilms. However, beyond the extensively studied Ti3C2Tx, other promising members of the MXene family remain largely underexplored. Therefore, we spray-coated multi-layer vanadium carbide (V2CTx) coatings (thickness ∼10.8 μm) on steel substrates and studied their tribological performance for prolonged times (10,000 cycles) using a reciprocating ball-on-disk tribometer with acting contact pressure of 445 MPa in ambient conditions. Results show that V2CTx-coated substrates demonstrate an 8-fold reduction in friction (COF of 0.11) and a 10-fold wear rate reduction (1.405 × 10−6 mm3 N−1 m−1). High-resolution materials characterization confirmed that the remarkable tribological performance of these coatings can be traced back to the formation of protective films on the substrate (tribofilm) and counterbody (transferfilm) consisting of contact pressure and frictional heat-induced degraded, deformed, exfoliated V2CTx nanosheets, nanocrystalline oxides, and amorphous carbon debris. This work fully elucidates the tribological potential of V2CTx, which is of utmost relevance for designing high-performance lubricating materials. Our work has assessed the performance of multi-layer V2CTx (M2XTx) due to its remarkable thermal stability, low molecular weight, good mechanical properties, and high interlayer spacing, thus serving as an entry point into diverse MXene compositions, including M4X3Tx (V4C3Tx).

Microstructure and mechanical property regulation of plasma-sprayed high-entropy (La0.2Nd0.2Sm0.2Eu0.2Gd0.2)2Zr2O7 thick coatings

The effect of critical plasma spraying parameters (CPSPs) on phase composition, microstructure and mechanical property of (La0.2Nd0.2Sm0.2Eu0.2Gd0.2)2Zr2O7 thick coatings was investigated. After coating deposition, the phase structure of (La0.2Nd0.2Sm0.2Eu0.2Gd0.2)2Zr2O7 was transformed from pyrochlore to fluorite in the coating. When the CPSP value increased from 0.83kW/Lpm to 1.17kW/Lpm, the porosity of as-deposited coating was decreased from (16.46 ± 0.65)% to (6.94 ± 0.44)%. As a result, the elastic modulus of the coating was improved from (59.34 ± 2.39) GPa to (79.19 ± 4.78) GPa, and the corresponding micro-hardness was also increased from (2.59 ± 0.30) GPa to (3.39 ± 0.37) GPa. Consequently, the fracture toughness of as-deposited coating was decreased with the increasing CPSP value, while the corresponding residual stress was obtained to be compressive stress and it increased from -(43.00 ± 1.96) MPa to -(70.42 ± 3.89) MPa, indicating that the lower CPSP value was beneficial to reducing the residual compressive stress, which might be in favor of enhancing thermal shock resistance of coating.