Excellent Wear Resistance Research Articles

Preparation and properties of ultra-high hardness Co-Cr-Mo-Nb-B high-temperature amorphous alloy coating

In this paper, a high temperature and amorphous alloy coating of Co26Cr26Mo26Nb7B15 was prepared by high-velocity oxy-fuel spraying. The phase structure, thermodynamic properties, hardness, friction and wear behaviors, and corrosion behavior and its mechanism were studied. The results showed that the glass transition temperature of the coating reached to 1058 K, and the hardness was as high as 1589.4 HV. The amorphous alloy coating of Co26Cr26Mo26Nb7B15 exhibited excellent wear resistance. Its friction coefficient was only 0.1152, which was about 25 % of 316 stainless steel, and the wear volume was only 0.1338 mm3. Additionally, the coating presented excellent corrosion resistance in 1 M hydrochloric acid solution, with the corrosion current density of 1.04 × 10−5 A·cm−2, and corrosion voltage of −0.32 V vs SCE.

Ti6Al4V alloy with diamond particle-reinforced Cu-based coatings: Microstructure and tribological performance

To enhance the surface wear resistance of the Ti6Al4V alloy, diamond particles-reinforced Cu-based composite coatings (D500/D1000/D2000 coating: 500/1000/2000 mesh diamond: Cu-based alloy powder = 1:30 (wt%)) were fabricated by vacuum cladding. Cu-based alloys with liquid phase temperatures lower than the phase transition temperature of Ti6Al4V alloys were employed as cladding materials to avoid performance deterioration of Ti6Al4V substrates. The microstructure, mechanical properties, and dry-sliding tribological properties of the Cu-based composite coatings have been investigated systematically. The Cu-based composite coatings are composed of the ductile intermetallic compounds Ti3Sn and SnTi2 as the metal matrix, the hard and brittle intermetallic compounds CuTi, CuTi2, Ti(Cu, Al)2 and CuSn3Ti5, in situ generated TiC and the directly introduced diamond particle as the reinforced phases. In addition, a TiC hard phase protective layer was formed around the diamond particles, which retained the original properties of the diamond. The hardness of diamond particles-reinforced Cu-based composite coatings is much higher than that of the Ti6Al4V. Among them, the D2000 coating possesses the highest microhardness. The average Vickers hardness (HV0.5) on the coating surface and nanoindentation hardness (H) on the coating cross-section (the middle part without diamond particles) of the D2000 coating are 1329.8 HV0.5 and 16.87 GPa), which are 4–5 times higher than that of the Ti6Al4V substrate (333 HV0.5 and 3.37 GPa). Nevertheless, the D2000 coating (wear rate of 50.75 ×10−5 mm3/Nm) demonstrates slightly inferior tribological performance compared to the D500 coating. The wear rate of the latter is approximately 13.37 × 10−5 mm3/Nm, which is only 1/5.6 of the substrate (75.67 ×10−5 mm3/Nm). The larger the diamond particle size, the more the diamond serves as a bearing capacity support point to prevent the hard WC ball from further ploughing into the composite coating, and the better the wear resistance of the coating. Notably, D500 coating with excellent wear resistance has the potential for application in various fields of the machinery industry, marine engineering, and aerospace.

High temperature mechanical properties and tribological behavior of nacre-inspired Ti (C, N)/Al-Cu composites

In order to improve the toughness of aluminum matrix composites with high ceramic contents, nacre-inspired Ti (C, N)/Al-Cu composites are prepared via freeze casting and pressure infiltration, and their mechanical properties and tribological behavior are investigated. The prepared composites can maintain excellent compressive strength, hardness and wear resistance when the experimental temperature increases from 25 °C to 300 °C. This can be attributed to the stable load bearing capacity of the Ti (C, N) ceramic layer at high temperature, the high interface binding capability between Ti (C, N) and Al, as well as the high crack growth inhibition ability of “layered network” structures. Moreover, the tribo-oxide layer formed during the wear process can further improve the wear resistance of the composites.

Microstructure and tribological performance of novel Ni-based alloy cladding with excellent high temperature wear resistance and self-lubrication performance

This paper aims to study the laser cladding of Ni-based alloy coatings with excellent high temperature wear resistance and self-lubrication performance on the surface of parts such that meet complex metallurgical service conditions. The composite alloy powders were formed by adding 3 wt%–11 wt% WS2 and Ti powder to NiCrCoMoBSi alloy powder, and the novel Ni-based alloy samples with high temperature wear resistance and self-lubrication performance were cladded on the surface of Cr28Ni48W5 substrate by laser cladding. The results show that the addition of WS2 and Ti powder had a significant influence on the microstructure evolution and high temperature wear resistance and self-lubrication performance of the samples. The laser cladding coating with 7 wt% WS2 and Ti had the 3 % TiS self-lubricating phase and 19 % enhanced phase with the best microstructure matching relationship, which improved the high temperature wear resistance and self-lubrication performance of the sample. At 800 °C, compared with the Cr28Ni48W5 superalloy substrate, the friction coefficient of the laser cladding coating was 0.22 and the wear ratio was 1.70 × 10−5 mm3 N−1 m−1, which were reduced by 60 % and 54.67 % respectively. The mechanism of the enhanced wear resistance and self-lubrication performance was elaborated.

New insights on impact wear of polycrystalline diamond compact: Effect of interface state on kinetic response and damage behavior

The impact wear of polycrystalline diamond compact (PDC) cutters caused by the discontinuous cutting during the drilling process significantly affects the lifespan and efficiency of the drilling tools. Different PDC impact contact interface states are realized through the selection of impact mating materials. Understanding the effects of different interface states on the kinetic response, damage behavior and impact wear mechanism of PDC is significant in guiding the practical design of material structures with excellent impact wear resistance. Therefore, the kinetic response and damage behavior of PDC impact with different mating materials are investigated. The results show that the kinetic response and damage behavior of PDC are correlated with the mechanical properties of the mating material and physicochemical changes at the impact surface interface. Adhesion and filling resulting from strong covalent bonding and filling effects mitigate the interfacial stress and reduce the average impact force of SiC and Al2O3. Moreover, brittle fracture and filling effects increase the consumption of kinetic energy of SiO2, resulting in an energy absorption of up to 86 %. In addition, the strong covalent bonding effects exacerbated the damage to the PDC interfaces, leading to the internal fracture of diamond particles and detachment at grain boundaries. Furthermore, the filling effect formed plays a specific protective role for diamonds. However, it increases the energy absorption rate and reduces the mating material damage efficiency. In this work, the relationship between impact interface state and impact wear mechanism has been established by understanding the kinetic response, damage morphology, and structural evolution.

Effect of introduction of MXene on low energy plasma electrolytic oxidation

This article discusses the development of 2D MXene-containing coatings on magnesium alloy LA91, which are produced using low-energy plasma electrolytic oxidation (LePEO) processing. The coatings enhance substrate corrosion resistance and offer improved wear resistance. Notably, the coatings exhibit increased corrosion and wear resistance, as well as higher microhardness, while simultaneously reducing the voltage required for the PEO process. The addition of MXene to electrolyte enhances its conductivity, leading to the incorporation of MXene into the oxide coating. Despite a reduction in coating thickness, the resulting coatings demonstrate excellent corrosion resistance, wear resistance, and hardness. The MXene-enriched PEO coatings show impressive performance metrics compared to the MgLi alloy substrate. The corrosion current density of the MXene-enriched coatings is only 3.3 % of that of the MgLi alloy, while the average friction coefficient is reduced to 39.9 %, and the hardness is 6.6 times greater. Additionally, the coatings exhibit enduring corrosion resistance during prolonged immersion and neutral salt spraying tests. These performance improvements are attributed to MXene's ability to hinder the transmission of corrosive media, as well as its interlayer shear and self-lubrication properties, which enhance wear resistance.

Biomimetic Layered Hydrogel Coating for Enhanced Lubrication and Load-Bearing Capacity

Biomimetic hydrogel lubrication coatings with high wettability and low friction show great promise in tissue engineering, wound dressing, drug delivery, and intelligent sensing. Inspired by the hierarchical structure of natural cartilage, a layered hydrogel coating was constructed to functionalize rigid polyetheretherketone (PEEK). The layered hydrogel coating features a structural design comprising a top soft layer and a middle robust layer. The porous structure of the top soft hydrogel layer stores water molecules, providing surface lubrication, while the dense structure of the middle robust hydrogel layer offers load-bearing capacity. These synergistic effects of the gradient hydrogel layer endow the PEEK substrate with an ultra-low coefficient of friction (COF~0.010 at 5 N load), good load-bearing capacity (COF~0.031 at 10 N load), and excellent wear resistance (COF < 0.05 at 5 N load after 20,000 sliding cycles). This study introduces a novel design paradigm for robust hydrogel coatings with exceptional lubricity, displaying the potential application in cartilage replacement materials.

The effect of the modification mechanism of SiO2 in resin‐based friction materials on the mechanical and tribological performance

AbstractThis study aimed to address the thermal degradation of resin‐based friction materials in the mid‐temperature stage (200–250°C), as well as the resulting instability of the friction coefficient and decrease in the mechanical properties. To investigate the impact on the toughening and wear resistance properties, this study employed nanosilica‐modified resin‐based friction materials. The mechanical, friction, and wear properties of the modified samples were tested using a Rockwell hardness tester, hydraulic universal testing machine, and constant speed friction tester. The phase composition and microstructure of the samples were analyzed by scanning electron microscope, energy‐dispersive x‐ray spectroscopy, x‐ray diffraction. When the mass fraction of nanosilica was 3%, modified sample S3 exhibited excellent mechanical properties, with shear strength and compressive strength reaching 40.3 and 171.7 MPa, respectively, which were increased by 30% and 9% compared to unmodified sample S1. Moreover, the density and hardness of sample S3 showed minimal variation compared to those of unmodified sample S1. In the temperature range of 100–250°C, the wear rate of modified sample S3 remained within the range of 0.22 × 10−7–0.38 × 10−7 N−1 m−1, with a friction coefficient of 0.38 at 200°C, demonstrating excellent wear resistance.

The phase structure, hardness, and wear properties of the Cu–Cr–Zr–Nb alloy under different aging states

As a typical age-strengthened alloy, Cu–Cr–Zr alloys have high strength, good electrical conductivity, and excellent wear resistance. In this work, the Cu–Cr–Zr–Nb alloys were in different aging states after the aging process. After aging at 460 °C for 4 h, the alloy was peak-aging. The common effect of the existence of the FCC Cr particle, which was coherent with the Cu matrix, and the increase in hardness improved the wear property of the alloy. The results of the wear test showed that the optimal wear parameter was a speed of 300 rpm and a load of 5 N. Under these wear parameters, the alloy had the lowest mean coefficient of friction (COF) value and the least mass loss, having the best wear resistance. Furthermore, the wear mechanism of the alloy was mainly adhesive wear and abrasive wear.

Preparation and tribocorrosion behavior of electrodeposited Ni–W/ SiC composite coatings

Ni-W composite coatings that are applied using electrodeposition exhibit excellent mechanical strength, corrosion resistance and wear resistance and are a substitute for hard chrome because they involve fewer environmental hazards than regular chromium plating processes. This study determines the effect of process parameters, such as current density (5, 10 and 15 A/dm2) and SiC concentration (0.5, 1.0 and 1.5 g/L), on the chemical composition, structure, mechanical properties and corrosion resistance of electrodeposited Ni-W/SiC composite coatings and determines the interaction between the mechanical behavior and the electrochemical reactions that occur during corrosion and friction. The experimental results show that there are no cracks on the surface of the coating and that the surface roughness increases as current density increases. As the content of W and SiC particles in the composite coating increases, the hardness and corrosion resistance of the coating increase because of solid solution strengthening and nano-ceramic particle dispersion strengthening.In order to verify the protective performance of the coating in complex environments, a ball-on-disk abrasion tester and a potentiostat are used to determine the tribocorrosion behavior of the Ni-W/SiC composite coating against the sliding of the Al2O3 counter-body. In 3.5 wt%NaCl solution and at +600 mV, the corrosion and wear characteristics of composite coatings that are produce using different process parameters are determined. Analysis of the synergistic effects of corrosion and friction shows that the wear component (△Wwear) is 3–5 times greater than the corrosion component (△Wcorr), which is the main cause of coating damage. The greater the hardness of the coating, the less mass is lost for the wear component (△Wwear). The results show that the operating parameters for producing ideal Ni-W/SiC composite coatings are a SiC particle concentration 1.0 g/L and a current density of 10A/dm2. These settings give the best wear resistance in corrosive environments.

Competitive relationship between the FCC + BCC dual phases in the wear mechanism of laser cladding FeCoCrNiAl0.5Ti0.5 HEAs coating

This work elaborated the microstructure and wear behavior of laser cladding (LC) FeCoCrNiAl0.5Ti0.5 high-entropy alloys (HEAs) coatings on AISI 1045 steel substrates. The microstructure of the HEAs coatings is mainly comprised of a body-centered-cubic (BCC) + face-centered-cubic (FCC) dual-phase structure. Besides, the coating exhibites high hardness. During the friction process, the FCC phase was more prone to deformation and peeling than BCC structure. As the alloying elements (such as Al, Ti, and Cr) tend to form oxide film at high temperatures during friction, the friction process of the LC FeCoCrNiAl0.5Ti0.5 coating was mainly controlled by oxidative wear and adhesive wear mechanisms. Friction test results showed that the coating owned excellent wear resistance and the wear rate of the HEAs coating was only 6.53 % of the wear rate of the steel substrate.

The microhardness, morphology and tribological property of TC4 subjected to machine hammer peening

Ti alloy has become an indispensable material in harsh working environments due to its excellent wear resistance, corrosion resistance and impact resistance. These environments place stringent requirements on the fatigue life, friction and wear, and surface strength of materials. Therefore, this study aims to deeply explore the surface mechanical properties of Ti-6Al-4V (TC4) alloy after machine hammer peening (MHP) treatment. By conducting experiments on TC4 alloys treated with different hammering energies, the changes in surface hardness, morphology, roughness, tensile properties, and friction properties were analyzed, and the strengthening mechanism of MHP was discussed. Experimental results show that MHP treatment can effectively improve the surface properties of TC4. With the increase of hammer energy, due to the double-sided hammering of the plate, the microhardness first increases, then decreases, and then rises again. The tensile strength and yield strength of the sample increase slightly, but the elongation at break decreases. The surface roughness of the sample increases first and then decreases. Similarly, after MHP treatment, the wear resistance of the samples increased, the friction coefficient decreased, and the wear amount and surface height difference showed a trend of first increasing and then decreasing. The wear mechanism mainly included adhesive wear, abrasive wear and fatigue wear.

Targeted assembly of hierarchical sea-urchin inspired NiPS@LDH architecture for enhanced toughness, wear-resistance and fire-safety of epoxy composites

Epoxy resin (EP) is a versatile material widely used in fields such as electronic encapsulation, coatings, adhesives, and composites. The targeted assembly of nanomaterials to optimize the flame retardancy, mechanical properties, and interfacial properties of composite materials is a prominent research hotspot in the field of EP. Therefore, a hierarchical sea-urchin inspired architecture (NiPS@LDH), based on layered double hydroxide (LDH) nanosheets grown on nickel phyllosilicate (NiPS), was rationally constructed as a functional filler for EP with a view to building high-performance EP composites. The addition of 1 wt% NiPS@LDH increased the tensile strength, modulus of elasticity, and elongation at break of EP by 44.1 %, 27.6 %, and 66.2 %, respectively, showing excellent strengthening and toughening effects. Meanwhile, under dry friction conditions, the wear rate of the composites was 0.86 mm3·N−1·m−1, reduced by 87.8 % compared to that of pure EP, indicating excellent wear resistance. Besides, the pHRR, THR, pSPR, TSP, pCO and pCO₂ of EP/NiPS@LDH-3 composites were found to be significantly reduced by 54.0 %, 61.9 %, 50.7 %, 54.4 %, 51.2 %, and 58.2 %, respectively. The LOI value of the composites increased to 26.4 %, and the maximum weight loss (Rmax) was reduced by 27.7 %. This study provides an innovative strategy for the targeted assembly of nanomaterials, paving the way for the preparation of high-performance EP nanocomposites.

Investigation of microstructural, hardness, and wear properties of AlCrCuFeNi high entropy alloys produced by hot-pressing with the enhancement of manufacturability through electroless Ag incorporation

This study involves the production of HEA materials using low-temperature and high-pressure principles by mechanical-alloying AlCrCuFeNi high-entropy alloy powders, followed by electroless Ag coating for enhanced interface properties and hot-pressing without additional sintering. The Ag interface significantly improved the bonding of HEA powders. While increasing temperature causes a 10 % weight gain due to oxidation in HEA samples, this rate is only 1.5 % in those produced with Ag-coated HEA. The Ag interface improved the hardness of the HEAs by 50 %. The wear rate was reduced by more than twofold due to the Ag-interfaces. Ag exhibited a self-lubricating effect due to the Ag layers that repeatedly emerge during sliding, resulting in a low friction coefficient of 0.19 and excellent wear resistance.

Novel Design of Eco-Friendly High-Performance Thermoplastic Elastomer Based on Polyurethane and Ground Tire Rubber toward Upcycling of Waste Tires.

Waste rubber tires are an area of global concern in relation to reducing the consumption of petrochemical products and environmental pollution. Herein, eco-friendly high-performance thermoplastic polyurethane (PU) elastomers were successfully in-situ synthesized through the incorporation of ground tire rubber (GTR). The excellent wet-skid resistance of PU/GTR elastomer was achieved by using mixed polycaprolactone polyols with Mn = 1000 g/mol (PCL-1K) and PCL-2K as soft segments. More importantly, an efficient solution to balance the contradiction between dynamic heat build-up and wet-skid resistance in PU/GTR elastomers was that low heat build-up was realized through the limited friction between PU molecular chains, which was achieved with the help of the network structure formed from GTR particles uniformly distributed in the PU matrix. Impressively, the tanδ at 60 °C and the DIN abrasion volume (Δrel) of the optimal PU/GTR elastomer with 59.5% of PCL-1K and 5.0% of GTR were 0.03 and 38.5 mm3, respectively, which are significantly lower than the 0.12 and 158.32 mm3 for pure PU elastomer, indicating that the PU/GTR elastomer possesses extremely low rolling resistance and excellent wear resistance. Meanwhile, the tanδ at 0 °C of the above-mentioned PU/GTR elastomer was 0.92, which is higher than the 0.80 of pure PU elastomer, evidencing the high wet-skid resistance. To some extent, the as-prepared PU/GTR elastomer has effectively solved the "magic triangle" problem in the tire industry. Moreover, this novel research will be expected to make contributions in the upcycling of waste tires.

Thermal properties and microstructure of Al–Sn alloys

The Al–Sn alloys feature excellent wear and corrosion resistance, along with good mechanical properties. They are mostly used as bearing materials. However, the application of these alloys as phase change materials (PCMs) for thermal energy storage (TES) has recently been suggested. To assess the adequacy of these alloys in a given area, a detailed evaluation of their thermal properties is required. In the present study, Al–Sn alloys with 11.7, 22.4, 32.8, 41.1, and 53.4 at.% Sn were produced by melting of pure metals. The melt was continuously stirred to avoid segregation, after which casting was carried out in a stainless steel mold. The obtained ingots had a homogeneous microstructure without the appearance of cracks and pores. The thermal diffusivities of the solid Al–Sn alloys in the temperature interval 25–150 °C were measured using the light flash method. The densities at room temperature were measured by the Archimedes method, and the specific heat capacities at different temperatures were calculated using the calculation of phase diagrams (CALPHAD) method. Then the thermal conductivities for studied Al–Sn alloys were obtained by the specific conversion equation. The phase transition temperatures and related heat effects were studied using differential scanning calorimetry (DSC). Variations of thermal conductivity with composition and temperature were determined as well as variation of latent heat of fusion with alloy composition. Moreover, the microstructures and phase compositions of the alloys were examined using scanning electron microscopy (SEM) combined with energy dispersive spectrometry (EDS). The present research results provide important information on the thermal properties and microstructure of the Al–Sn alloys for designing new PCM for thermal energy storage.

Deformation strengthening mechanism of laser remelted high manganese steel

In order to further improve the deformation hardening ability of high manganese steel (HMnS) under low stress or small deformation, a low speed laser remelting technology was proposed to process the HMnS surface. Through parameters optimization, microstructure characterization, wear testing, and deformation strengthening analysis, the deformation strengthening mechanism of laser remelted HMnS (LR-HMnS) was systematically studied, and excellent wear resistance properties was also achieved. Firstly, by optimizing the parameters of laser remelting, high-quality microstructures with large remelting depth and fewer porosities were obtained. Then, the sliding wear tests showed that although the surface hardness of LR-HMnS (252.83HV0.3) was only 2.56 % higher than that of continuous casting HMnS (CC-HMnS) (246.53HV0.3), its volume wear rate (1.87×10−5 mm3/N·m) was only 10 % of CC-HMnS (18.71×10−5 mm3/N·m), which exhibited excellent wear resistance properties. Finally, for quantitative evaluating its work hardening at high strain rates, Hopkinson compression test of LR-HMnS was conduced according to the operating conditions of HMnS parts. The microstructure after small compression deformation was analyzed using EBSD and TEM. It was found that the larger grain size of LR-HMnS was helpful of reducing the nucleation stress of twins, forming high-density nano-twins, high-density stacking faults, and high-density dislocations. The synergistic effect of stacking faults, dislocations, and twins which segmented the matrix and refined the grains, and achieved the dynamic Hall-Petch effect. The superior deformation strengthening and wear resistance exhibited by larger grain HMnS were called the inverse grain size effect. Additionally, the large number of C-Mn strong bond networks formed by element segregation could enhance the pinning effect of dislocations, promote deformation hardening rate and wear resistance properties under low stress or small deformation. The research results provided a new method for pre-hardening of HMnS, and will also expand the application potential of HMnS in combined conditions of high, medium, and low impact.

Utilization of graphene nanoplatelets for friction coefficient reduction in NiCu/WC-12Ni composite materials

Graphene Nanoplates (GNPs), known for their outstanding performance, have found extensive applications in the preparation of metal composite carbon materials. In this investigation, a Directed Energy Deposition system was employed to effectively produce deposition specimens of NiCu/WC-12Ni + x wt% GNPs (x = 0, 0.5, 1.0, 1.5) composite material. The findings suggest that incorporating GNPs improved the microstructure of the NiCu/WC-12Ni deposited specimens, leading to a reduction in grain size with predominantly equiaxed and cellular grains. GNPs transformed into amorphous graphene spheres, uniformly distributed within the deposited structure. When 1 wt% GNPs were added, the average microhardness of the deposited specimens increased by approximately 15 %, the friction coefficient decreased from the original 0.318 to 0.257, and the wear rate decreased by 23.2 %. The primary wear mechanism observed was abrasive wear, demonstrating excellent wear resistance. Moreover, introducing a suitable quantity of graphene improved the electrochemical corrosion resistance of the deposited specimen.

Exploring Electrochemical Direct Writing Machining of Patterned Microstructures on Zr702 with Polyacrylamide Polymer Electrolyte.

Zirconium alloys possess excellent wear resistance, which ensures the durability and longevity of the components, making them widely used in medical and other fields. To enhance the functionality of these materials, it is often necessary to fabricate functional microstructures on their surfaces. Electrochemical machining (ECM) techniques demonstrate excellent machining performance for these metals, particularly in the processing of microstructures on complex curved surfaces. However, ECM often faces challenges due to the fluid nature of the electrolyte, resulting in low machining accuracy and localization. This paper proposes a novel method for fabricating complex patterned microstructures using a maskless electrochemical direct writing technique with a polyacrylamide (PAM) polymer electrolyte. By leveraging the non-Newtonian properties of PAM, this method effectively confines the electrolyte to specific areas, thus addressing the issue of poor localization in traditional ECM and reducing stray corrosion. To elucidate the electrochemical removal mechanism of Zr702 in the presence of PAM, polarization curves, viscosity characteristics, and current efficiency parameters were analyzed. Additionally, an experimental study was conducted using a custom-designed nozzle structure. The results showed that the PAM electrolyte could effectively reduce the EF, positively impacting machining accuracy and localization. By controlling the nozzle's motion trajectory, complex microstructures were successfully fabricated through direct writing, demonstrating promising application prospects.

Surface modification of geopolymer coatings with polymethylhydrosiloxane-tetraethyl orthosilicate (PMHS-TEOS) for inhibiting efflorescence

Geopolymer coatings, as novel environmentally friendly inorganic coating, hold promising prospects in the field of concrete protection due to their characteristics such as corrosion resistance and fire resistance. However, its vulnerability to efflorescence can alter surface colouration and damage the structural integrity of the surface film, thereby diminishing its concrete protective efficacy. To inhibit efflorescence in geopolymer coatings, this study reports a surface modification method using polymethylhydrosiloxane-tetraethyl orthosilicate (PMHS-TEOS) for the first time. To explore the underlying mechanism, the effects of PMHS-TEOS on the geopolymer gel structure, mechanical properties, and ion leaching concentration were investigated. The experimental results indicate that PMHS-TEOS can penetrate the surface of geopolymer coatings and participate in the activation reaction, generating a new gel phase that effectively fills pore structure. Moreover, its hydrophobic groups facilitate the establishment of a waterproof structure, thereby inhibiting water infiltration and alkaline ion leaching. After PMHS-TEOS modification, the contact angle of the geopolymer coating reached 136.5°, demonstrating excellent wear resistance. The dissolution rate of alkaline cations in the modified geopolymer coatings was reduced by approximately 90 % and no efflorescence was observed in the long-term accelerated tests. This method is convenient for practical engineering of geopolymer coatings.