Oxygen Flow Rate Research Articles

Optimization of diformylfuran production from 5-hydroxymethylfurfural via catalytic oxidation in a packed-bed continuous flow reactor.

DFF's diverse applications in pharmaceuticals, fungicides, and polymer synthesis motivate the development of efficient production methods. This study reports the continuous-flow synthesis of DFF from 5-HMF in a packed-bed reactor. The Box-Behnken design coupled with response surface methodology (RSM) was employed to optimize the reaction parameters (catalyst, solvent, temperature, oxygen flow rate, catalyst amount) for DFF yield. Ru/Al2O3 in toluene proved to be the most effective catalyst-solvent combination. The optimal conditions for DFF production were identified as: 140 °C reaction temperature, 10 ml min-1 oxygen flow rate, and 0.15 g catalyst loading. Under these conditions, a DFF yield of 84.2% was achieved.

The effect of oxidation on tribology behavior of nickel-graphite coated stainless steel SS420

The main solution to the challenge of maintaining maximum sealing in the compressor section of each gas turbine is the use of abradable coatings. These coatings have a double duty, including (a) maintaining the lagging and (b) protecting the tips of the rotor blades. Choosing the type of abradable coating primarily depends on the service temperature of the coating. Nickel-graphite (Ni-G) coating is a good choice for use up to 480 °C and, or steel/sub-alloy rotor blades. In this research, the Ni-G coating was applied by the flame spraying method of Ni-G powder with a thickness of about 250 μm on an SS420 stainless steel substrate. The effect of the composition of the bonding layer was also investigated using two compositions, Ni-5Al and NiCrAlY. Obtaining the knowledge of applying Ni-G coating by flame spraying, identifying the structural and compositional characteristics of the coating (through optical and electron metallography), and the effect that oxidation can have on the tribological behavior of the coating were among the goals of this project. The best conditions for spraying the Ni-G coating were achieved an oxygen gas pressure of 6 bar, oxygen flow rate of 18 L min−1, acetylene pressure of 1.5 bar, acetylene flow rate of 24 L min−1, and the distance between the gun head and the sample surface was 22 cm. The results showed that placing the coating in oxidizing conditions increases its coefficient of friction. The increase in the coefficient of friction was attributed to the formation of oxide shells on the surface of the coating after 500 h of exposure to oxidation conditions. Corresponding to the higher coefficient of friction, the oxidized coating showed a decrease in wear resistance as a result of oxidation. This result can show the decrease in abradable of this coating with increasing service time.

The n-MoO3/p-Si heterojunction photodiode: Influence of the MoO3 film thickness on the ultraviolet and infrared photodetector performance

Here, we studied the effect of the MoO3 thin film thickness on the ultraviolet (UV) and infrared (IR) photodiode properties of the n-MoO3/p-Si heterojunction structure. Initially, the metal molybdenum (Mo) thin films with different thicknesses (50,150, and 250 nm) were created via DC magnetron sputtering on a p-type Si substrate. Then, the MoO3 thin films were synthesized using a thermal oxidation method with an optimal oxygen flow rate of 60sccm. XRD and Raman analysis showed that the structure of prepared thin films has converted from an amorphous to an orthorhombic (α-MoO3) crystalline phase with increasing thickness. The optical transmittance of the layers was tuned by controlling the thickness, and the maximum transmittance for the 50 nm-thick film was achieved in the broad wavelength range of 300–1100 nm. The current density–voltage (J–V) characteristics indicate the prepared samples' rectifying behavior under dark conditions. The heterojunction photodiode with a 50 nm-thick MoO3 layer shows the best performance. This sample had a maximum amount of transmittance in the UV–visible and IR regions, compared to other samples, which leads to efficient electron-hole separation and transportation. This sample demonstrates a significant photoresponse ratio (ILight/IDark) of about 55 and 52.5 in the ultraviolet (UV) and infrared (IR) regions, respectively.

There is No Increased Pulmonary Risk Following Total Hip Arthroplasty in Patients Who Have Obstructive Sleep Apnea Without Underlying Lung Disease

BackgroundObstructive sleep apnea (OSA) is a frequent comorbidity. The current study evaluated whether there is a difference in the perioperative outcome after total hip arthroplasty (THA) in patients who had a low to moderate risk for OSA and high risk for OSA, respectively. MethodsAfter excluding patients who had concomitant lung disease (chronic obstructive pulmonary disease, asthma, or lung fibrosis) and those missing a STOP-Bang Score, 1,141 THA patients who had OSA were included in this retrospective study. Patients at low to moderate risk for OSA (STOP-Bang Score 0 to 4) and patients at high risk for OSA (STOP-Bang Score 5 to 8) were compared, and SpO2 (oxygen saturation) drops < 90% as well as readmission rates were compared between patients who did and did not use continuous positive airway pressure (CPAP). ResultsThere was no difference in the risk of SpO2 drop below 90% (1 versus 0%, P = 0.398) and readmission rate (2 versus 2%, P = 0.662) between patients who had low to moderate OSA risk (327 THA) and high OSA risk (814 THAs). There was no difference in SpO2 (P > 0.999) and a decrease in oxygen flow rate from the postanesthesia care unit to the morning of the first postoperative day. A CPAP device was used by 41% (467 of 1,141) of patients. There were no differences in SpO2 drop < 90% (0 versus 0%, P = 0.731) and readmission rate (2 versus 2%, P = 0.612) between patients who did and did not use a CPAP machine. ConclusionsThe current study showed no difference in perioperative outcomes between OSA patients undergoing THA who had a low STOP-Bang Score and patients who had a high STOP-Bang Score, regardless of the use of a CPAP machine. These data suggest that an elevated Stop-Bang Score does not indicate an increased perioperative risk for OSA patients when deciding on outpatient discharge.

A novel approach to wastewater treatment control: A self-organizing fuzzy sliding mode controller

&lt;p&gt;The treatment of wastewater plays a crucial role in protecting the environment and ensuring the sustainable use of resources. This research paper presents a new methodology for managing wastewater treatment operations, utilising Self-Organizing Fuzzy Sliding Mode Controller (SOFSMC) to enhance the efficiency of treatment procedures. MATLAB Simulink functions as a simulation tool that facilitates meticulous analysis. SOFSMC presents a control strategy that is both adaptive and robust. This strategy effectively regulates crucial parameters, including dissolved oxygen levels, pH levels, and flow rates. It achieves this within the challenging and complex framework of wastewater treatment, which is characterised by dynamic and nonlinear dynamics. Using a SOFSMC for wastewater treatment control is novel approach. This novel technique creates a self-learning, dynamic system using fuzzy logic (FL) and sliding mode control (SMC). This unique approach can autonomously adapt to wastewater treatment processes' complex and nonlinear dynamics, improving efficiency, resource optimisation, and system dependability. The results emphasise the potential of SOFSMC as a revolutionary approach for wastewater treatment. This approach can improve treatment effectiveness, conserve resources, and protect the environment. The proposed method SOFSMC, exhibits commendable outcomes, with an integrated absolute error of 0.082 mg/L, an integrated square differential error of 0.091 mg/L, and a response time of 1.85 seconds This study offers a substantial advancement in the field of wastewater treatment regulation, highlighting its significance in the context of sustainable water management and environmental conservation.&lt;/p&gt;

Preparation, microstructure and properties of Yb2O3-x optical hydrophobic films for infrared windows

In order to improve the adaptability of infrared windows in harsh wet environments, Yb2O3-x films were prepared by ion assisted reactive thermal evaporating deposition. The surface morphology, microstructure, composition, optical properties, hardness, residual stress and hydrophobicity of Yb2O3-x films were comprehensively characterized. The effects of the oxygen flow rate on the properties of the Yb2O3-x films had been explored. It is found that the root-mean-square roughness of the films increases as the flow rate increases from 10 sccm to 35 sccm. The crystallization characteristics are closely related to the oxygen flow rate, and the film prepared at 15 sccm exhibits the best crystallinity. X-ray photoelectron spectroscopy (XPS) testing shows that the ratio of Yb to lattice oxygen decreases, while the content of trivalent Yb ions in the film increases with increasing oxygen flow rate. Thin film prepared at lowest oxygen flow rate exhibits highest optical absorption, which is related to oxygen defects in the films. Moreover, films prepared at 15 sccm, 25 sccm and 35 sccm show good transparency in the long-wave infrared band. The hardness of the film prepared at 15 sccm is about 9 GPa. Due to change in density of the thin film, the compressive stress of the film decreases with increase of oxygen flow rate. The hydrophobicity of the film is affected by the surface chemical composition and surface roughness, and the maximum water contact angle is 100°. In a word, the Yb2O3-x films are found to be excellent hydrophobic protective coatings for infrared windows.

CsxWO3 films with excellent infrared shielding ability and high visible light transmittance prepared via magnetron sputtering

Caesium tungsten bronze materials are widely used in various applications, such as architectural glass, medicine, insulation coating and textile fibre, owing to their excellent mechanical, optical and thermal properties. In this study, a caesium tungsten bronze (CsxWO3, x = 0.3–0.32) target with a relative density of 99.63 % and uniform microstructure was successfully prepared via hot-pressing sintering. CsxWO3 films were deposited on a quartz glass substrate via magnetron sputtering, and the mechanisms and effects of the substrate temperature and oxygen flow rate on the phase structure, microstructure and optical properties of CsxWO3 films were investigated. When the substrate temperature increased, the crystallinity and oxygen vacancy concentration of the CsxWO3 film improved. Consequently, the visible light transmittance of the film decreased, whereas the infrared blocking rate considerably increased, reaching up to 93.877 %. With the increase in the oxygen flow rate, the visible light transmittance exhibited an increasing trend, reaching a maximum value of 84.319 %, whereas the infrared blocking rate remained relatively stable. We successfully fabricated CsxWO3 films possessing a visible light transmittance of 66 % and infrared blocking rate of 94.97 % under the conditions of a substrate temperature of 300 °C and an oxygen flow rate of 2.5 sccm. Our study offers a method for the large-scale production of CsxWO3 films, which are excellent infrared shielding materials, rendering a substantial contribution to global energy conservation and emission reduction.

DIELECTRIC BARRIER DISCHARGE BASED PLASMA DEVICE FOR COLD STERILIZATION IN WATER WITH ADDITIONAL ULTRASONIC CAVITATION

A prototype of plasma sterilizer based on dielectric barrier discharge (DBD) with additional ultrasonic cavitation for cold sterilization has been developed. It provides sterilization of reusable small dental instruments, and components made from corrosion-resistant metals and alloys (stainless steel, titanium, etc.), as well as surgical instruments, implants, small drills, plastic sundries, ozone resistant medical rubbers (silicone, etc.), polymers, epoxy resins and glass. The sterilizer is well suited for dentistry and can be used in medical, sanatorium, outpatient and other medical institutions, as well as in military field surgery. The volume of the sterilization bath is 2.5 l. The ozone concentration at the output of the ozone generator is 35…52 mg/l, the ozone concentration in the sterilizer chamber is 6.5…8 mg/l, depending on the water temperature and its volume in the bath. The dependence of the increase of ozone concentration in water on time at different oxygen flow rates is monitored.

Vanadium doped Fe-Mn bimetallic oxides as cathodic materials for boosted heterogeneous electro-Fenton degradation of organic contaminants

The design of cathode materials with both sustainable H2O2 selectivity and accelerated recyclable regeneration remains a challenge for contaminants removal in heterogeneous electro-Fenton (HEF) process. Herein, a series of ternary Fe0.50Mn0.5−δVδOx (δ = 0.005, 0.01, 0.05) metal oxides have been synthesized and employed as cathodic materials for the degradation of various organic contaminants in water matrix. 99.7 % removal rate was achieved for carbamazepine (CBZ) in 60 min with 98.8 % mineralization rate. Simultaneously, the catalyst exhibited outstanding degradation efficiency (96.0–99.7 %) with other pollutants including sulfonamides (SMX), bisphenol A (BPA), 2,4-dichlorophenol (2,4-DPC) and ofloxacin (OFX), demonstrating its potential application. Factors affecting the EF process, including current density, pH, oxygen flow rate and compatibility of inorganic anions were thoroughly evaluated and the degradation mechanism was studied in detail. Density functional theory (DFT) calculations revealed that the improved catalytic efficiency was originated from vanadium doping to access optimized electronic structure, which endows enhanced 2e− ORR selectivity as well as excellent overall performance for the EF process. This work may enrich the study on EF system and offers a promising strategy for contaminants removal with FeMnVO materials in water treatment applications.

Simulation of thermodynamic systems in calcium-based chemical looping gasification of municipal solid waste for hydrogen-rich syngas production

This study explores calcium-based chemical looping gasification (CLG) as a method for managing municipal solid waste (MSW), with a focus on converting MSW into hydrogen-rich syngas. The innovative CS-MgO-ZrO2 calcium-based sorbent has been identified as optimal, facilitating fluidization crucial for operational stability and economic feasibility. Key discoveries include heightened H2 concentration and CO2 capture efficiency under specific operational parameters (4000 kg/h solid flow rate, 6000 kg/h steam flow rate), despite diminished H2 production at carbon conversion rates (≥0.80). Below 0.38 carbon conversion rates, a syngas injection ratio of 0.18, and oxygen flow rates >1200 kg/h induce spontaneous reactor heating, compromising efficiency and escalating costs. Furthermore, utilizing syngas in the regenerator ensures self-sufficiency and supplementary thermal energy, thereby reducing dependence on external energy sources. This research addresses critical deficiencies in waste-to-energy technologies, emphasizing potential strides in sustainable municipal waste management and energy generation.

Oxygen blown steam gasification of different kinds of lignocellulosic biomass for the production of hydrogen-rich syngas

In this study, the gasification performance of different kinds of lignocellulosic biomass, including corn straw (CS), soybean straw (SS), cotton straw (CTS), rice straw (RS), wheat straw (WS), bamboo wood (BW), maple sawdust (MS), and pine sawdust (PS), was studied in a tube furnace reactor system under identical conditions (temperature = 800 °C, oxygen flow rate = 30 mL/min, steam flow rate = 5 ± 1 mL/min, and time = 55 min). SS showed good gasification characteristics and delivered the highest H2 yield of 28.96 mol/kg. By using the SS, additional optimization was carried out by considering different temperatures (650, 700, 750, 850, 950, and 1050 °C) and different oxygen flow rates (10, 20, 30, 40, and 50 mL/min). After optimization, the initial temperature and oxygen concentration were reduced to 750 °C and 10 mL/min, respectively. An H2 yield of 30.86 mol/kg was achieved with an increase of 6.56 %. Finally, catalytic steam gasification employing three potassium-based catalysts, KCl, KOH, and K2CO3, was tested using SS. KOH and K2CO3 performed distinctly better than KCl. The utilization of KOH as a catalyst resulted in the greatest H2 yield, measuring 39.22 mol/kg, which represents a notable improvement of 27.09 %.

Investigation of diodic behavior in p-NiO/n-SnO2 bilayer heterojunctions fabricated via DC magnetron reactive sputtering

Tin oxide (SnOx) thin films at varying oxygen flow rates and Nickel oxide (NiO) thin films were deposited by reactive dc magnetron sputtering on glass substrates. Structural, chemical, morphological, optical and electrical properties of the deposited films were studied. XRD studies confirmed that the deposited films were polycrystalline in nature. SnOx thin films have shown two phases such as SnO and SnO2. AFM and SEM were used to analyse the morphology of the films and EDS confirmed the presence of Sn and Ni in the respective films. The examination of the x-ray photoelectron spectrum showed that the sputtered SnOx films contain both Sn2+ and Sn4+ oxidation states and NiO films contain Ni+2 and Ni+3 oxidation states. Photoluminescence study shows strong violet and weak red emission peaks for SnOx films and NiO showed strong emission peaks in the orange-red region. The optical results demonstrate that the films were transparent. The bandgap of SnOx and NiO samples were ∼3.3 eV and − 3.42 eV, respectively. Further we constructed a p-NiO/n-SnO2 heterojunction diode and its electrical characteristics were thoroughly assessed. Using dark current–voltage measurements, electrical characteristics such saturation current, ideality factor and barrier height were determined. The increase in oxygen flow rate led to reduction in the rectification of the devices. Our findings support the creation of high-performance metal oxide heterojunction for optoelectronic devices.

Effect of O2/Ar ratio on the microstructure and tribological properties of Y2O3 films by multi-arc ion plating

Multi-Arc Ion Plating (MAIP) technology was used to deposit yttrium oxide (Y2O3) ceramic thin films on Al2O3 ceramics and silicon wafers. The effects of varying the O-to-Ar gas flow ratio (Rc: 0.5, 1.0, 1.5, 2.0) and the annealing conditions on the phase composition, microstructure, mechanical properties, and tribological performance of the Y2O3 films were assessed. The films deposited at Rc values of 1.0 and 1.5 consisted of a single cubic phase structure. In contrast, films deposited at Rc values of 0.5 and 2.0 contained a small monoclinic phase and the cubic phase structure. The film deposited at an Rc value of 1.0 (oxygen flow rate of 200 sccm) exhibited a dense microstructure, the best mechanical properties (hardness of 14.2 ± 0.191 GPa), and the lowest friction coefficient (0.142 ± 0.003). Furthermore, the colour of the film changed from grey-black to white after annealing at 800 °C for 6 h. The oxygen vacancy of the thin film increased, with improving crystallinity, decreasing hardness and elastic modulus, and increasing grain size, friction coefficient and wear rate. The film exhibited the best tribological properties at 25 °C.

Optimization of HVOF Spray Parameters for WC-Co-Cr Coatings on AMMC (Al-RHA) for Pump Impeller Protection

Present study investigates the enhancement of pump impeller materials using aluminium matrix composites (AMCs), specifically focusing on Al 7075 Alloy strengthened with rice husk ash (RHA) for enhanced durability and resistance to corrosion. It employs Thermal spraying using high-velocity oxygen-fuel (HVOF) to apply WC-Co-Cr powder, emphasizing low porosity, high adherence, and superior wear and corrosion resistance. By optimizing HVOF spray parameters using Taguchi L25 Orthogonal array, the research aims to minimize porosity and maximize hardness, addressing challenges in material dispersion, sustainability, and process control. The objective is to develop predictive models for the microhardness and porosity characteristics of WC–10Co–4Cr coating powder utilized through HVOF on AMMC substrates. AMMC substrates. Spray distance, carrier gas flow rate, powder feed rate, oxygen flow rate, and LPG flow rate are examined, with spray distance exerting the most significant influence on porosity, followed by powder feed rate and other parameters. This study contributes to improving coating characteristics crucial for industrial applications.

Influence of Oxygen Flow Rate on the Phase Structures and Properties for Copper Oxide Thin Films Deposited by RF Magnetron Sputtering

Influence of Oxygen Flow Rate on the Phase Structures and Properties for Copper Oxide Thin Films Deposited by RF Magnetron Sputtering

Effect of cleaning parameters on the molten pool shape and molten slag dynamics in the corner scarfing process of the casting slab

In the steel industry, improving the hot charging and heat delivery ratio in the continuous casting of slabs and thick slabs can effectively reduce carbon emissions, lower energy consumption, and improve production efficiency. However, this puts very strict requirements on the surface quality of continuous-casting slab. Flame scarfing (or cleaning) technology is currently an important process in the metallurgy field, which can effectively remove impurities and crack defects on the surface and corners of continuous casting slab to ensure the quality and performance of the final product. Under the action of cleaning flame and iron oxide reaction heat, a cleaning molten pool is formed in the corner of the casting slab, and the shape and depth of the molten pool have an important influence on the cleaning effect. A three-dimensional mathematical model is developed to study the effect of slab cleaning speed and oxygen flow rate on the shape of the molten pool in the corners for the corner flame cleaning process. Simultaneously, a two-phase flow volume of fluid (VOF) model for gas-slag interactions is employed to examine the motion behavior of the molten slag. The results showed that when the operating conditions changed, the cleaning speed increased by 1 m/min, the length of the wide and narrow sides decreased by approximately 9.2 mm, and the depth of the corner pool decreased by approximately 5.3 mm. Moreover, a slag-blocking device was designed to mitigate the issue of slag splashing effectively based on the numerical simulation results compared with and without the slag-blocking device. These study works provide beneficial theoretical support and practical guidance for refining and optimizing flame-cleaning techniques.

Simultaneous effect of oxygen impurity and flow rate of purge gas on adsorption capacity of and heel buildup on activated carbon during cyclic adsorption-desorption of VOC

Irreversible adsorption, or heel buildup, negatively impacts activated carbon performance and shortens its lifetime. This study elucidates the interconnections between flow rate and the oxygen impurity of desorption purge gas with heel buildup on beaded activated carbon (BAC). Nine thermal desorption scenarios were explored, varying nitrogen purge gas oxygen impurity levels (<5 ppmv, 10,000 ppmv, 210,000 ppm (21 %)) and flow rates (0.1, 1, 10 SLPM or 1 %, 10 %, 100 % of adsorption flow rate) during thermal desorption. Results reveal that increasing purge gas flow rate improves adsorption capacity recovery and mitigates adverse effects of purge gas oxygen impurity. Cumulative heel increased with higher purge gas oxygen impurity and lower flow rates. In the least effective regeneration scenario (0.1 SLPM N2, 21 % O2), a 32.8 wt% cumulative heel formed on BAC after five cycles, while the best-case scenario (10 SLPM N2, <5 ppmv O2) resulted in only 0.3 wt%. Comparing the pore size distributions of virgin and used BAC shows that heel initially forms in narrow micropores (<8.5Å) and later engages mesopores. Thermogravimetric analysis (TGA) showed that oxygen impurity creates high boiling point and/or strongly bound heel species. TGA confirmed that higher purge gas flow rates reduce heel amounts but encourage chemisorbed heel formation in oxygen's presence. These findings can guide optimization of regeneration conditions, enhancing activated carbon's long-term performance in cyclic adsorption processes.

Sputtered thin film deposited laser induced graphene based novel micro-supercapacitor device for energy storage application

Pioneering flexible micro-supercapacitors, designed for exceptional energy and power density, transcend conventional storage limitations. Interdigitated electrodes (IDEs) based on laser-induced graphene (LIG), augmented with metal-oxide modifiers, harness synergies with layered graphene to achieve superior capacitance. This study presents a novel one-step process for sputtered plasma deposition of HfO2, resulting in enhanced supercapacitance performance. Introducing LIG-HfO2 micro-supercapacitor (MSC) devices with varied oxygen flow rates further boosts supercapacitance performance by introducing oxygen functional groups. FESEM investigations demonstrate uniform coating of HfO2 on LIG fibers through sputtering. Specific capacitance measurements reveal 6.4 mF/cm2 at 5 mV/s and 4.5 mF/cm2 at a current density of 0.04 mA/cm2. The LIG-HfO2 devices exhibit outstanding supercapacitor performance, boasting at least a fourfold increase over pristine LIG. Moreover, stability testing indicates a high retention rate of 97% over 5000 cycles, ensuring practical real-time applications.

Optimization of HVOF spraying parameters for enhanced Fe-based amorphous coatings: A taguchi approach

In this work, Fe57Cr15Mo8P10C7B3 amorphous coatings (ACs) were fabricated on 316L stainless steel (316L SS) substrate using high-velocity oxygen-fuel (HVOF) spraying technique. The Taguchi's method guided the design of L16 (43) orthogonal experiments to optimize the process parameters, including spraying distance, oxygen flow rate, and kerosene flow rate. Through statistical analyses, including signal-to-noise ratio analysis, analysis of variance (ANOVA), and response surface methodology (RSM), empirical relationships for evaluating the influence of these parameters on coating quality were established, with porosity as the primary metric. Our findings indicate a pronounced sensitivity of the porosity of the ACs to spraying conditions, in which oxygen flow rate has the most significant effect on the porosity of the ACs, while kerosene flow rate has the smallest impact. Meanwhile, it is predicted that a minimum coating porosity of 0.75 % can be achieved under the optimal deposition conditions of the spraying distance of 330 mm, the kerosene flow rate of 6.0 GPH, and an oxygen flow rate of 1900 SCF. Experimental validation confirmed these conditions, yielding coatings with superior coating quality and performance with a minimum coating porosity of 0.68 %, a microhardness of 826 ± 65 HV0.1, improved corrosion resistance in 3.5 wt% NaCl solution with a high self-corrosion potential of −0.37 V, a low self-corrosion current density of 1.08 × 10−6 A/cm2, and a low passivation current density of 1.16 × 10−5 A/cm2, and enhanced wear performance with a wear volume loss of only 4.00 × 10−5 mm3 N−1 m−1 and a friction coefficient of as low as 0.42 ± 0.022. The present study confirms the reliability of Taguchi's method in determining optimal HVOF processing parameters, evidenced by the consistency between theoretical predictions and experimental results.

Oxygen concentration – A governing parameter for microstructural tailoring of duplex AlCrSiON coatings for superior mechanical, tribological, and anti-corrosion performance

This study investigates the impact of increasing oxygen levels on structure, and mechanical properties and tribological performance of duplex AlCrSiON coatings. AISI H13 steel and tungsten carbide substrates are coated using arc ion plating with increasing oxygen flow rate up to 200 sccm with varying oxygen concentration. High-resolution transmission electron microscopy, scanning electron microscopy, X-ray photoelectron spectroscopy, X-ray diffraction, and three-dimensional profilometer are used to study morphological and structural evolution. Correspondingly, the coatings are assessed for hardness, adhesion strength, friction coefficient, and resistance against corrosion and wear. A 50–100 sccm oxygen flow rate is considered as an optimal range to receive lower surface roughness. Generally, the addition of oxygen has compromised hardness and friction coefficient but improve adhesion strength, wear and corrosion resistance with increasing oxygen concentration. The immersion tests have identified pitting corrosion as a dominating failure mechanism for AlCrSiON coatings when exposed to molten A380 aluminium alloy. This corrosion resistance stems from their dense microstructure, excellent thermal stability, and the presence of fcc-(Al, Cr)2O3 phase structure. This study demonstrates that controlled oxygen concentration is a crucial parameter for tuning the microstructure of AlCrSiON coatings to achieve superior mechanical, tribological, and anti-corrosion performance, particularly for high-pressure die-casting applications.