Microstructure Of Coatings Research Articles

Effects of Y2O3 Content on the Microstructure and Tribological Properties of WC-Reinforced Ti-Based Coatings on TC4 Surfaces

To extend the safety service life of aviation TC4 alloy, the composite coatings of TC4 + Ni-MoS2 + WC + xY2O3 (x = 0, 1, 2, 3, 4 wt.%) were prepared on TC4 by coaxial powder feeding laser cladding technology. The results showed that all the coatings had the same generated phases which mainly consisted of TiC, Ti2Ni, Ti2S, matrix β-Ti, and unfused residual WC. Y2O3 formed co-dependent growth relationships with TiC, Ti2S, and Ti2Ni. Meanwhile, TiC-Ti2S, TiC-Ti2Ni, and Ti2S-Ti2Ni coherent composite structure phases were effectively synthesized in all the coatings. With the increase in the Y2O3 content, the exposed area of the matrix increased and other phases refined progressively. When the Y2O3 content in the coatings were 3 and 4 wt.%, the degree of phase refinement in the coatings was consistent and the phases grew along grain boundaries, but microstructure segregated in the 4 wt.% Y2O3 coating. The microhardness of all the coatings was higher than that of TC4 and decreased with the increase in the Y2O3 content. Higher friction coefficients and lower wear rates both appeared in all the coatings than in the substrate, and they presented a trend of decreased first and then increased with the addition of Y2O3, in which the 3 wt.% Y2O3 coating had the lowest friction coefficient and optimal wear resistance. The research found that the Y2O3 could not change the types of phases in the coatings and could serve as a heterogeneous nucleation center for the refinement of the TiC-Ti2S-Ti2Ni coherent structure phase. Meanwhile, except for the matrix phase, Y2O3 could attract other phases to pinning on the grain boundaries of the coatings. The content of Y2O3 was negatively correlated with the hardness and wear resistance of the coating and it had the optimal tribological properties with the moderate amount of Y2O3. The wear mechanism of all coatings was abrasive wear.

Effect of scanning speeds on microstructure evolution and properties of 70Cr8Ni2Y coatings by direct laser deposition

Abstract The 70Cr8Ni2Y coatings were prepared by direct laser deposition (DLD) with different scanning speeds. The microstructure evolution and the relationship between microstructure and properties of the coatings were studied. The results demonstrated that the microstructure of DLD 70Cr8Ni2Y coatings was martensite, and the phases were α′ (Fe-Cr) and γ-Fe (Fe-Ni). With the increased of scanning speed, the martensite size decreased from 5.42 ± 0.04 μm to 4.42 ± 0.01 μm and 3.20 ± 0.02 μm. When the scanning speed was 20 mm s−1, the fabricated coating displayed the highest average microhardness (883 ± 37 HV) and the lowest mass wear rate (0.061 mg mm−1) without pores. The combined strengthening effect of fine grain strengthening and solid solution strengthening, as well as good formability, were the fundamental reasons for the high hardness and wear resistance of the coating. The results of this study can provide an experimental basis for the DLD alloy coatings with high hardness and wear resistance.

Effect of Reactive Magnetron Co-Sputtering on the Microstructures and Optical Characteristics of TiAlN Coating

Effect of Reactive Magnetron Co-Sputtering on the Microstructures and Optical Characteristics of TiAlN Coating

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.

Microstructure and high-temperature oxidation resistance of Ti-6Al-4V alloy with in-situ SiC-SiO2 nano-composite coating by LPDS technique

A SiC-SiO2 nano-composite coating was prepared via a novel liquid-phase plasma-assisted particle deposition and sintering (LPDS) method to enhance the oxidation resistance of the Ti-6Al-4V alloy. For comparison, a conventional plasma electrolytic oxidation (PEO) ceramic coating is fabricated on the Ti-6Al-4V alloy. The microstructure and formation mechanisms of both ceramic coatings were investigated using scanning electron microscopy (SEM), X-ray diffraction (XRD), and transmission electron microscopy (TEM). The results indicated that the thickness of the SiC nano-composite coating (∼40 μm) increased significantly by 285 % compared to the PEO coating (∼14 μm). The microstructural evolution and isothermal oxidation performance of the PEO and SiC-SiO2 nano-composite coating were comparatively investigated at 800 °C. After 100 h, the thickness gain of the SiC-SiO2 nano-composite coating (∼14 μm) was lower than that of the PEO coating (∼26 μm). The improved oxidation performance is primarily attributed to the outermost layer containing abundant SiC nanoparticles, which transform into SiO2 during the oxidation process and effectively inhibiting the inward penetration of oxygen.

Effects of CrC interlayer on tribocorrosion properties of DLC-coated TC4 alloy in a 0.9 wt% NaCl solution

In this study, DLC coatings with varying thicknesses of CrC interlayers were fabricated on the surface of TC4 alloy by regulating the flow rate of C2H2. The effects of the interlayer layer on the microstructure, mechanical properties, corrosion resistance, and tribocorrosion resistance of DLC coatings were systematically investigated. The results show that as the C2H2 flow rate increases, the CrC interlayer exhibits the structure transitions from columnar crystals to amorphous, resulting in improved hardness. The hardness of the CrC40 interlayer reaches 17.2 GPa, significantly higher than the 9.3 GPa of the Cr underlayer. The CrC interlayer notably enhances the mechanical properties and adhesion strength of DLC coatings. The corrosion current density of the CrC40/DLC coating is 3.07 × 10−8 A/cm2, significantly lower than that of the DLC coating with only a Cr underlayer. Under high load conditions of 20 N, the tribocorrosion rate of the CrC40/DLC coating is reduced to 2.09 × 10−7 mm3.(N.m)−1, representing a significant decrease of 93.9 % compared to the DLC coating. The CrC40/DLC coating exhibits strong adhesion strength, appropriate internal stress and a relatively hard CrC40 interlayer, showing exceptional tribocorrosion resistance.

Influence of WC Content on Microstructure of WC-Ni Coatings on AISI 18-2Mn Austenitic Stainless Steel Using TIG Cladding

Influence of WC Content on Microstructure of WC-Ni Coatings on AISI 18-2Mn Austenitic Stainless Steel Using TIG Cladding

Microstructure and performance of (CoCrNi)88Al6Ti6-cBN composite coatings by high-speed laser cladding (HSLC): A novel strategy for synergizing wear-resistance and friction reduction

To enhance the wear-resistance of nickel-based blade surfaces, a (CoCrNi)88Al6Ti6-cBN composite coating was produced on GH4169 substrates using HSLC. The microstructure, microhardness and tribology properties of the coating at 25 and 600 °C were evaluated. The finding demonstrates that the hardness of the cBN composite coating increase by 91.6 HV0.3 attributed to precipitation strengthening, second phase strengthening and dislocation strengthening. Furthermore, the anti-wear performance of the coating increased by 3.72 times at 25 °C and by 3.23 times at 600 °C, respectively. Additionally, the friction coefficient exhibited by the coating diminished significantly by converting a portion of the cBN to hBN under the high temperatures generated by laser and oxides generating.

Insights into 1200 °C steam oxidation behavior of Cr coatings with different microstructure on Zircaloy-4 alloys for enhanced accident tolerant fuel cladding

In order to improve the 1200°C steam oxidation properties of Cr-coated zirconium alloy accident tolerant fuel cladding tubes, chromium coatings with various micro-structures were fabricated by bipolar high-power impulse magnetron sputtering technology. The microstructures of chromium coatings transforms from unconsolidated column structure to dense & column-oblate structure with the bias voltage increase. Hardness and elastic modulus values of optimal chromium coatings are approximately 19.1 GPa and 374.8 GPa, respectively, which are 2.09 and 1.60 times higher than those of chromium coatings with unconsolidated column structures. Optimal chromium coatings with dense & column-oblate structures display preferable 1200°C steam oxidation resistance because of possession lower weight gain value and thicker Cr2O3 oxide layer after 2 h exposure periods. The fabrication strategy of chromium coatings with dense & column-oblate structure is expected to pave the way for enhancing 1200 °C steam oxidation resistance for Cr-coated zirconium alloys.

Effect of Laser Power on Microstructure and Properties of WC-12Co Composite Coatings Deposited by Laser-Based Directed Energy Deposition.

During the laser-based directed energy deposition (DED-LB) processing, a WC-12Co composite coating with high hardness and strong wear resistance was successfully prepared on a 316L stainless steel substrate by adopting a high-precision coaxial powder feeding system using a spherical WC-12Co composite powder, which showed a large number of dendritic carbides and herringbone planar crystals on the substrate-binding interface. The influences of laser power on microstructural and mechanical properties (e.g., hardness, friction resistance) of WC-12Co composite surfaces were investigated. The results show that laser power has a significant effect on determining the degree of Co phase melting around the WC particles and the adhesion strength between the matrix and the coating. Lower laser power does not meet the melting requirements of WC particles, thus weakening the molding quality of the composite coating. At high laser power, it is possible to dissolve the WC particles and melt the metal powder between the particles, thus improving the material properties. The laser power increased from 700 W to 1000 W and the average hardness of the coating surface gradually increased from 1166.33 HV to 1395.70 HV, which is about 4-5 times higher than the average hardness of the substrate (about 281.76 HV). In addition, the coatings deposited at 1000 W showed better wear resistance. This work shows that the processing parameters during laser-directed energy deposition can be optimized to prepare WC-12Co composite coatings with excellent mechanical properties.

Understanding of the irradiation response of Cr-based ATF coatings using in-situ TEM

Although CrNb coated zirconium alloy materials are considered as ATF candidates with excellent oxidation resistance and mechanical properties, the irradiation response behavior under harsh and complex service conditions is still unrevealed. Here, we report the evolution of the microstructure of pure Cr and CrNb coatings with different Nb contents under simultaneous irradiation with Cr+-He+-H2+ triple ion beams at 633 K by using an advanced in-situ transmission electron microscope (TEM). The results show that CrNb coatings with high Nb content have better irradiation stability. Under high-temperature irradiation conditions, irradiation-induced oxidation and grain growth or crystallization are observed for both Cr-8 Nb with a nanocrystalline structure and Cr-18 Nb coatings with an almost amorphous structure, whereas Cr-37 Nb coatings maintains relatively intact in the amorphous phase after irradiation at a dose of 10 dpa. Based on the in-situ tracking of the microstructural evolution, it is revealed that the mechanism of irradiation-accelerated oxidation and crystallization of coatings originates from displacement cascades enhancing local atomic diffusion and rearrangement.

A Comparison of the Tribological Properties of SiC Coatings Prepared via Atmospheric Plasma Spraying and Chemical Vapor Deposition for Carbon/Carbon Composites

The microstructure, mechanical performance, and tribological properties of SiC ceramic coatings prepared via atmospheric plasma spraying (APS) and chemical vapor deposition (CVD) method were compared to provide good anti-wear protection for carbon/carbon composites. The surface morphology of the APS-SiC coating was characterized as having a porous structure, whilst the CVD-SiC coating presented with many pyramidal-shaped crystals constituting the surface. The APS-SiC coating consists of a dominating SiC phase and a small fraction of the Si phase, while the XRD pattern of the CVD-SiC coating mainly consists of the SiC phase. The dense crystalline microstructure of the CVD-SiC coating made it possess a higher hardness and Young’s modulus at 31.0 GPa and 275 GPa, respectively. The higher H/E and H3/E2 parameters of the CVD-SiC coating implied that it exhibited better plastic resistance, which is also beneficial for anti-wear properties. The scratch test reflected the critical loads of the spallation of the APS-SiC coating and CVD-SiC coating, which were evaluated to be 25.9 N and 36.4 N, respectively. In the tribological test, the friction coefficient of the APS-SiC coating showed obvious fluctuations at high load due to damage to the SiC coating. The wear mechanism of the APS-SiC coating was dominated by abrasive wear and fatigue wear, while CVD-SiC was mainly dominated by abrasive wear. The wear rate of the CVD-SiC coating was far below that of the APS-SiC coating, suggesting the better wear-resistance of the CVD-SiC coating.

Fabrication and tribological behavior of laser cladding Cu/Ti3SiC2 reinforced CoCrW matrix composite coatings on Inconel718 surface

To satisfy the need for high wear resistance of Inconel718 alloy under harsh working conditions, laser cladding technique was adopted to fabricate the Cu/Ti3SiC2-CoCrW metal matrix composite coatings on that surface. The phase composition, microstructure, microhardness, surface energy, and tribological properties of the composite coatings were systematically analyzed by characterization methods such as XRD/ SEM/ EDS/ XPS and performance test methods such as high-temperature friction and wear test, and the wear mechanism at different temperatures was deeply discussed. The research results indicate that the microhardness of coatings is increased by 2.2–2.9 times compared to the substrate, which is mainly owing to the solid solution strengthening effect and the diffusely distributed hard reinforcing phases such as Cr7C3, WCx, and TiC. Regarding the wear resistance, the wear rate of coatings is significantly reduced by 1–2 orders of magnitude over the substrate. Among them, the Co-based coating adding 10 wt% Cu - 10 wt% Ti3SiC2 exhibited the lowest wear rates at room and high temperatures, which were 0.22 and 3.23 × 10−5 mm3/ N·m, respectively, with 98.22 % and 88.19 % reductions in comparison with the substrate. The low surface energy (27.94 mN/m) was one of the main reasons for the good tribological properties. When the friction environment changes from room temperature to 600 °C, the primary wear mechanism of coatings changes from abrasive and adhesive wear to oxidative wear.

Mitigating fuel cladding chemical interactions by enhancing chromium diffusion barrier performance using pulse reverse electroplating

Fuel cladding chemical interaction (FCCI) is a critical issue affecting the safe usage of metallic nuclear fuel in sodium-cooled fast reactors (SFRs). Although a chromium (Cr) coating diffusion barrier has been developed to effectively mitigate FCCI, Cr coatings formed by direct current (DC) and pulse current (PC) electroplating generate hydrogen-induced micro-cracks that reduce diffusion barrier performance. In this study, electroplating with a pulse reverse (PR) current and optimized anodic time was utilized to minimize the effects of hydrogen. Consequently, this approach enabled the formation of a crack-free and highly stable microstructure in the electroplated Cr coating. A diffusion couple test (FCCI test) was conducted at 923 K for 25 h to evaluate that the diffusion barrier performance of the Cr coating formed by DC, PC and PR electroplating. The test results demonstrate the superior diffusion barrier performance of the Cr coating formed by PR electroplating through a systematic analysis comparing the microstructures of Cr coatings formed by different waveforms.

Degradation of LaPO4-8YSZ composite thick thermal barrier coatings by molten calcium-magnesium-aluminosilicate

The effect of LaPO4 content on the calcium-magnesium-aluminosilicates (CMAS) corrosion resistance of the plasma-sprayed LaPO4-8YSZ composite coatings at 1250 °C was investigated. The microstructure and corrosion products of the LaPO4-8YSZ composite coatings after CMAS attack was determined by using SEM/TEM/SAED. The results indicated that LaPO4 was segregated at the grain boundaries of the composite coatings and the addition of LaPO4 into 8YSZ coating increased their CMAS reactivity, which led to the formation of planar reaction zone while the CMAS infiltration depth decreased from ∼658 μm to ∼119 μm. The CMAS infiltration depth of the composite coatings firstly increased with LaPO4 addition, reaching its maximum for the composite coating with 5 wt% LaPO4, and then showed a downtrend. For the composite coating with 20 wt% LaPO4, a dense apatite layer formed in the corrosion front, which inhibited CMAS penetration and resulted in the shallowest CMAS infiltration depth among the test samples.

Effect of Powder Oxidation on Microstructures and Mechanical Properties of Cold-Sprayed Nickel Coatings and Improvement by Post-spray Heat Treatment

Effect of Powder Oxidation on Microstructures and Mechanical Properties of Cold-Sprayed Nickel Coatings and Improvement by Post-spray Heat Treatment

Construction of hard BCC phases FeCrVMnTix wear-resistant high-entropy alloy coatings enhanced by solid solution of Ti elements

To address the complex working conditions encountered by 1Cr13 ferritic/martensitic steel during operation, it is imperative to develop high-entropy alloys (HEAs) protective coatings with enhanced friction resistance. In this work, guided by the valence electron concentration criterion, we constructed a single-phase body-centered cubic (BCC) structure with high hardness. This was achieved through the introduction of titanium (Ti), which has a significantly different atomic radius compared to other elements. FeCrVMnTix (x = 0, 0.5, 1.0, 1.5, and 2.0) coatings were fabricated on 1Cr13 steel surfaces using laser cladding techniques, and the microstructure, mechanical properties, and wear-resistance properties of Ti-doped HEA coatings were investigated. The results reveal that the FeCrVMnTix coatings are comprised of a BCC solid solution. Increasing Ti content refined the dendritic structure of the coatings, enhancing the Vickers hardness from 4.35 GPa to 8.27 GPa and the Young's modulus from 232.6 GPa to 273.2 GPa. Additionally, the wear rate decreased from 3.07 × 10−5 mm3·N−1·m−1 to 4.94 × 10−6 mm3·N−1·m−1. Notably, the FeCrVMnTi2.0 coating demonstrated excellent wear resistance that can be attributed to the solid solution strengthening effect of Ti. These findings underscore the pivotal role of Ti in enhancing the wear resistance of the coatings.

Preparation and performance of graphene-doped indium tin oxide coatings on titanium bipolar plate surface

To enhance the corrosion resistance of titanium bipolar plates, indium tin oxide (ITO) coatings doped with varying quantities of graphene were fabricated using the sol-gel method. The coatings' surface morphology and microstructure were characterized using scanning electron microscopy (SEM), atomic force microscopy (AFM), X-ray diffraction (XRD), and X-ray photoelectron spectroscopy (XPS). The hydrophobicity of the coatings was evaluated using a contact angle goniometer, and their corrosion resistance in a simulated proton exchange membrane fuel cell (PEMFC) corrosion solution (0.5 mol/L H2SO4 + 2 mg/L HF) was measured using an electrochemical workstation. The findings revealed that increasing graphene doping resulted in a more uniform, smooth, and dense coating surface. The ITO coating primarily consisted of In2O3. However, with graphene doping, diffraction peaks of the InOCl phase appeared, indicating changes in the material's composition and structure. Additionally, the valence peaks of the main elements shifted, reflecting alterations in their chemical states. Graphene doping significantly enhanced the coating's hydrophobicity compared to the undoped ITO coating. The water contact angle of the ITO coating with 0.375 g/L graphene increased from 104° to 126°. Furthermore, this graphene-doped coating demonstrated superior corrosion resistance, with a corrosion current density of 0.06 μA/cm2, representing a decrease by three orders of magnitude compared to the titanium substrate. Additionally, it exhibited the largest capacitive arc radius, indicating enhanced charge transfer resistance and better overall electrochemical stability.

Optimizing substrate bias voltage to improve mechanical and tribological properties of ductile FeCoNiCu high entropy alloy coatings with FCC structure

Conventional hard coatings are limited in their tribological applications due to their high brittleness. High-entropy alloy (HEA) coatings, which combine high toughness and hardness, represent a new class of tribological coatings with great potential. The microstructure and stress state of HEA coatings can be significantly affected by the deposition parameters of magnetron sputtering, which can regulate their mechanical and tribological properties. In this study, DC magnetron sputtering with varying substrate bias voltages was used to deposit FeCoNiCu HEA coatings with an FCC single phase structure on 316 stainless steel. The microstructure, mechanical, and tribological properties of these coatings were studied in detail. The residual tensile stress of the coatings decreases, while toughness and hardness increase as the bias voltage increases. The coatings exhibited optimal toughness, highest hardness (11.3 GPa), and the lowest wear rate (as low as 6.01 × 10−5 mm3/N·m) when the bias voltage was set to −200 V. The formation of a metal oxide adhesion layer during friction improved the tribological properties of the coatings. This study demonstrates that optimizing the deposition bias voltage is an effective way to improve the mechanical and tribological properties of high-entropy, face-centered cubic alloy coatings, which are intrinsically tough and ductile.

Irradiation response of microstructure and mechanical properties of NbMoVCr multi-principal element alloy coatings

In this study, NbMoVCr multi-principal element alloy (MPEA) coatings with near-equal atomic ratios were deposited onto the ferritic/martensitic (F/M) steel substrate by magnetron sputtering and then irradiated using 6 MeV Au2+ at room temperature (RT) and 550 °C, respectively. The results demonstrate that the NbMoVCr coatings have excellent irradiation resistance in terms of phase stability. RT-irradiation introduces both interstitial- and vacancy-type dislocation loops, and the dislocation loop density increases with the increase of irradiation damage dose. Meanwhile, RT-irradiation could also induce grain growth of the coating. However, under high-temperature irradiation, more recombination and annihilation of irradiation-induced defects, and recrystallization occur in the coating. In addition, irradiation also promotes the desegregation of V and Cr elements at the grain boundaries and enhances the uniformity of the distribution of coating elements. Irradiation softening and hardening in NbMoVCr coatings are also found to depend strongly on both irradiation damage dose and irradiation temperature. The creep deformation mechanism of the coating is dominated by diffusion; thus, the irradiation-enhanced diffusion reduces the creep resistance of the coating.