Morphology Of Coatings Research Articles

High-temperature oxidation behavior of direct-aged bimodal Al2O3-reinforced Inconel625 plasma sprayed composite coatings

Plasma-sprayed (PS) coatings in industrial or aerospace applications are chosen as a technique for enhancing the high-temperature oxidation performance of parts operating under strenuous conditions. However, the presence of microstructural defects and amorphous phases developed in as-sprayed plasma coatings can restrict the potential of such coatings when exposed to thermal cycling conditions. Examining the oxidation performance and microstructural characterization of three heat-treated Inconel 625-Al2O3 plasma-sprayed composite coatings over an ASTM SA210 GrA1 (uncoated) substrate is the goal of the current study: The three prepared compositions are; a) Inconel625-30 wt% micron-sized Al2O3 (INC625-CHT) coating, b) Inconel625-30 wt% nano-sized Al2O3 (INC625-NHT) coating and c) Inconel625-15 wt% micron-sized Al2O3 + 15 wt% nano-sized Al2O3 (INC625-BHT/bimodal) coating. High-temperature oxidation tests were conducted at 900 °C temperature in air for 50 cycles in a simulated environment using a laboratory silica tube furnace. The microstructures and morphologies of the composite coatings in the as-sprayed and oxidized conditions were characterized using SEM, EDX, and XRD techniques. The furnace heat treatment (HT) improves the oxidation resistance of the coatings in order INC625-BHT, INC625-NHT, and INC625-CHT coating by healing interlamellar defects like pores and cracks.

Examining the microstructure, morphological features, and wetting characteristics of Ti/TiN/TiAlN thin films produced through RF/DC magnetron co-sputtering

This study reports synthesizing and characterizing Ti/TiN/TiAlN thin films deposited on 316 L stainless steel and silicon wafer substrates using the reactive RF/DC magnetron sputtering technique. The films' microstructure, morphology, thickness, roughness, and wettability were investigated experimentally and theoretically using density functional theory (DFT) calculations with the CASTEP program. X-ray diffraction analysis confirmed the formation of the fcc-TiAlN phase for coatings deposited at a DC power of 100 W, while increasing DC power to 150 W resulted in the appearance of a second phase, w-AlN. Field emission scanning electron microscopy images showed the formation of nanostructured coatings with a grain size range of 70–100 nm. The morphology of coatings was altered from a pyramid-like structure to a cauliflower structure by increasing the nitrogen amount in the N2/(Ar+N2) flow ratio. An increase in aluminum amount by increasing the DC power to 150 W enhanced the deposition rate and thickness of the coatings. The coatings deposited at a high N2/(Ar+N2) flow ratio exhibited minor surface roughness attributed to the compact structure. The contact angles obtained from the fabricated Ti/TiN/TiAlN coatings ranged from 86.2° to 114.2°, demonstrating values higher than the contact angle of uncoated 316 L stainless steel, which measured at 82°. Theoretical analysis using DFT calculations with CASTEP provided a fundamental understanding of the thin films' electronic structure and properties, consistent with the experimental results. This study highlights the importance of combining practical and theoretical analyses for a comprehensive understanding of material properties and the design of materials for various applications.

Bio-inspired nanocomposite coatings on orthodontic archwires with corrosion resistant and antibacterial properties.

The corrosion resistance and antibacterial properties of fixed orthodontic devices are insufficient in the complex oral cavity, which delays tooth movement and causes enamel demineralization. To overcome the challenges, this research constructs a series of polydopamine-graphene oxide (PDA-GO) nanocoatings on representative NiTi archwires via self-assembly. The morphology, chemical structure, and multifunctional properties of coatings showed tunability dependent on the PDA/GO ratio. Optimized PDA-GO coatings with uniform and dense characteristics prolonged the diffusion path for the corrosive medium and reduced Ni dissolution in NiTi alloys. Meanwhile, the applied coatings endowed NiTi alloys with antibacterial activity against Streptococcus mutans due to the surface structures and inherent properties of PDA-GO. In vitro cytotoxicity tests further verified their good biocompatibility. This bio-inspired nanocomposite coating provides a practical reference for modification of dental metal surfaces to better behave in the intraoral environment.

Structure, mechanical and tribological properties of Ti-doped and Cr-doped a-C:H:SiOx coatings

The work is devoted to the deposition of Ti- and Cr-doped a-C:H:SiOx coatings on WC-8Co substrates using plasma-assisted chemical vapor deposition and magnetron sputtering methods. The structure, surface morphology, mechanical and tribological properties of coatings are investigated depending on the Ti or Cr content. It is shown that only a small concentration of Ti or Cr in coatings improves their mechanical and tribological properties compared to undoped coatings. The addition of 0.8 at.% Ti to the a-C:H:SiOx coating reduces its wear rate by 3 times, and the addition of 3 at.% Cr to the a-C:H:SiOx coating reduces its friction coefficient by 30% and the wear rate by 10 times. According to VDI 3198 standard, the Ti- and Cr-doped a-C:H:SiOx coatings with a low concentration of metals have the adhesive strength quality HF1. At higher metal concentrations, the properties of the coatings deteriorate due to graphitization of the carbon structure.

Surface morphology, microstructure and emissivity of rhenium electrodeposited from molten salts

Rhenium (Re) has a high melting point and unique high temperature mechanical properties, making it an optional material that acts as a high emissivity coating on the outer wall of iridium/rhenium combustion chambers, improving their radiant heat dissipation. In this study, the effects of the electrodeposition (ED) process parameters in molten salts on the surface morphology, microstructure, and emissivity of Re coatings were investigated. The emissivity of the coating was related to the oxygen content, preferred orientation and, particularly, its morphology. The emissivity of the Re coatings increases with decreasing average radius or increasing surface density of the coating characteristic microstructures. With increasing cathodic overpotential, corresponding to high CsCl content or high current density or low molten salt temperature, the Re coating tended to change from lateral growth mode to outward growth mode, with preferred growth plane of the coating changing from (200) to (110), and meanwhile the surface morphology of the Re coating changing from stout branch-like to spiked starfish-like, leading to an increase in emissivity. The optimal deposition process parameters for the high emissivity black Re coatings were as follows: temperature ranging from 720 °C to 780 °C, cathode current density of 50 mA/cm2 to 90 mA/cm2, and the CsCl content higher than 60 wt%. The obtained black Re coatings had an emissivity higher than 0.7, with a preferred growth crystal plane of (110), and a typical spiky starfish shaped micromorphology.

Anti-corrosive yet color-tunable AlN/Si multilayer hard coatings on 304 stainless steel by magnetron sputtering

AlN based coatings are widely used to protect metal substrates from corrosion. However, synthesizing anti-corrosive yet color-tunable AlN based coatings is challenging. In this study, the AlN/Si multilayer coating was deposited on 304 stainless steel by embedding nine film layers of Si in an AlN monolayer coating using magnetron sputtering. The effects of embedded Si thin layers on the morphology, structure, composition, hardness, friction, optical and corrosion resistance of the AlN coatings were investigated. With the embedding of Si thin layers, the surface pinhole defects and columnar structure of the AlN monolayer coatings were significantly suppressed, and the surface particle size was reduced from 200 to 40 nm, and the average grain size of AlN was reduced from 19.7 to 12.9 nm. The hardness increased from 8.9 to 12.2 GPa, and the friction coefficient decreased from 0.96 to 0.75. The corrosion current density decreased from 6.81 × 10−8 to 2.57 × 10−10 A/cm2 in 3.5 wt% NaCl solution, and from 3.76 × 10−6 to 4.69 × 10−8 in 1 mol/L H2SO4 solution, which is about 4 orders of magnitude lower than the 304 steel. When the thickness of the AlN top layer was controlled to 220, 200, 185, 170, 160, 150 and 140 nm, the colors of the AlN/Si multilayer coatings were red, orange, yellow, green, blue, indigo and violet, respectively. The mechanism of anti-corrosion enhancement and color tunability of AlN/Si multilayer coatings was revealed in detail.

Fabrication of Cr2AlB2 and Cr4AlB4 MAB Phase Coatings by Magnetron Sputtering and Post-Annealing

Cr2AlB2 and Cr4AlB4 are members of the MAB phases that exhibit unique properties of both metals and ceramics. However, despite these unique characteristics, Cr2AlB2 and Cr4AlB4 phase coatings have not been widely investigated. In this study, Cr2AlB2 and Cr4AlB4 MAB phase coatings were fabricated by magnetron sputtering at room temperature and post-annealing. A composite target, consisting of a phase-pure disc-shaped CrB target overlapped by uniformly dispersed fan-shaped Al slices, was placed parallel to the substrates. The Al content of the coatings was adjusted by altering the areal proportion of the Al slices. MAB phases have crystallized upon post-annealing the as-deposited coatings on Al2O3(0001) substrates in Ar. The phase compositions and morphologies of the crystalline coatings were found to be dependent on the Al content and the annealing temperature. As-deposited coatings with a Cr:Al:B ratio close to 2:1:2 could crystallize as pure and dense Cr2AlB2 phases within the temperature range of 650–800 °C; higher annealing temperatures resulted in the decomposition of Cr2AlB2, while crystallization at lower temperatures was not evident from X-ray diffraction. As-deposited coatings with a Cr:Al:B ratio close to 3:1:3, despite containing a relatively higher Al content than required by the stoichiometry of Cr4AlB4, exhibited insufficient crystallization of Cr4AlB4 with unknown phases below 840 °C. Higher annealing temperatures resulted in the coexistence of Cr4AlB4 and CrB, indicating that achieving phase-pure and well-crystallized Cr4AlB4 coatings proved challenging, possibly due to the inevitable loss of Al during annealing. The configuration of the composite target and the substrates provides a promising strategy for fabricating phase-pure and dense Cr2AlB2 coatings.

Fabrication of Superhydrophobic Coatings by Using Spraying and Analysis of Their Anti-Icing Properties

Ice accumulation on glass insulators is likely to cause faults such as flashover, tripping and power failure, which interfere with the normal operation of the power grid. Accordingly, superhydrophobic coatings with great anti-icing potential have received much attention. In this study, three superhydrophobic coatings (PTFE, Al2O3 and SiO2) were successfully prepared on glass surfaces by using one-step spraying. The microscopic morphology, wettability, anti-icing and anti-glaze icing properties of the superhydrophobic coatings were comparatively analyzed. The results indicated that the PTFE coating had a densely distributed rough structure, showing a contact angle of 165.5° and a sliding angle of 3.1°. The water droplets on the surface could rebound five times. Compared with the Al2O3 and SiO2 coatings, the anti-icing performance of the PTFE coating was significantly improved. The freezing time was far more than 16 times that of glass (4898.7 s), and the ice adhesion strength was 9 times lower than that of glass (27.5 kPa). The glaze icing test in the artificial climate chamber showed that the icing weight of the PTFE coating was 1.38 g, which was about 32% lower than that of the glass. In addition, the icing/melting and abrasion cycles destroyed the low-surface-energy substances and nanostructures on the surface, leading to the degradation of the anti-icing durability of the PTFE coatings. However, the PTFE coating still maintained excellent hydrophobicity and anti-icing properties after UV irradiation for up to 624 h. The superhydrophobic coatings prepared in this work have promising development prospects and offer experimental guidance for the application of anti-icing coatings on glass insulators.

A Study on the Influence of the Electroplating Process on the Corrosion Resistance of Zinc-Based Alloy Coatings

A comprehensive analysis was conducted to examine the crystal phase composition, surface and cross-section morphology, elemental composition, thickness, and corrosion resistance of coatings. X-ray diffraction (XRD) was employed to investigate the texture and crystal phase of the materials while scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) were utilized to assess the surface and cross-section structure. Additionally, electrochemical techniques were employed to evaluate the corrosion performance. Compared to DC electroplating, the corrosion potential of pulsed galvanized ferroalloy alloy coating increased from −1031 mV to −1008 mV, and the corrosion current density decreased from 3.122 × 10−5 A∙cm−2 to 0.321 × 10−5 A∙cm−2. Moreover, the corrosion rate value of the coating obtained by the pulse rectifier (0.386 × 10−5 g m−2 h−1) was lower than that obtained by the DC power supply (3.75 × 10−5 g m−2 h−1). Additionally, pulsed electrodeposition reduced the iron content of the coating by 0.7%, thereby enhancing its corrosion resistance and flatness. The impedance parameters of the zinc–iron alloy coating acquired through the 30% duty cycle monopulser process exhibit superior performance compared to DC electroplating. Evidently, the monopulse coating’s structure enhances crystal packing density, augments coating thickness, improves adhesion to the substrate interface, and optimizes grain distribution uniformity. These factors are crucial determinants of the corrosion behavior exhibited by Ze–Fe coating.

Heat treatments for thermal sprayed lead-free piezoelectric ceramic coatings

[0.94(Bi0.5Na0.5)TiO3-0.06BaTiO3]0.98-(LiNbO3)0.02 (BNBTLN) piezoelectric ceramic coating was fabricated by thermal spray process on stainless steel substrates with thermal barrier coating (TBC) as an intermediary layer. The morphology, structure, and electrical properties of the thermal-sprayed BNBTLN coatings after furnace heat treatment (F-HT) and plasma torch heat treatment (P-HT) were studied, respectively. The BNBTLN coatings after F-HT and P-HT both had the coexisting rhombohedral and tetragonal perovskite phases and exhibited excellent electrical properties, with an effective piezoelectric coefficient d33 of 68 p.m./V and 40 p.m./V, respectively. These results reveal that high quality piezoelectric coatings can be achieved by the P-HT method, which is promising for scaling up the fabrication of piezoelectric ceramic coatings.

Improving tribological behavior of titanium nitride (TiN) hard coatings via zirconium (Zr) or vanadium (V) doping

This research expounds on the influence of zirconium (Zr) or vanadium (V) doping on titanium nitride (TiN) coatings deposited via magnetron sputtering technique. The study focuses on microstructure analysis, tribological properties, and the implications of these doping. Previous research has shown that doping can modify the microstructure, coating substrate adhesion, friction, and wear resistance of TiN coatings. However, further investigation is required to understand the specific effects of doping levels and the underlying mechanisms. This study addresses the need to enhance TiN coating performance by exploring the potential of Zr and V doping. It fills a gap in knowledge by examining the influence of specific doping levels on coating properties and contributes to resolving disputes in the literature. Analytical methods, including GI-X-ray diffraction, energy dispersive X-ray spectroscopy, scanning electron microscopy and atomic force microscopy, were used to analyze the coatings microstructure, morphology, chemical composition, phase composition, and roughness. The findings reveal that Zr-doped TiZrN coatings outperform TiVN and TiN coatings in terms of mechanical and tribological properties. TiZrN coatings exhibit higher texture coefficients, elastic modulus, and hardness. Moreover, Zr or V doping enhances the anti-wear properties of the coatings, shifting the dominant wear mechanism from adhesive to abrasive. The implications of this research are significant for industries seeking improved wear resistance and durability in coatings. This study expands knowledge on the microstructural and tribological characteristics of doped TiN coatings, contributing to advancements in the field.

Ultrasonic visualization and quantitative analysis of internal defects in RTV coatings

Room temperature vulcanised (RTV) silicone rubber coatings effectively enhance the insulation properties of electrical equipment. However, RTV coatings are prone to internal defects caused by the coating process and the effects of aging during service, which can lead to debonding of the coatings. Internal debonding defects are challenging to detect and can ultimately lead to accidents due to a reduction in the insulation capacity of the equipment. To visualize the internal defect morphology of RTV coatings and quantify the defect size, an ultrasonic pulse-echo-based method for detecting and imaging debonding defects is proposed. The method involves the development of a finite element model to investigate how ultrasonic waves propagate in RTV coatings and the influence of ultrasonic probes and inspection conditions on defect echoes. Furthermore, an ultrasonic detection system specifically designed for RTV coating debonding defects is constructed. This system utilizes wavelet packets in the time-frequency domain to analyze the echo signals in both normal and defective regions. The three-dimensional reconstruction of the debonding defect morphology is accomplished by integrating ultrasonic echo amplitude and position information. Finally, the size of the debonding defects is quantified using an adaptive threshold segmentation method. The findings indicate that ultrasound waves reflected in RTV materials propagate as spherical waves, with the acoustic energy primarily concentrated near the acoustic axis. As the propagation distance increases, the sound beam disperses along the axis and extends beyond the transducer, resulting in a decrease in the sound field's directionality. The developed visual reconstruction method in this study offers the capability of three-dimensional visualization for defects present within RTV coatings, including their length, width, and depth. The accurate determination of defect size is achieved through the utilization of the adaptive threshold segmentation method, yielding an average error rate of 5.7 % across different defect types. In comparison, the maximal interclass variance method (OTSU) and the fuzzy C-means (FCM) method produced results with error rates of 9.8 % and 7.9 %, respectively. The research presented in this paper enables precise assessment of debonding defect severity and establishes a reliable foundation for on-site inspection, operation, and maintenance of RTV coatings.

Electrochemical synthesis of boron-containing coatings on Mg alloy for thermal neutron shielding

The work provides the results of the one-step formation of boron-containing coatings on an Mg–Mn–Ce alloy by plasma electrolytic oxidation. The results of studies of the composition, structure and morphology of heteroxide coatings are presented. It was established that the boron is contained in the coating mainly in the form of B or B2O3. The introduction of B changes the color of coatings, and also helps to increase their porosity. The method of determining the full cross section of the interaction of thermal neutron absorption efficiency by samples material using the installation of neutron-activation analysis based on 252Cf was developed. It was shown that the introduction of boron into the formed coatings allows to increase the macroscopic cross-section of the interaction of samples with thermal neutrons by 3.8 times. This effect opens the potential for the use of synthesized material in the field of nuclear technologies and aerospace industry.

Effect of copper content on the microstructure, morphology, and optical properties of ZrSiN coatings deposited using pulsed-direct current reactive magnetron sputtering

The incorporation of an element such as silicon, silver, or copper, etc. into transition metal nitrides has allowed the production of multifunctional materials. These materials exhibit distinct properties contributed by each phase, thereby enhancing the industrial application of metal nitrides. This study focuses on the deposition of ZrSiNCu coatings using pulsed-DC reactive magnetron sputtering, aiming to investigate the influence of copper on the chemical composition, morphology, microstructure, and optical behavior of the coatings. The results showed that the deposited coatings were nanostructured, with a mixture of ZrN, ZrO2, and nanocrystalline Cu, which had a profound impact on the Cu segregation on the surface and columnar boundary due to the fact that copper is relatively inert with respect to a ceramic matrix. Furthermore, an increase in the Cu content led to the presence of large aggregates on the surface and lower bandgaps.

Formation of targets and investigation of Mn4Si7 coatings produced by magnetron sputtering

The morphology, composition, electrical and optical properties of bulk samples and vacuum coatings of Mn4Si7 obtained by magnetron sputtering on a SiO2/Si structure were studied. It is shown that manganese silicide coatings with a thickness of about 150 nm are close in properties to bulk Mn4Si7, have a uniform finegrained structure of a semiconductor nature, which is characterized by thermal sensitivity up to 20-30 μV per degree. In addition, this article presents the electrophysical properties of high manganese silicide films produced by the authors by magnetron sputtering method. Heated films Mn4Si7 -146 nm coating has a uniform structure with fine grains, due to sufficient coating density. Since Mn4Si7 nanoclusters are semiconductor materials, it can be assumed that there will be energy barriers for charge carriers at the nanocluster–amorphous phase interface separating this phase. An increase in thermal sensitivity from 0 μV/K to 20 μV/K up to 800 K is explained by the disappearance of energy barriers for charge carriers at the nanocluster–amorphous phase interface due to the ordering of nanoclusters. The change from 20 µV/K to 28 µV/K upon cooling is explained by the appearance of structural relaxation in the amorphous phase.

TiO2 Microparticles Incorporation in Coatings Produced by Plasma Electrolytic Oxidation (PEO) on Titanium

This research describes the influence of two types of particles, namely rutile and anatase microparticles (average d < 5 µm), on the morphology, structure, and anticorrosive properties of PEO coatings on titanium produced in an alkaline solution based on NaOH and sodium metasilicates. The paper reports the experimental results relating to the study of the influence of the electrical regime and working frequency of the anodizing treatment on the interaction between the particles, the substrate, and the oxide to determine the optimal conditions that favour the incorporation of the particles and the production of a thick oxide. PEO coatings are characterized by using a scanning electron microscope (SEM), energy dispersive spectroscopy (EDS) analysis, and X-ray diffraction (XRD) testing. The electrochemical behaviour is evaluated by free corrosion potential monitoring and electrochemical impedance spectroscopy analysis (EIS) performed in a sulphuric acid solution. The particles are successfully incorporated into the coating under any electrical condition and at any frequency. However, only treatments carried out at 1000 Hz allow the production of coatings that combine a large thickness (up to 50 µm) and improved anticorrosion behaviour. In contrast, oxide layers produced at 20 Hz and in DC show a quite damaged structure, affecting their anticorrosion behaviour and resulting in lower corrosion potential and impedance values.

Improving anti-corrosion properties AZ31 Mg alloy corrosion behavior in a simulated body fluid using plasma electrolytic oxidation coating containing hydroxyapatite nanoparticles

Orthopaedic implants often make use of magnesium and its alloys. These alloys are more mechanically compatible with bone tissue than other alloys, such as titanium, cobalt, and nickel, but a loss of implant mechanical strength can occur due to their low corrosion resistance. The plasma electrolytic oxidation (PEO) method was used to modify the surface of AZ31 magnesium alloy in this study. The effects of varying concentrations of hydroxyapatite (HA) nanoparticles (1, 3, and 5 g/l) on the morphology and corrosion characteristics of coatings were examined using phosphate-based electrolytes. The elemental composition was determined using Energy dispersive spectroscopy (EDS), elemental map analysis (MAP) and phase X-ray diffraction analysis (XRD). Field emission-SEM was employed to investigate the surface morphology and cross-section of the coatings. The corrosion characteristics of all samples were evaluated by electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization (PDP) in Ringer’s solution. The sample with 3 g/l HA showed the best anti-corrosion performance, as it had the smallest average pore size (8.7 µm), the thickest coating (22.5 µm) and the lowest corrosion current density (0.034 µA/cm2) among all the samples tested.

The Effect of Heat Treatment on Phase Structure and Mechanical and Corrosion Resistance Properties of High Tungsten Ni-W Alloy Coating

The present study investigated the surface morphology, phase composition, mechanical properties, and corrosion resistance of Ni-W alloy coatings prepared under current densities of 1–5 A/dm², after undergoing heat treatment at 400 °C, 600 °C, and 900 °C. The grain size of the as-plated Ni-W alloy coating was below 10 nm. After heat treatment at different temperatures, the grain size increased, reaching a maximum value of around 30 nm at 900 °C. Heat treatment crystallized and altered the structure of the coating. Different heat treatment temperatures yielded different precipitates, including Ni4W, Ni6W6C, and WC. The highest coating hardness (820–940 Hv) was achieved at 400 °C, while the best corrosion resistance was achieved at 600 °C. The precipitation hardening phase can be obtained by proper heat treatment temperature, yielding the desired properties of the composite coating.

Cyclic Oxidation Behavior of HVOF Thermally Sprayed WC Cermet Based on AISI 1045 Steel

Thermal spray coating technology High-Velocity Oxygen Fuel (HVOF) has become one of solution for metal protect and parts recondition that work in critical environments such as oxidative, erosive, and corrosive. One of the thermal spray coatings (TSC) application has been carried out to improve the oxidation resistance of the Induce Draft Fan (IDF) as a part on coal fired steam power plant unit. Cermet WC10Co4Cr and WC17Co are intended to sustain the AISI 1045 steel substrate against the oxidative environment. In this works, the cyclic oxidation at a temperature 500oC were conducted to reveal the oxidation resistance behavior of the coatings. Several mechanical tests are also presented including surface roughness of the coatings, coatings microhardness, and coatings adhesion. The coatings morphology was also characterized using SEM microscope, as well as X-ray diffraction (XRD) for phase analysis after the oxidation test.

Superior multifunctional polypyrrole anticorrosion coating modified by polydopamine decorated barium titanate nanoparticles on NiTi shape memory alloys

The enhancement of corrosion protection capabilities through the use of conducting polymer coatings has become a necessity in order to safeguard metallic materials for biomedical purposes. In the present study, the hydroxylated barium titanate nanoparticles (BT-OH) were functionalized with polydopamine (PDA) to promote the dispersion of nanoparticles in a polypyrrole (PPy) matrix. The TEM analysis confirmed the formation of the PDA layer on the BT nanoparticles (BT NPs). Then, PPy coating was successfully electropolymerized on NiTi alloy in the presence of various concentrations (1, 3, 5, and 10 wt %) of PDA functionalized BT (PBT). The morphology, structure, and topography of PPy and composite coatings were investigated utilizing the field emission scanning electron microscope (FESEM), Fourier transforms infrared spectroscopy (FTIR), and atomic force microscope (AFM). Surface morphology analysis exhibited that the augmentation of the PBT nanoparticles changed it from cauliflower-like for PPy to nodular-like for composite coatings. Nano-indentation evaluations of the coatings have demonstrated that the hardness and elastic modulus of composite-coated NiTi was raised favorably by PBT enhancement, reaching 0.86 ∓ 0.2 (GPa) and 16.06 ∓ 3.23 (GPa) in PPy with 5 wt % PBT (PPy/5PBT), respectively. Electrochemical examinations demonstrated that PPy/5PBT coating revealed superb corrosion protection in Ringer solution, serving as a physical barrier and preventing the pitting corrosion of NiTi alloy. Finally, the constructive effect of PBT inclusion in the PPy coating on the corrosion performance of NiTi substrate was authenticated by lower Ni ion release from composite-coated NiTi compared with PPy coating.