Nanostructured Coatings Research Articles

Porous metal/metal-oxide nanostructured coatings produced using gas aggregation sources of nanoparticles as recyclable SERS active platforms

Porous metal/metal-oxide nanostructured coatings produced using gas aggregation sources of nanoparticles as recyclable SERS active platforms

Zein-based nanostructured coatings: A green approach to enhance virucidal efficacy of protective face masks.

Face masks represent a valuable tool to prevent the spreading of airborne viruses; however, they show poor comfort and scarce antiviral efficacy. Zein-based coatings are herein exploited to enhance antiviral performance. Zein functionalization is done through acidifying agents (lactic acid, LA). Coatings are characterized in terms of morphological, mechanical, breathability, and cytotoxicity analyses. The antiviral efficacy is tested in vitro against four viruses (Human Coronavirus OC43, Herpes Simplex Virus type 1, Human Adenovirus type 5, and MPox Virus) according to a biological assay on cell cultures. Zein/Zein LA antiviral activity seems to be linked to its positive surface charge that enables to form electrostatic interactions with negatively charged-viruses, resulting in the highest activity (reduction >2 Log) on Human Coronavirus OC43 and Herpes Simplex Virus type 1, with efficacy comparable or higher than that of copper/copper oxide-based- coatings. No significant activity is observed against Human Adenovirus type 5 and MPox Virus, due to their high resistance to inactivating treatments. Zein-based systems are not cytotoxic and their water vapor permeability is reduced of 26 % compared to those of not-coated systems. These promising results offer interesting insights into design of antiviral and sustainable coatings for personal protective equipment.

A Review of Nanostructure Coating Techniques to Achieve High-Precision Optical Fiber Sensing Applications

Optical fiber sensors have emerged as a critical sensing technology across various fields due to their advantages, including high potential bandwidth, electrical isolation that is safe for utilization in electrically hazardous environments, high reliability, and ease of maintenance. However, conventional optical fiber sensors face limitations in achieving high sensitivity and precision. The integration of nanostructures with advanced coating technology is one of the critical solutions to enhancing sensor functionality. This review examined nanostructure coating techniques that are compatible with optical fiber sensors and evaluated etching techniques for the improvement of optical fiber sensing technology. Techniques such as vapor deposition, laser deposition, and sputtering to coat the nanostructure of novel materials on the optical fiber sensors are analyzed. The ability of optical fiber sensors to interact with the environment via etching techniques is highlighted by comparing the sensing parameters between etched and bare optical fibers. This comprehensive overview aims to provide a detailed understanding of nanostructure coating and etching for optical fiber sensing and offer insights into the current state and future prospects of optical fiber sensor technology for sensing performance advancement, emphasizing its potential in future sensing applications and research directions.

Zr-Based Thin Film Metallic Glasses As High-Efficiency Materials for Electrocatalysis of the Hydrogen Evolution Reaction

The production of hydrogen through water electrolysis is a major limiting step in the implementation of hydrogen-based energy storage. Currently used materials for catalyzing the hydrogen evolution reaction require large overpotentials, reducing the efficiency of hydrogen production. Metallic glasses are of interest for use in electrocatalysis due to their high activity and diversity of catalytic sites. However, only a small selection of metallic glass compositions can be manufactured into bulk parts, necessitating the use of metallic glass coatings. In this research, a Zr-based metallic glass was produced as a thin film using sputtering deposition. Combinatorial co-sputtering was used to produce a library of quaternary Zr-based metallic glasses to enable high-throughput characterization of the anode material and electrochemical testing. Metallic glass surfaces were characterized prior to and after electrochemical testing using a range of techniques to explore the physiochemical properties of the catalytic surface. Nano-structured metallic glass coatings are a promising material for catalysis of the hydrogen evolution reaction. This work is funded by ARPA-e under DE-AR0001697. JRH is funded as a fellow under the NSF GRFP.

Mechanical and tribology performance of nanostructured ZrN-Cu coatings obtained by hybrid HiPIMS-DCMS technology

One of the biggest players in the world economy is the naval industry, which mainly controls the merchandise transportation sector. Any issue with ships could represent millions of USD of loss and increases in the cost of goods for the population worldwide. Two main problems which this industry has fought are corrosion and biofouling. Lastly, the pollution of the sea has gained importance, and more strict policies have been applied regarding the use of certain products by this industry. One of these is paintings, which represented this industry's definitive solution to avoid the mentioned problems for a long time. This situation allowed to explore other solutions like PVD coatings through multifunctional coatings. Zirconium nitride has been demonstrated to be useful in resisting corrosion with reliable mechanical properties. However, this material does not possess antimicrobial action. The present study presents a nanostructured coating combining ZrN with Cu, which works as a biocide, contributing to the desired multifunctionality. The developed coating was obtained using a hybrid magnetron co-sputtering employing High-power impulse (HiPIMS) and direct current (DCMS) power sources under a reactive atmosphere. SEM, EDX, XRD and Raman spectroscopy were used to assess the physico-chemical properties of the coatings. Besides, depth-sensing nano-indentation explored the mechanical properties. The tribological performance was tested by a reciprocating tribometer under dry and wet (with 3.5 % w/w NaCl solution) contact conditions and employing a soda lime glass ball as a counterbody. The results showed that adding Cu to ZrN through this technology resulted in a limited hardness reduction from 19 (pure ZrN) to 14 GPa. Also, the chemical activation with NaOCl solution softens the obtained coating and, together with the saline solution, influences the wear resistance. However, the nanostructured coating has been demonstrated to be suitable for use under real conditions, without loss of its protection over the used substrate. It opens a new possibility of a solution for the naval industry.

Highly Active and Durable Nanostructured Nickel-Molybdenum Coatings as Hydrogen Electrocatalysts via Solution Precursor Plasma Spraying.

The increasing demand for green hydrogen is driving the development of efficient and durable electrocatalysts for the hydrogen evolution reaction (HER). Nickel-molybdenum (NiMo) alloys are among the best HER electrocatalysts in alkaline electrolytes, and here we report a scalable solution precursor plasma spraying (SPPS) process to produce the highly active Ni4Mo electrocatalysts directly onto metallic substrates. The NiMo coating coated onto inexpensive Ni mesh revealed an excellent HER performance with an overpotential of only 26 mV at -10 mA cm-2 with a Tafel slope of 55 mV dec-1. Excellent operational stability with minimum changes in overpotential were also observed even after extensive 60 hour high-current stability test. In addition, we investigate the influence of different substrates over the catalytic performance and operational stability. We also proposed that a slow, but consistent, dissolution of Mo is the primary degradation mechanism of NiMo-based coatings. This unique SPPS approach enables the scalable production of exceptional NiMo electrocatalysts with remarkable activity and durability, positioning them as ideal cathode materials for practical applications in alkaline water electrolysers.

The effect of ZnO nanoparticles morphology on the barrier and antibacterial properties of hybrid ZnO/graphene oxide/montmorillonite coatings for flexible packaging

The need for eco-friendly packaging solutions is continuously increasing, with several materials being investigated to develop functional coatings able to contrast food degradation due to oxidation and bacterial growth. In this work, ZnO nanoparticles (NPs) with various morphology and size from spherical to hexagonal, dots-like and platelets-like shape, were synthesized. Hybrid coatings constituted by ZnO NPs, graphene oxide (GO) and montmorillonite (MMT) were applied onto flexible polyethylene (PE) in order to exploit the 2D nanomaterials self-assembly ability and gas barrier properties and to synergistically combine these functionalities with the antibacterial activity of ZnO. The effect of ZnO NPs morphology and the ZnO/GO/MMT relative content was explored to obtain nanostructured coatings with optimized functionality. Results evidence a correlation between oxygen permeability and microbial proliferation, allowing to reach 88 % of reduction of PE oxygen permeability and about 60 % inhibition towards Gram-positive (i.e. Weizmannia coagulans) and Gram-negative (i.e. Escherichia coli) microorganisms.

Advancements in biomedical coatings: A comprehensive review of DC magnetron sputtering on Ti–6Al–4V alloy

This study investigates the application of DC magnetron sputtering (MS) technology for producing TiN and ion-substituted Ca-P coatings on dental implant materials, demonstrating ultimate tensile strength (UTS) of 887 MPa, a modulus of elasticity of 11.3 × 106 MPa. The influence of various physical vapor deposition (PVD-MS) parameters—such as substrate temperature, post-heat treatment, deposition duration, discharge power, and bias voltage—on the characteristics of these coatings is examined. The research evaluates the advantages and limitations of PVD-MS in fabricating TiN and Ca-P coatings, with an emphasis on their impact on surface topography and chemical composition, which are critical factors influencing cellular behavior. The study reveals that while ion-substituted HA coatings can enhance cell adhesion, they may also exhibit cytotoxic effects, potentially limiting cell growth. It compares osteogenic cell proliferation rates between low-crystalline HA coatings and highly crystalline variants on Ti-based substrates, highlighting significant performance disparities. Additionally, PVD-MS demonstrates robust adhesion capabilities and facilitates the incorporation of therapeutic ions, effectively replicating bioapatite properties. The addition of coating on the substrate promotes additional strengthening mechanisms of the layers, leading to improved wear resistance compared to an alloyed substrate. Estimated values for hardness range between 7.2 and 8.4 GPa, and for Young's modulus, they range from 126 to 162 GPa. The study highlights the potential of PVD-MS in creating nanostructured Ca-P coatings on biodegradable metals, alloys, and polymeric biomaterials. This technology improves corrosion resistance, biocompatibility, chemical stability, wear resistance, and overall performance in various biomedical applications.

The effect of roughness and top layer in solid particle impingement erosion of multilayer nanostructured nitride PVD coatings

The effect of the surface roughness of the coating and the composition of the upper layer on the solid particle erosion of multilayer nanostructured coatings applied via cathodic arc evaporation (CAEPVD) method was investigated. CrN/TiN nanostructured multilayer coating (TiN as the upper layer) and TiN/CrN nanostructured multilayer coating (CrN as the upper layer) were applied on 410 stainless steel through the CAEPVD method with the following architecture. 1) a bottom layer of Cr and CrN deposited on the substrate, 2) nanolayers of TiN and CrN deposited on the bottom layer alternately and 3) an upper layer of CrN or TiN deposited on the nanolayers. After applying the coating, half of the samples were polished to obtain smooth surfaces, while the other half remained unpolished, resulting in rough surfaces. Surface morphology, phases identification, adhesion, mechanical, and erosion behavior of the coatings were characterized using SEM, XRD, Rockwell adhesion measurements, nanoindentation test, and solid particle impingement, respectively. The nano-scale indentation results demonstrated that the hardness, Young's modulus, H/E, and H3/E2 of the CrN/TiN coating were 5.57, 1.42, 3.86, and 85.39 times larger than those of the substrate. For the TiN/CrN coating, the values were 4.04, 1.13, 3.53 and 51.68 times greater than those of the substrate. The results of the erosion test showed that the erosion mass loss for the CrN/TiN and TiN/CrN coatings decreased up to 73% and 67%, respectively. Additionally, surface smoothing improved erosion resistance by 40% for both coatings. This shows that the smoothed CrN/TiN nanostructured multilayer coating is an excellent candidate for increasing the erosion resistance due to the higher ratios of H/E and H3/E2 and smoother surface.

Thermal Spray Nanostructured Coatings Integrated with Artificial Intelligence: A Sustainable Approach in Industry for Corrosion Applications

Coatings are the most common method for protecting metals from corrosion. The use of nano-sized coating materials can enhance the strength and decrease the porosity level of the developed coatings. The nano-coatings have shown improved mechanical properties, corrosion resistance, and wear resistance in recent studies. As a result, the use of nano-sized coatings can provide the benefit to the Industrial machinery components for longer operational periods. This review article covers the corrosion behavior of nano-structured coatings in the initial section followed by the role of artificial intelligence in predicting the corrosion rate of nanostructured coatings.

Robust All-Day Frostphobic Surfaces.

The application of solar-thermal surfaces for antifrosting and defrosting has emerged as a passive and environmentally friendly approach to mitigate the negative consequences of frost formation, such as structural damage and reduced heat transfer efficiency. However, achieving robust all-day frostphobicity solely through interfacial modification and solar-thermal effects is challenging in practical applications: The thick frost that accumulates at night strongly scatters solar radiation, rendering the solar-thermal coatings ineffective during the daytime. Additionally, these nanostructured coatings are susceptible to wear and tear when exposed to the outdoors for extended periods of time. To address these challenges, we present an innovative frostphobic surface that incorporates V-grooved structures with superhydrophobic solar-thermal layers (VSSs). The out-of-plane gradient structures facilitate spatially regulated vapor diffusion, an enhanced photothermal effect, and robust water repellency. These features not only prevent frost from covering the entire surface overnight, enabling effective solar-thermal defrosting during the daytime, but also protect the surface from deterioration. The combined merits ensure robust all-day frostphobicity and exceptional durability, making the VSS surface promising for practical applications and extending the lifespan in extreme environments.

Synthetic or Natural (Bio-Based) Hydroxyapatite? A Systematic Comparison between Biomimetic Nanostructured Coatings Produced by Ionized Jet Deposition.

Calcium phosphate (CaP)-based materials are largely explored in orthopedics, to increase osseointegration of the prostheses and specifically in spine surgery, to permit better fusion. To address these aims, nanostructured biogenic apatite coatings are emerging, since they better mimic the characteristics of the host tissue, thus potentially being better candidates compared to their synthetic counterpart. Here, we compare hydroxyapatite (HA) nanostructured coatings, obtained by ionized jet deposition, starting from synthetic and natural sources. The starting materials and the corresponding films are characterized and compared from a compositional and morphological point of view, then their stability is studied after post-treatment annealing. Although all the films are formed by globular aggregates and show morphological features at different scales (from nano to micro), significant differences are found in composition between the synthetic and naturally derived HA in terms of magnesium and sodium content, carbonate substitution and Ca/P ratio, while differences between the coatings obtained by the different natural HA sources are minor. In addition, the shape of the aggregates is also target-dependent. All coatings have a good stability after over 14 days of immersion in medium, with natural apatite coatings showing a better behavior, as no cracking and detachments are observed during immersion. Based on these results, both synthetic and naturally derived apatitic materials appear promising for applications in spine surgery, with coatings from natural sources possessing physiochemical properties more similar to the mineral phase of the human bone tissue.

Cellulose binary coatings with spherical envelope structure via structure rearrangement in ball milling for integrated radiative cooling-electricity generation

Passive daytime radiative cooling is a zero-energy consumption cooling technology, which can dissipate heat to outer space via infrared radiation. Recently, coupling radiative cooling technology and thermoelectric devices to generate electricity has attracted much attention. However, existing radiative cooling integrated thermoelectric devices still suffer from low-temperature gradient and output voltage. Here, based on the Mie scattering and internal reflection enhancing principle, an impact-inducing geometry reconstruction approach was proposed to fabricate hierarchical nanostructured cellulosic coatings with good daytime cooling performance to achieve stable electricity generation function, which can be realized by using a scalable and facile wet ball milling technology. Guided by the theoretical simulations of the finite difference time domain method (FDTD), the cellulose and TiO2 nanoparticles can assemble into spherical envelope structured coatings drying by the shear, impact, and friction interaction in the ball milling process, dramatically enhancing the Mie scattering and internal reflection of coatings. The cellulosic coatings exhibit sunlight reflectivity of 0.962 and infrared emissivity of 0.94, resulting in a daytime radiative cooling efficiency of 5.9 °C under direct sunlight. Energy Plus stimulation demonstrated 35 % cooling energy and 468.9 kWh of cooling energy can be saved annually in China. Meanwhile, this cellulosic coating-based thermoelectric device can deliver a high voltage output of 150 mV under 1 Sun due to the strong bonding and high-temperature gradient formation (30 °C), which is higher than previous reports. This study will facilitate the development of sustainable power generation device for the goal of green future.

Nanotechnological Antibacterial and Conductive Wound Dressings for Pressure Ulcer Prevention.

The development of pressure ulcers, associated with increased temperature and moisture in specific areas of the body, and the risk of microbial infections in patients lying in a static position for prolonged periods of time represents a serious issue in medicine. In order to prevent the formation of pressure ulcers, this work aims to present advanced nanostructured coatings developed by three research groups. Nanometric silver, ash and functionalized torrefied biomass were the basis for the treatment of wound dressings to improve thermal conductivity and antimicrobial properties of the conventional cotton gauzes. Each treatment was performed according to its own optimized method. The treated fabrics were characterized in terms of antimicrobial properties, heat transfer, morphology and hydrophobic behavior. The results demonstrated the effectiveness of the deposition treatments also in synergistic actions. In particular, the antibacterial efficacy was improved in all the samples by the addition of silver treatment, and the thermal conductivity was enhanced by around 58% with nanometric ashes. A further step of the study involved the designing of two multilayer systems evaluated using circuit models for determining the total thermal conductivity. In this way, both systems were designed with the aim to guarantee simultaneous efficacy: high antibacterial and hydrophilic properties at the skin level and more hydrophobic and conductive behaviors toward the external environment.

Reaction-sintered zircon-based nanostructured coatings obtained by suspension plasma spraying

Zircon (ZrSiO4) is an inexpensive and widely available material with excellent thermal properties that makes it an ideal candidate for thermal barrier coatings. Previous works have demonstrated the feasibility of obtaining coatings with a high retention of zircon by plasma spraying of ZrSiO4 and ZrSiO4/ZrO2 suspensions.Suspensions of ZrSiO4/Al2O3 and ZrSiO4/TiO2 were produced by dispersing a micrometric zircon powder into alumina and titania colloidal sols, optimising their colloidal stability and rheological behaviour. Optimised slurries were plasma sprayed onto metallic substrates, obtaining coatings with the typical morphologies obtained by suspension plasma spraying (SPS). Nanostructured coatings with nanoparticles embedded in the molten matrix were obtained at higher proportions of sprayed colloidal sol. The high retention of ZrSiO4 in the final coatings and the formation of new crystallographic phases of mullite and zirconium titanate by reaction of the by-products of zircon decomposition (SiO2 and ZrO2) and the Al2O3 and TiO2 colloids was demonstrated.

Optical and electrophysical properties of nitride TiAlSiN and carbonitride TiAlSiCN coatings: influence of reactive magnetron deposition regimes

The development of thin-film thermal control coatings for small spacecraft is relevant. Coatings based on titanium nitride are capable of functioning in unfavorable conditions of near and deep space, due to their high resistance to the irradiation by high-energy particles. Using the reactive magnetron sputtering method, the nanostructured TiAlSiN and TiAlSiCN coatings were formed on the substrates of silicon oxide (SiO2), glass-ceramic CT-1 and single-crystalline silicon (Si(100)). A study of the electrophysical and optical properties of the formed coatings was carried out. The deposited coatings demonstrate a good reflectivity in the infrared range of spectrum (700–2000 nm), what is important for reducing the overheating of the spacecraft (SC) under the influence of the direct sunlight. In the visible range of spectrum (400–700 nm), a low level of total Rtotal reflection is observed. This is promising for satellites designed to observe the Earth’s surface. The values of solar absorption coefficients αs, emissivity coefficients ε0, ratios αs/ε0, as well as the equilibrium temperature Tр for the samples under study were obtained. The values of resistivity ρ and surface resistance R□, electron concentration N and electron mobility μ were determined. It has been discovered that TiAlSiN, TiAlSiCN films are electrically conductive: ρTiAlSiN = (92÷4260) ∙ 10–7 Ω ∙ m, ρTiAlSiCN = (51÷2360) ∙ 10–7 Ω ∙ m. It has been found that adding carbon to the coating composition reduces the resistance. The obtained nanostructured coatings of TiAlSiN nitride and TiAlSiCN carbonitride can be used as temperature control coatings for small spacecrafts.

New Fe3O4-Based Coatings with Enhanced Anti-Biofilm Activity for Medical Devices.

With the increasing use of invasive, interventional, indwelling, and implanted medical devices, healthcare-associated infections caused by pathogenic biofilms have become a major cause of morbidity and mortality. Herein, we present the fabrication, characterization, and in vitro evaluation of biocompatibility and anti-biofilm properties of new coatings based on Fe3O4 nanoparticles (NPs) loaded with usnic acid (UA) and ceftriaxone (CEF). Sodium lauryl sulfate (SLS) was employed as a stabilizer and modulator of the polarity, dispersibility, shape, and anti-biofilm properties of the magnetite nanoparticles. The resulting Fe3O4 functionalized NPs, namely Fe3O4@SLS, Fe3O4@SLS/UA, and Fe3O4@SLS/CEF, respectively, were prepared by co-precipitation method and fully characterized by XRD, TEM, SAED, SEM, FTIR, and TGA. They were further used to produce nanostructured coatings by matrix-assisted pulsed laser evaporation (MAPLE) technique. The biocompatibility of the coatings was assessed by measuring the cell viability, lactate dehydrogenase release, and nitric oxide level in the culture medium and by evaluating the actin cytoskeleton morphology of murine pre-osteoblasts. All prepared nanostructured coatings exhibited good biocompatibility. Biofilm growth inhibition ability was tested at 24 h and 48 h against Staphylococcus aureus and Pseudomonas aeruginosa as representative models for Gram-positive and Gram-negative bacteria. The coatings demonstrated good biocompatibility, promoting osteoblast adhesion, migration, and growth without significant impact on cell viability or morphology, highlighting their potential for developing safe and effective antibacterial surfaces.

Structure and properties of composite nanostructured coatings on steel

Abstract In the recent years, the development of nanotechnology has increased the applications of nanoparticles, and the possibility of incorporating them into innovative composite coatings. In this paper, we aim to improve the corrosion resistance of 42CrMo4 and 65G steels by electroless chemical deposition of Ni, reinforced by adding of nanoparticles of nanodiamants (ND), boron (B) or cubic-BN (CBN). Consequently, by this approach we extend the useful-life of these mechanical parts, making them suitable for aerospace and automotive industry.

Evading the strength and toughness trade-off dilemma in Lu2Si2O7 environmental barrier coatings via micro-nano reinforcement

Lu2Si2O7 nanostructured environmental barrier coating was prepared using as–synthetic Lu2Si2O7 feedstock via atmospheric plasma spraying. The structure and mechanical performances of Lu2Si2O7 coatings were characterized in detail. Results indicate that nanostructured Lu2Si2O7 coating exhibits a bi-modal microstructure, lamella structure and unmelted particles. The phase components of nanostructured Lu2Si2O7 coatings consist of β-Lu2Si2O7 and a small number of X2-Lu2SiO5. Furthermore, the nanohardness and elastic modulus of Lu2Si2O7 coatings have the characterization of bi-modal properties via Weibull analysis, i.e., the large Weibull modulus and the small Weibull modulus represent molten lamella structure and unmelted particles, respectively. Meanwhile, the fracture toughness of nanostructured Lu2Si2O7 coatings is superior to conventional Lu2Si2O7 coatings, and the adhesion strength of Lu2Si2O7 coatings is about 22.6 MPa by pull-extend test. Results of research are helpful for the design and preparation of advanced thermal spray coating.

Assessment of the microstructural features and electrochemical corrosion behaviour of nanostructured Gd2Zr2O7 EB-PVD TBCs under three salt conditions

Improving corrosion resistance is a challenging task, as it determines the life time of thermal barrier coatings (TBCs). In this regard, this study was aimed to characterize the electrochemical corrosion behaviour of nanostructured Gadolinium Zirconate in three different corrosive salt conditions such as Na2SO4 + 55 wt% V2O5 (SM1), Na2SO4 + 10 wt% NaCl (SM2), and Na2SO4 + 7.5 wt% NaCl +7.5 wt% V2O5 (SM3). The uniformity of the coated surface was verified by mapping the vibrational bands associated with Gd and Zr using FT-IR and Raman spectroscopy. The coated surface possessed a uniform columnar structure with leafy appearance. Potentiodynamic polarisation studies and electrochemical impedance spectroscopic data demonstrated that the nanostructured GZ exhibited superior corrosion resistance properties under SM1 salt condition as compared to SM2 and SM3 conditions. SEM and EDS analysis were used to evaluate the nanostructured GZ coatings that were subjected to electrochemical corrosion. In the case of SM2 and SM3 conditions, the surfaces were degraded with microcracks. The formation of corrosion products and the exposure of succeeding layers as a result of corrosion were also characterized using FT-IR, Raman spectroscopy, XRD technique and 3D optical microscope.