Oxidation Resistance Of Coatings Research Articles

Effects of doping with Zr and Hf on the structure and properties of Mo-Si-B coatings obtained by magnetron sputtering of composite targets

The Mo-Si-B, Mo-Zr-Si-B, and Mo-Hf-Si-B coatings were deposited by magnetron sputtering of the MoSi2-MoB, MoSi2-MoB-ZrB2 and MoSi2-MoB-HfB2 targets. The composition and structure of coatings were investigated by glow discharge optical emission spectroscopy, scanning electron microscopy, X-ray diffraction, transmission electron microscopy, X-ray photoelectron and Raman spectroscopy. Mechanical properties were measured by nanoindentation method. The short-time oxidation resistance of coatings was evaluated at temperatures of 1100, 1300, and 1500 °C. The results showed that all coatings deposited onto alumina substrates were characterized by a dense columnar structure. Mo-Si-B coatings contained phases of hexagonal h-MoSi2 and amorphous a-MoB. With the addition of Zr and Hf, an increase in the lattice parameter and a decrease in the grain size of h-MoSi2 by 50 and 25%, respectively, were observed. The base Mo-Si-B coating had a high hardness of 30 GPa. The introduction of Zr and Hf led to a decrease in hardness by 24 and 20%, respectively. The Mo-Si-B coating was characterized by a minimal oxidation depth (<10 nm) at 1100 °C and 1300 °C, but a network of cracks that penetrated to the substrate was formed. Cracks on the surface of the Mo-Zr-Si-B and Mo-Hf-Si-B coatings were not observed; the formation of oxide layers, 0.3–2.0 μm thick, was revealed. The oxidation resistance of coatings at temperature of 1500 °C increased in direction Mo-Si-B → Mo-Hf-Si-B → Mo-Zr-Si-B. The best results for the Mo-Zr-Si-B coating were associated with a smaller grain size, higher thermal stability, and the formation of a protective layer based on SiO2 with the inclusion of ZrO2 crystallites.

The Role of Stress–Strain State of Gas Turbine Engine Metal Parts in Predicting Their Safe Life

The influence of various factors on the workability of critical metallic parts of a gas turbine engine (GTE) is analysed and systematized. As shown, compressor blades fail as a result of foreign-objects’ damage, gas corrosion, and erosion. Compressor blade roots in most cases fail due to fretting wear caused by vibrations, while the fir-tree rim of turbine discs fails due to low-cycle fatigue (LCF) damage and creep. An increase in the radial gaps between the rotor and stator of the turbine reduces the thrust force and causes changes in the gas-dynamic loading of the engine components. Additional oxidation of metal parts is observed under the action of hot gases from the combustion chamber. The principles of material selection for manufacturing turbine blades and disks, concepts of alloying heat-resistant alloys, and modern methods of surface engineering due to applying protective oxidation-resistant coatings, in particular, chemical vapour deposition (CDV), physical vapour deposition (PVD), air plasma spraying (APS), etc., are also described. To predict the lifetime of turbine disks, it is proposed to use the modified Walker model and Miner’s rule. To specify the time before the failure of the metal blades of the turbine, it is proposed to use the finite element method. To monitor the working-surfaces’ deformations of the gas turbine engine, it is recommended to use optical-digital methods.

Recycling MoSi2 heating elements for preparing oxidation resistant multilayered coatings

Spent MoSi2 heating elements were used to fabricate MoSi2, ZrB2/MoSi2 and MoSi2-ZrB2/MoSi2 oxidation resistant coatings via a two-step process of slurry painting and spark plasma sintering. Cracks appeared in simple MoSi2 and ZrB2/MoSi2 coatings, whilst MoSi2-ZrB2/MoSi2 coating was crack-free as CTE mismatch was reduced. Mo5Si3 and MoB diffusion layers formed under MoSi2-ZrB2 transition layer in MoSi2-ZrB2/MoSi2 coating, revealing good metallurgical combination between the substrate and coating. On one side the silica layers covering MoSi2 and ZrB2/MoSi2 coatings displayed diffused cracks after oxidation at 1773 K for 100 h, on the other side it was dense and continuous for MoSi2-ZrB2/MoSi2 coating, showing low oxidation rate constant at 1773 K. Furthermore, MoSi2-ZrB2 transition layer in MoSi2-ZrB2/MoSi2 coating possessed good short-term oxidation protective properties at 1873 and 1973 K since the formation of ZrSiO4 improved the stability of Si-O-Zr composite oxide scale and diminished the oxygen permeability, therefore demonstrating good high-temperature oxidation resistance.

The Effect of High-Temperature Water Vapour on Degradation and Failure of Hot Section Components of Gas Turbine Engines

For the past decade, the aviation industry has been adopting sustainable aviation fuels (SAF) for use in aircraft to reduce the impact of aviation on climate change. Also, some nations look to SAF as an option for energy security for their military fleets. Understanding the critical impact of alternative fuel sources on hardware will provide the gas turbine industry with strategic options in sustainability and maintainability of the existing and new fleets. The alternative fuels with high hydrogen/carbon ratio (H/C) (such as synthetic paraffinic kerosenes (SPK)) could produce more water vapour content than the conventional jet fuels upon combustion, and this increased water vapour level could exert a significant impact over the long-term durability on hot section components such as the substrate blades, oxidation resistant coatings, thermal barrier coatings (TBCs), environmental barrier coatings (EBCs), resulting in an accelerated degradation of the turbine components. The possible detrimental effect of high-temperature water vapour on degradation and lifespan of hot section components was examined. Examples were specifically given on degradation and spallation of thermally grown oxides (TGO), formation of non-protective oxides and ceramics topcoats in TBCs. Results show that water vapour can lead to volatilization of TGO (Al2O3), and is responsible for the formation of non-protective oxides in both Pt-modified β-NiAl and MCrAlY coatings, leading to their early spallation. However, water vapour does not appear to directly affect the ceramic topcoat of the TBC. For EBCs coated on SiC-based substrates, the substrate recession via silica (TGO) volatilization was reviewed. These EBCs were observed undergoing degradation in highly hostile environments, e.g., constantly operating under high temperatures, pressures, and velocities condition in the presence of water vapour steam. The review intends to provide a perspective of high-temperature water vapour effect on the EBCs’ topcoat properties such as durability, degradation, crack nucleation and crack growth, and possible guidance for mitigating these degradation effects.

Effect of Spray Distance on the Microstructure and High Temperature Oxidation Resistance of Plasma Spray-Physical Vapor Deposition 7YSZ Thermal Barrier Coating

In order to study the effect of spray distance on the structure and high temperature oxidation resistance of feather-columnar thermal barrier coatings, the feather-columnar ZrO2-7wt. % Y2O3 (7YSZ) thermal barrier coatings were prepared at spray distances of 650 mm, 950 mm, 1100 mm, 1250 mm, and 1400 mm by plasma spray-physical vapor deposition (PS-PVD) technology. The surface roughness, micro morphology, and porosity of the sprayed 7YSZ coating were analyzed by 3D surface profiler, SEM, XRD, etc., and the impedance spectrum characteristics of the 7YSZ coating were characterized by electrochemical alternating current (AC) impedance technology. In addition, the high temperature oxidation resistance test of 7YSZ coating under different spray distances was carried out at a temperature of 1000 °C to study the influence of spray distance on the high temperature oxidation resistance of 7YSZ coating. The research results show that the surface roughness and porosity of feather-columnar 7YSZ coating increased sequentially with the increase of spray distance. At the same time, The YSZ grain boundary resistance value increased exponentially as the porosity of the coating increases. Where the spray distance was in the range of 650 mm and 1250 mm, the high temperature oxidation rate constant of the coating increased with the spray distance. However, the spray distance was greater than 1250 mm, and the spray distance had no significant effect on the high temperature oxidation resistance of the coating.

Controlled Lay-By-Layer Etching of CVD Grown Multilayer h-BN Single Crystal

Being a 2D insulator with alternating sp2 hybridized B and N atoms in a honeycomb structure, Hexagonal Boron Nitride(hBN) not only have uniqure properties like high transparency, large thermal conductivity, high mechanical strength and superior chemical inertness by itself, but also be able to promote other 2D materials’ performance when serving as the ultra-smooth dielectrilayer.[1,2] Since CVD process is established as the most effective way to grow large area hBN materials, it is critical to understand and control the growth process so as to making them ready for the large scale industrial applications. Etching of 2D materials should provide a scalable route for fabrication of highly desired various nanostructures such as nanoribbons with controlled termination providing a simple and direct way for 2D material property design, such as controlling the band gap and optical properties. [3,4] However, it is often easy to initiate the etching, but difficulty the control the location, shape, and size of the etching pattern. Previously reported etching patterns for 2D materials can be generally divided into four different categories: domain, boundary, fractal, and adlayer etching. [3-6] These etching patterns may co-exist in the etching process, but the dominant pattern depends on competition between various factors such as atmosphere, temperature, substrate, time etc. Layer number increase can often be achieved by increase the reaction temperature, time, and precursor concentration.While the layer number reducing after the multilayer hBN growth process remain challenging. Here we use the as-grow multilayer hBN single crystal from CVD process for controllable etching experiment, then both temperature related hydrogen etching and electronic energy related e-beam etching will be used to remove single layer of as-grown multilayer hBN. References Lu, G.; Wu, T; Yuan, Q.; Wang, H.; Wang, H.; Feng Ding, F.; Xie, X.; Jiang, M. Synthesis of large single-crystal hexagonal boron nitride grains on Cu–Ni alloy. Nat. Commun. 2014, 6, 6160.Liu, Z.; Gong, Y.; Zhou, W.; Ma, L.; Yu, J.; Idrobo, J. C.; Jung, J.; MacDonald, A.H.; Vajtai, R.; Lou, J.; Ajayan, P.M. Ultrathin high-temperature oxidation-resistant coatings of hexagonal boron nitride. Nat. Commun. 2013, 4, 2541.Vlassiouk, I.; Regmi, M.; Fulvio, P.; Dai, S.; Datskos, P.; Eres, G.; Smirnov, S. Role of hydrogen in chemical vapor deposition growth of large single-crystal graphene. ACS nano 2011, 5, 6069-6076.Wang, L.; Wu, B.; Jiang, L.; Chen, J.; Li, Y.; Guo, W.; Hu, P.; Liu, Y. Growth and Etching of Monolayer Hexagonal Boron Nitride. Adv. Mater. 2015, 27, 4858–4864.Rong, Y.; He, K.; Pacios, M.; Robertson, A. W.; Bhaskaran, H.; Warner, J. H. Controlled Preferential Oxidation of Grain Boundaries in Monolayer Tungsten Disulfide for Direct Optical Imaging. ACS Nano, 2015, 9, 3695–3703.Stehle, Y.; Sang, X.; Unocic, R.; Voylov, D.; Jackson, R.; Smirnov, S.; Vlassiouk, I., Anisotropic etching of hexagonal boron nitride and graphene: question of edge terminations Nano letters, 2017, 17 (12), 7306-7314

Improved oxidation resistance of γ-TiAl intermetallics by sputtered Ni+CrAlYHfSiN composite coating

NiCrAlYHfSi coating and Ni+CrAlYHfSiN coating were deposited on γ-TiAl alloy by magnetron sputtering. This work mainly focuses on the influence of cracks on the oxidation resistance of coatings, and the suppression cracking effect by doping nitrides. It was found that longitudinal cracks in the NiCrAlYHfSi coating increase with oxidation time prolonged. Cracks in NiCrAlYHfSi coating provide quick-diffusion channels for Ti and O ions. The Ni+CrAlYHfSiN coating is intact crack free during the whole oxidation process. Owing to the “fix effect” of nitrides, the Ni+CrAlYHfSiN composite coating effectively inhibits Ti diffusing to the surface to destroy the integrity of Al2O3 scale.

Control of the preferential orientation Cr coatings deposited on zircaloy substrates and study of their oxidation behavior

Cr coatings deposited on zircaloy substrates generally exhibit (110) and (200) preferred orientations, which in turn affects the microstructure and oxidation performance of coatings. In this study, the preferential orientation of Cr coatings has been regulated in order to enhance the oxidation resistance of Cr coatings. For the pristine coatings, the deposition rate and surface morphologies depend strongly on the bias voltage and Ar pressure. While the evolutions of the texture coefficients are affected significantly by temperature, bias voltage and Ar pressure, especially for the (110) texture. The oxidation resistance of coatings with different texture has been investigated according to the energy-dispersive X-ray spectrometry. After oxidized in steam at 800 ℃ for 1 h, a transition layer and dispersed particles with higher oxygen content have been discovered. In addition, coatings deposited at pressure higher than 1.0 Pa exhibit through-film cracks and the zirconium substrates have been partially oxidized.

On the Characteristics of Cold Spray Technology and Its Application in Aerospace Industries

Cold spraying technology is an advanced spraying technology developed based on the principles of aerodynamics. It is mainly used to deposit and repair the surface of metal alloy parts to ensure that the parts have better mechanical properties and service life. Compared with traditional thermal spraying technology, cold spraying technology has many advantages, such as low spraying temperature, low oxygen content and low porosity, and it is not easy to cause oxidation, burning, phase change and other phenomena during spraying. This article reviews the principles, technical parameters, and characteristics of cold spray technology, focusing on the effects of powder particle size and shape, particle and substrate temperature, critical speed, spray gun, collision angle, and spray distance on coating quality and deposition efficiency. In addition, the current research and application status of cold spray technology in the preparation of anti-corrosion coatings, high temperature resistant coatings, high temperature oxidation and wear resistant coatings are discussed, and the development prospects of cold spray technology are prospected.

Phase formation and structural evolution of multicomponent (CrFeCo)1-yNy films

The Cantor alloy (CoCrFeMnNi) and its variants, in bulk as well as thin films, have been extensively studied. They are known to exhibit cubic crystal structures and thermodynamic stability regardless of their complex chemical composition. Therefore, they may find use as hard, wear-resistant, corrosion and oxidation-resistant coatings. The addition of light elements, such as nitrogen, is known to help improve these properties further through processes such as amorphization and nitride compound formation. Here, we investigate the ternary CrFeCo system to study the effects of nitrogen addition. (CrFeCo) 1-y N y multicomponent thin films are grown on silicon substrates by DC magnetron sputtering. Changes in crystal structure, morphology, mechanical and electrical properties with gradual increases of nitrogen in the film are described and discussed. Increased addition of nitrogen from 14 at.% to 28 at.% in the film leads to a transformation from an fcc to a bcc crystal structure, affects both the mechanical and electrical properties. XPS analysis shows the tendency of nitrogen to bond with Cr over other metals. The films display hardness values between 7 and 11 GPa with resistivities values ranging between 28 and 165 μΩ cm. • Multicomponent (CrFeCo)Ny coatings deposited by reactive magnetron sputtering • Effect of nitrogen content on structure, morphology and composition was studied. • Phase formation and evolution with changes in nitrogen content • Mechanical and electrical properties of (CrFeCo)Ny thin films

Influence of Growth Defects on the Oxidation Resistance of Sputter-Deposited TiAlN Hard Coatings

This paper reports the results of an investigation of the oxidation of a sputter-deposited TiAlN hard coating in air at temperatures of 800 and 850 °C for times ranging from 15 min to 2 h. The study is focused on the role of growth defects in the oxidation process. The mechanism of oxidation at the site of the defect was studied on cross-sections made by the consecutive sectioning of oxidized coatings with the FIB technique. We found that in the early stage of oxidation, the locally intense oxidation always starts at such defects. Although the growth defects reduce the oxidation resistance of the coating locally, we believe that they do not have a decisive influence on the global oxidation resistance of the coating. There are several reasons for this. The first is that the surface area covered by growth defects is relatively low (less than 1%). Secondly, the coating is permeable only at those defects that extend through the entire coating thickness. Thirdly, the permeability at the rim of some defects strongly depends on the density of pores at the rim of defects and how open they are. The size and density of such pores depend on the shape and size of topographical irregularities on the substrate surface (e.g., seeds, pits), which are responsible for the formation of growth defects. We also found that oxidation of the TiAlN coating is accelerated by oxygen and titanium diffusion through the pores formed by crystal grain growth in the outer alumina overlayer. Such pores are formed due to the compressive stresses in the Ti-rich oxide layer, which are caused by the large difference in molar volumes between the oxide and nitride phases.

Effect of Vacuum Heat Treatment on the High-Temperature Oxidation Resistance of NiCrAlY Coating

NiCrAlY coatings were prepared using high-velocity oxygen fuel spraying (HVOF), and the coatings were removed from the substrate to achieve a uniform shape. Vacuum heat treatment (VHT) of the as-sprayed coatings was conducted at different temperatures (1000, 1100, and 1200 °C), and the specimens were subjected to isothermal oxidation exposure testing in air at 1100 °C for up to 21 h. The results show that the high temperature oxidation resistance of the coating increased gradually with the increase in VHT temperature, and the coating of VHT1200 had higher oxidation resistance. The high temperature oxidation resistance of the coating was related to the microstructure transformation of the coating. In VHT coatings, β-NiAl became a dispersed irregular block morphology. The γ’-Ni3Al in VHT1000 presented a granular morphology. However, in VHT1100 and VHT1200, γ’-Ni3Al became a lamellar morphology. This transformation of microstructure promotes the form of exclusive α-Al2O3 scale. With the increase in VHT temperature, the content of yttrium on coatings’ surface was increased and the pores were gradually eliminated. The concentration of yttrium on coatings’ surface prevented the formation of θ-Al2O3 and low porosity was beneficial in improving the internal oxidation of the coating.

Structure, Oxidation Resistance, Mechanical, and Tribological Properties of N- and C-Doped Ta-Zr-Si-B Hard Protective Coatings Obtained by Reactive D.C. Magnetron Sputtering of TaZrSiB Ceramic Cathode

Coatings in the Ta-Zr-Si-B-C-N system were produced by magnetron sputtering of a TaSi2-Ta3B4-(Ta,Zr)B2 ceramic target in the Ar medium and Ar-N2 and Ar-C2H4 gas mixtures. The structure and composition of coatings were studied using scanning electron microscopy, glow discharge optical emission spectroscopy, energy-dispersion spectroscopy, and X-ray diffraction. Mechanical and tribological properties of coatings were determined using nanoindentation and pin-on-disk tests using 100Cr6 and Al2O3 balls. The oxidation resistance of coatings was evaluated by microscopy and X-ray diffraction after annealing in air at temperatures up to 1200 °C. The reactively-deposited coatings containing from 30% to 40% nitrogen or carbon have the highest hardness up to 29 GPa and elastic recovery up to 78%. Additionally, coatings with a high carbon content demonstrated a low coefficient of friction of 0.2 and no visible signs of wear when tested against 100Cr6 ball. All coatings except for the non-reactive ones can resist oxidation up to a temperature of 1200 °C thanks to the formation of a protective film based on Ta2O5 and SiO2 on their surface. Coatings deposited in Ar-N2 and Ar-C2H4 demonstrated superior resistance to thermal cycling in conditions 20-T−20 °C (where T = 200–1000 °C). The present article compares the structure and properties of reactive and “standard-inert atmosphere” deposited coatings to develop recommendations for optimizing the composition.

Self-healing ceramic coatings that operate in extreme environments: A review

This paper provides an overview of the latest research developments in the design and exploration of ceramic coatings with high temperature adaptive behavior. The adaptive behavior, triggered by thermal or thermomechanical stimulus, may be used to create smart surfaces that are able to change their chemistry and structure to achieve the desired functionality. The initial focus of the paper will be to provide an overview on the basics of self-repairing materials. This will be followed by a brief outline of the work that has been reported on self-healing/adaptive mechanisms in bulk ceramics. We will then focus on providing a thorough review on self-healing ceramics with a focus on adaptation/healing in tribology as well as thermal barrier, anticorrosion, and oxidation resistant coatings. Advantages and disadvantages of using hybrid polymer-ceramic coatings will also be discussed toward the end of the article. This overview will provide a fundamental understanding of the changes in the structural and chemical properties of these materials and how that correlates to their performance. This review also includes a discussion on anticipated future developments in this important and upcoming area of research.

Mechanical properties and oxidation resistance of coatings in the Ta-Zr-Si-B-C-N system obtained by magnetron sputtering of a TaZrSiB target in an Ar, N&lt;sub&gt;2&lt;/sub&gt;, and C&lt;sub&gt;2&lt;/sub&gt;H&lt;sub&gt;4&lt;/sub&gt; atmosphere

The method of magnetron sputtering in an argon, nitrogen, and ethylene atmosphere was used to obtain Ta-Zr-Si-B-C-N coatings. The coating structure was studied using scanning electron microscopy, energy dispersive and X-ray phase analysis. Mechanical properties of the coatings were determined using the nanoindentation method. Tribological tests were conducted using a Tribometer automated friction machine at a load of 1 N. Wear tracks were examined on an optical profilometer. The coating oxidation resistance was studied at a temperature of 1000 °C. It was found that coatings deposited in an argon atmosphere feature the highest hardness (30 GPa) and elastic recovery (79%). In addition, they can resist to oxidation up to 1000 °C inclusive due to a protective film consisting of silicon and tantalum oxides formed on their surfaces. Reactive coatings deposited in N 2 were inferior to non-reactive coatings in terms of oxidation resistance as they completely oxidized already at 1000 °C. However, they had a low coefficient of friction that was below 0.15.

Synthesis of all equiatomic five-transition metals High Entropy Carbides of the IVB (Ti, Zr, Hf) and VB (V, Nb, Ta) groups by a low temperature route

The six possible equiatomic five-transition metal High Entropy Carbides (HECs) of the IVB (Ti, Zr, Hf) and VB (V, Nb, Ta) groups of the periodic table, i.e., TiZrHfVNbC5, TiZrHfVTaC5, TiZrHfNbTaC5, TiZrVNbTaC5, TiHfVNbTaC5 and ZrHfVNbTaC5, were successfully obtained via a powder metallurgy route at room temperature, specifically, by one-step diffusion mechanosynthesis starting from the elemental constituents (using graphite as the carbon source). Three of those HECs, TiZrHfVTaC5, TiZrVNbTaC5 and ZrHfVNbTaC5, were developed for the first time. Their development was possible without any subsequent thermal treatment, in contrast to the usual way (reactive sintering at 1800–2200 °C), and in a powder form, make them potential advanced raw ceramics for hard, refractory and oxidation resistance coatings or matrix phase composites.

Evolution behavior of rare-earth yttria modified silicide oxidation-resistant coating at 1700 oC

Yttria-modified silicide (MoSi2-Y2O3) oxidation-resistant coatings with multiple Y2O3 contents were prepared using supersonic atmospheric plasma spraying, and the oxidation resistance was investigated at 1700 °C with static atmosphere. Experimental results indicated that the sprayed MoSi2-Y2O3 coating possessed good compactness, which adhered well to the SiC transition layer. Meanwhile, the Y2O3 addition greatly enhanced the bonding strength of the coating, and extended its service life at 1700 °C. Wherein the MoSi2-20 wt.%Y2O3 coating exhibited the highest adhesive strength and best oxidation resistance with the lowest mass loss among all the coatings. In practice, the Y2O3 changed the microstructures of formed oxide glass scale during oxidation, and then modified the oxidation resistance of the coating. The action mechanism of Y2O3 on the oxidation behavior of MoSi2-Y2O3 coating was analyzed.

The research on oxidation resistance ability and mechanical properties of carbon fiber reinforced phenolic resin composites

Carbon fiber reinforced composite (CFRP) has been widely used in a lot of areas with its distinguished properties, especially mechanical properties. However, both carbon fibers and polymer substrate cannot resist high air temperature environment, limiting the application of CFRP, such as in the aerospace fields. The paper proposes two kinds of carbon fiber with oxidation resistance coatings, which are used as reinforced components to make phenolic resin substrate composites. Weight difference method, mechanical test machine and scanning electron microscope are used to characterize the antioxidation ability, mechanical properties, and surface morphology of composites. The results show that SiC/SiO2 coated carbon fibers and SiC–ZrO2–MoSi2/Ni coated carbon fibers can increase the anti-oxidation ability without decreasing the mechanical properties of composites. The failure temperature is around 1200 °C and 1600 °C respectively.

Preparation of Cyclic Oxidation Resistant Coating Consisting of Ni Aluminide and Ni-Hf Alloy Layers on Ni-Cr-Al Alloy by Electrodeposition

Preparation of Cyclic Oxidation Resistant Coating Consisting of Ni Aluminide and Ni-Hf Alloy Layers on Ni-Cr-Al Alloy by Electrodeposition

Review of Growth Defects in Thin Films Prepared by PVD Techniques

The paper summarizes current knowledge of growth defects in physical vapor deposition (PVD) coatings. A detailed historical overview is followed by a description of the types and evolution of growth defects. Growth defects are microscopic imperfections in the coating microstructure. They are most commonly formed by overgrowing of the topographical imperfections (pits, asperities) on the substrate surface or the foreign particles of different origins (dust, debris, flakes). Such foreign particles are not only those that remain on the substrate surface after wet cleaning procedure, but also the ones that are generated during ion etching and deposition processes. Although the origin of seed particles from external pretreatment of substrate is similar to all PVD coatings, the influence of ion etching and deposition techniques is rather different. Therefore, special emphasis is given on the description of the processes that take place during ion etching of substrates and the deposition of coating. The effect of growth defects on the functional properties of PVD coatings is described in the last section. How defects affect the quality of optical coatings, thin layers for semiconductor devices, as well as wear, corrosion, and oxidation resistant coatings is explained. The effect of growth defects on the permeation and wettability of the coatings is also shortly described.