Stainless Steel Substrates Research Articles

Preparation and mechanical properties of Al-doped TiC films

Abstract Al-doped TiAlxC films were prepared on different substrates (single crystal Al2O3 (0001), stainless steel, and silicon wafer substrates) by co-sputtering, and microstructures and corresponding mechanical properties of TiAlxC films were tested and analyzed. The results indicate that the microhardness of the prepared TiAlxC films would decrease with the increased doping amount of Al while the corresponding friction coefficient would increase. With the increase of Al doping, the excess Al hinders the growth of the nanocrystalline phase in the TiAlxC film, thereby affecting the hardness and wear resistance of the TiAlxC film. When the Al doping is 4.1 at%, the hardness of the film reaches 2, 890 HV, while the friction coefficient is 0.2, indicating that a small amount of Al plays a role in solution strengthening the film. Therefore, the mechanical properties of the Al-doped TiAlxC films could be tailored by the doping amount of Al.

Microstructures evolution and properties of titanium vacuum sintering on metal injection molding 316 stainless steel via dip coating process

Enhancing the surface coating of 316 L stainless steel, fabricated via metal injection molding, is crucial for its application in cost-effective, mass-produced components. This study investigated the titanium coating on 316 L stainless steel to address its limitations in mechanical performance. Titanium was coated on the 316 L stainless steel via a dip coating process, followed by vacuum sintering at temperatures of 1100 °C, 1150 °C, and 1200 °C. The optimal mechanical properties were achieved with a 100 μm thick coating sintered at 1200 °C, which exhibited uniformity and good bonding strength. The microstructure results demonstrated an average yield strength of 342.63 MPa and a polarization impedance of 968.48 Ω·cm2. Electron probe microanalysis confirmed the uniform diffusion of titanium into the stainless steel substrate, forming intermetallic phases such as Fe2Ti and NiTi. In addition, this study conducted a heat treatment process for the as-coated specimens. It was found that annealing at 750 °C for 4 h oil quenched and a 550 °C three-hour aging treatment the polarization impedance increases to 1243.3 Ω·cm2 without compromising the yield strength. These findings indicate that the titanizing process enhances the mechanical properties of 316 L stainless steel, making it more suitable for demanding applications.

(Invited) Development of Novel Coatings on Stainless Steel based Bipolar Plates for Proton Exchange Membrane (PEM) Water Electrolyzer Application

The stainless steel (SS) is an appropriate material for bipolar plate of PEM water electrolyzer owing to its high electron transport, superior mechanical characteristics, and formability, but it needs a coating to increase corrosion resistance. Herein, the multilayer coating of Au/Cr/Au on the SS was developed by electroplating method and corrosion studied were performed for bipolar plate application of PEM water electrolyzer. The gold striking underlayer on the SS substrate passivated the surface oxides and facilitated a dense electroplated chromium layer. Furthermore, a uniform gold protective layer was electroplated on the chromium coated substrate to achieve a promising anti-corrosive property. The Au/Cr/Au 316L SS substrate presented approximately ten times lower corrosion current density, and positive shift of corrosion potential as compared to uncoated SS substrate. The Au/Cr/Au/ 316 L SS was analysed for long time, and it depicted slower corrosion as compared to without striking underlayer of gold (Au/Cr/ 316L SS).

Enhanced electrochemical performance of ZrTe-Mn2O3 nanocomposite electrocatalyst for HER and OER in alkaline medium

Electrochemical energy conversion in renewable-energy technologies relies on the OER and HER towards next-generation fuels. Herein, we have coupled zirconia telluride (ZrTe) and manganese oxide (Mn2O3) nanosheets heterointerfaces by a facile hydrothermal method, which are engineered on stainless steel substrate (ZrTe-Mn2O3/SS). The physical properties, including crystallinity, phase purity, morphology, conductivity, and chemical interacted states of the developed composite, are systematically investigated by XRD, HRTEM, I-V, and XPS. The XPS observation showed unique redox properties of hydrogen peroxide species on the ZrTe-Mn2O3 catalyst and the oxidation state of Zr and Mn that was more easily changed in the ZrTe-Mn2O3 electrocatalyst compared with the pristine catalysts. The very decent electrochemical performance of the catalyst activation step (Mn3+→Mn4+ and Zr2+→Zr4+ oxidations) observed from electrochemical cyclic voltammetry (CV) and linear sweep voltammetry (LSV) studies that are tested in the alkaline environment. Concerning higher bifunctional activity for ZrTe-Mn2O3, the current density of 10 mA cm−2 is revealed only at a lower overpotential of 244 mV and Tafel slope of 48 mV/dec toward better OER. At the same time, composite material also exhibited a minimal overpotential of 61 mV toward HER to attain 100 mA/cm2. It was also found that introducing a connection of ZrTe with Mn2O3 improves the precise surface area and exposes more multi-active sites for easy transfer of electrons. In addition, it maintains excellent long-term stability for almost 110 hrs through chronoamperometry, which leads to no activity loss and further represents higher OER/HER activity in industrial applications. We conclusively demonstrate that the first-time reported research provides valuable insights attributed to the defective structure, porous nature, and covalently bridging between atomic-level heterogeneous interfaces, favouring rapid electron transfer process activation for continuously produced O2 and H2 gas bubbles.

Effect of ZrO2 Particles on the Microstructure and Ultrasonic Cavitation Properties of CoCrFeMnNi High-Entropy Alloy Composite Coatings

CoCrFeMnNi-XZrO2 (X is a mass percentage, X = 1, 3, 5, and 10) high-entropy alloy composite coatings were successfully prepared on 0Cr13Ni5Mo martensitic stainless steel substrates using laser cladding technology. The phase composition, microstructure, mechanical properties, and cavitation erosion behavior of the composite coatings under different contents of ZrO2 were studied. The mechanism of ZrO2 particle-reinforced cavitation corrosion resistance was studied using ABAQUS2023 finite element software. The results show that the phase structure of the composite coating organization is composed of FCC phase reinforced by ZrO2 phase. The addition of ZrO2 causes lattice distortion. The coatings have typical branch crystals and an equiaxed crystal microstructure. With the increase in ZrO2 content, the microhardness of the composite coatings gradually increases. When X = 10%, the coating’s microhardness reached 348 HV, which was 95.53% higher than the high-entropy alloys without ZrO2 added. Adding ZrO2 can prolong the incubation period of high-entropy alloys; the high-entropy alloy composite coating with 5 wt.% ZrO2 exhibited the best cavitation resistance, with a cumulative volume loss rate of only 15.74% of the substrate after 10 h of ultrasonic cavitation erosion. The simulation results indicate that ZrO2 can withstand higher stress and deformation in cavitation erosion, reduce the degree of substrate damage, and generate higher compressive stress on the coating surface to cope with cavitation erosion.

Mathematical modeling study to optimize the production of molybdenum and silica absorbing thin films

Reducing costs in renewable energy technologies, such as solar energy, can be achieved by optimizing manufacturing processes to enhance the performance of solar absorbers. This study investigates the optical characteristics of molybdenum (Mo) films deposited on AISI 304 stainless steel substrates, both with and without a silicon dioxide (SiO2) anti-reflective layer. The work involves optimizing film thickness and deposition conditions to improve solar absorption and minimize thermal emission. A mathematical model was developed to determine the optimal film thickness for achieving high optical selectivity, and this model was validated through experimental deposition and characterization. The results show that a 53 nm Mo film achieved a selectivity factor of 10.35, with an emissivity of 9.30 % and an absorptivity of 96.28 %. The addition of an 18 nm SiO2 layer further increased the spectral selectivity to 13.95, with an absorptivity of 98.00 % and an emissivity of 7.02 %. These findings confirm that the theoretical predictions align with the experimental data, validating effectiveness of the optimized deposition parameters in enhancing the performance of solar absorbers.

Use of carbon black powder for surface treatment of stainless steel substrates via a low-cost CO2 laser

Nowadays, AISI 304 stainless steel plays a crucial role in industry. However, stainless steel exhibits limited wear resistance as it is used in parts with relative motion. Laser treatment emerges as a promising approach to improve its superficial properties. Using a laser as a heat source presents unique properties for heating surfaces, as the first atomic layers of the material absorb the radiation from the laser beam. In this study, we used a low-cost 100 W CO2 laser with carbon black powder to treat the surface of AISI 304 steels. In addition, the reflectance of irradiation on steel is 90%. We used carbon black powder as a photo-absorbing material for radiation to overcome this obstacle. The characterization included field emission gun–scanning electron microscopy, energy dispersive x ray, microhardness, and pin-on reciprocation tribometer. The results showed a significant increase in surface hardness after laser treatment compared to the untreated substrate at a magnitude of 3.8 times. Elemental mapping analysis revealed carbon's presence on the substrate's surface. In addition to increasing surface hardness, we observed a decrease in the friction coefficient of the laser-treated samples compared to the reference substrate. Finally, it could be concluded that carbon black powder had a triple function; it acted as a photo-absorbent material, a carbon source to increase surface hardness, and a solid lubricant. These results show the predictions of using a low-cost CO2 laser with carbon black powder as an efficient, versatile, and fast alternative.

Metal-organic framework derived porous nanosheets-like Co3O4 electrodes on stainless steel with high-performance for supercapacitors

In this work, three-dimensional (3D) nanoporous MOF-derived Co3O4 was successfully prepared by a facile, easy, and rapid solvothermal method on a stainless steel substrate using 1, 4-BDC organic linker and a precursor. Additionally, the effects of the Co-precursor and organic linker on the structure, composition, and morphology of the prepared MOF-derived Co3O4 samples were investigated through an XRD study, which indicated that the MOF-derived Co3O4 thin films exhibited crystalline nature upon deposition on the stainless steel substrate. FE-SEM revealed a porous nanosheet-like morphology. EDAX analysis confirmed the formation of the MOF-derived Co3O4 structure, indicating the presence of cobalt, oxygen, and carbon elements. The oxidation states of the prepared MOF-derived Co3O4 thin films were determined by X-ray photoelectron spectroscopy. Furthermore, the electrochemical performance of the MOF-derived Co3O4 samples was evaluated in a three-electrode system using 1 M KOH electrolyte. Consequently, optimized MOF-derived Co3O4 exhibited excellent electrochemical performance attributed to these advantages. The C3 sample demonstrated an outstanding specific capacitance of 1210 F/g at a current density of 0.5 mA/cm², along with remarkable cyclic stability retention of 94.30 % after 4000 charging/discharging cycles. Additionally, the MOF-derived Co3O4 (C3) electrode showed an excellent energy density of 35.70 Wh/kg and a power density of 4.5 kW/kg. As a result, the unique hierarchical porous structure of MOF-derived Co3O4 also offers effective pathways and excellent electrochemical performance, making it a promising candidate for advanced electrode materials in high-performance supercapacitors.

Leveraging colloid and interface science for long-term marine performance of hybrid coatings: Effects of different nanoparticles on anticorrosion and antifouling properties

This study leveraged the unique colloidal and interfacial properties of synthesized SiO2, ZnO, and carbon (CN) nanoparticles as effective nanofillers to enhance the anti-corrosion and antifouling properties of PMMA coatings. By optimizing nanoparticle dispersion, stability, and functional performance within the polymer matrix, we achieved improved surface roughness, hydrophobicity, mechanical stability, and antimicrobial properties. Hybrid coatings containing 1.5 wt% of these nanoparticles were applied to stainless steel (SS) substrates and evaluated through water contact angle measurements, pull-off adhesion strength tests, antibacterial assays, and electrochemical impedance spectroscopy (EIS). The results demonstrate that the synergistic effects of SiO2, ZnO, and CN nanoparticles significantly enhance the coatings' anticorrosion and antifouling characteristics by increasing hydrophobicity, total impedance, and antibacterial activity via reactive oxygen species generated by ZnO and CN. Additionally, over two years, the coating’s long-term protection was assessed by submerging coupons at a 6-meter depth in the Bocana Chica reef barrier, a site with rapid biofouling colonization, making this test a demanding evaluation.

Facile synthesis of spherical-shaped CeC2–TiO2 nanocomposite electrocatalyst with boosted alkaline OER

Developing noble metal-free multifunctional electrocatalysts to catalyze water oxidation is vital for future renewable energy systems. Herein, through several defect modifications, the CeC2–TiO2 nanocomposite on the strength of enriched oxygen vacancies was successfully fabricated by facile hydrothermal method on SS (stainless steel) substrate, attributed to the conductive ability for fast electron transportation. A well-defined phase growth, vibrational bonding of metal atoms, morphological determination, and elemental composition for synthesized heterostructured electrocatalysts were revealed by XRD, FTIR, TEM, and EDX, respectively. XPS has complied to understand the moderate binding energies of CeC2–TiO2 for OER intermediates, which signifies the strong interactions between electronic states of Ce, C, Ti, and O atoms. With the plentiful catalytic active sites, the resultant CeC2–TiO2 entails low overpotentials of only 169 mV and 108.8 mV/dec Tafel slope to afford 10 mA cm−2 for OER in 1.0 M KOH are tested through cyclic and linear sweep voltammogram measurements, thereby exhibit promising activity in alkaline water electrolysis. EIS measurements revealed a decreased polarization resistance for the composite dominated by the small semicircle diameter, corresponding to the adsorption of intermediates. Finally, observed results strongly recommended that the CeC2–TiO2 catalyst exhibited superior OER performance due to excellent electrical chemical coupling between CeC2 and TiO2.

Comparative investigation on the microstructure and corrosion properties of surfacing cobalt alloys by various methods

This study applies three different welding methods, namely tungsten inert gas (TIG) welding, laser welding, and plasma arc welding, to perform cobalt alloy surfacing on austenitic stainless steel substrates, and compares their microstructure and corrosion properties. The results reveal that samples obtained through all three methods exhibit excellent metallurgical bonding between the austenitic stainless steel substrate and the cobalt alloy surfacing layer, with no observed defects such as cracks, pores, or inclusions. Among them, the cobalt alloy surfacing layer produced by laser welding shows a finer and more uniform microstructure, displaying a distinct growth direction along the surfacing direction away from the interface. Additionally, electrochemical polarization curve testing demonstrates that the corrosion resistance of the laser-welded surfacing layer surpasses that of TIG welding and plasma arc welding, exhibiting a lower corrosion rate. This study offers valuable insights into the selection of cobalt alloy surfacing welding methods on austenitic stainless steel substrates and the evaluation of the corrosion properties for the cobalt alloy surfacing layer, providing essential guidance for engineering practices in the power plant valves.

Patterned Ultraslippery Surfaces of Stainless Steel Prepared by Femtosecond Laser Ablation for Directional Manipulation of Liquid Droplets.

Slippery liquid-infused porous surfaces (SLIPS) have promising applications in chip laboratories, nanofriction power generation, and microfluidics due to their excellent properties such as good hydrophobicity and low adhesion. However, the self-driven stability of conventionally lubricated surfaces is not high, and the velocity of liquid droplets is difficult to regulate. This greatly limits the potential applications of SLIPS. A strategy is offered to prepare microporous structures of SLIPS directly on a stainless-steel substrate using femtosecond laser processing technology as the main means to realize exhibiting smoothness to liquids. At the same time, the principle of bionics is utilized, the porous structure of SLIPS is combined with the groove structure of rice leaves, or porous structures are combined with the wedge structure of shorebird beak to prepare the three-dimensional structure of SLIPS. Droplets exhibit significant individual anisotropy on three-dimensional (3D) SLIPS of leaf-like groove stripe structure in rice, enabling the precise control of droplet motion direction. When droplets are transported in wedge-shaped SLIPS with an asymmetric structure, the wedge edge can limit the direction of droplet motion while squeezing the droplet to generate Laplace pressure gradient, which achieves continuous self-driven transport of droplets. In addition, based on the above two processing strategies, an information transfer device is designed: the splicing of the self-driven transport surface with anisotropic topological channels enables the differential drive for liquid transport, which provides the conditions for the information transfer of the droplets. This strategy not only is simple and efficient but also provides new ideas for the effective development of multifunctional SLIPS as well as lab-on-a-chip and microfluidic domains.

Electrochemical measurements, structural and morphological studies of electrodeposited polypyrrole supercapacitor electrode

This study presented the electrochemical deposition of potassium nitrate-doped polypyrrole (Ppy:KNO3) on stainless steel (SS), graphite sheet (GRs), and carbon fiber (CF) substrates, Ppy:KNO3/SS, Ppy:KNO3/GRs, and Ppy:KNO3/CF supercapacitor electrodes. Structural, morphological, and molecular analyses were conducted using X-ray diffraction (XRD), scanning electronic microscope (SEM), and Fourier transform infrared spectroscopy (FTIR). SEM images exhibited distinct morphologies of Ppy:KNO3 films, varying with cycles, scan rates, and Ppy:KNO3 concentrations. Ppy:KNO3/CF film displayed a unique structure with minimal particle aggregation. Electrochemical performance was assessed through Cyclic voltammetry (CV), galvanostatic charge-discharge (GCD) measurements and electrochemical impedance spectroscopy (EIS). Notably, Ppy:KNO3/CF demonstrated a specific capacitance of 1020 F/g at 1 A/g. It exhibited 92 % capacitance retention after 1000 cycles, along with impressive power and energy densities of 310 W/kg and 71.2 Wh/kg, respectively. These results represented a significant progress in the development of high-performance, durable supercapacitors.

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

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

Laser scanning patterns induced surface properties variations of Ti-V-Hf-Zr non-evaporable getter film with 316L stainless steel substrates

The effects of laser treatment scanning patterns on the properties of Ti-V-Hf-Zr non-evaporable getter (NEG) film on 316L stainless steel (316L SS) substrates were analyzed. 316L SS substrates were laser-treated with different patterns, which resulted in spherical structure and protrusions on the surface of the substrates. Subsequently, Ti-V-Hf-Zr NEG films were deposited on ultrasonically cleaned laser-treated 316L SS by a direct current (DC) magnetron sputtering machine. Based on the XPS results of Ti-V-Hf-Zr, it has been revealed that the atomic proportions of film elements on the surface of samples #1-1∼#3–1 were about 2.2 (Ti):1.7 (Zr):0.9 (V):1.0 (Hf). In this paper, the Ar+-induced secondary electron yield (SEY) and surface resistivity of Ti-V-Hf-Zr NEG are discussed for the first time, and it has been observed that the laser treatment leads to an increase of the substrate surface roughness, which decreases the SEY and increases the surface resistivity.

Polymer-derived coatings with La2Zr2O7 and glass fillers: Preparation and characterisation

This study investigated the impact of La2Zr2O7 (LZ) and different types of glass on the performance of polymer-derived ceramic (PDC) coatings on AISI 441 stainless steel substrates. Four double-layer PDC-based glass-ceramic coatings containing LZ and different glass fillers were prepared by dip coating. The LZ powder was synthesised by solid-state reaction (SSR): powder morphology, crystal structure, and thermal stability were analysed. X-ray diffraction (XRD) detected a LZ pyrochlore phase after annealing at 1300 and 1400 °C with a trace of t-ZrO2. Four different glass compositions, namely BaO-Al2O3-SiO2 (BAS), BaO-Al2O3-La2O3-B2O3-SiO2 (BALBS), CaO-B2O3-SiO2 (CBS), and BaO-ZnO-MgO-B2O3-SiO2 (BZMBS), were also synthesised as fillers for PDC coatings. The glass transition and crystallisation temperatures of the glasses were determined using differential scanning calorimetry (DSC). The coating systems, consisting of a Durazane 2250 bond coat and a top coat (Durazane 1800 + LZ filler + different glass sealants), were prepared. After pyrolysis of the coatings at 900 °C, some of the glasses partially crystallised. Scanning electron microscopy (SEM) revealed that the layers containing BAS, BALBS and CBS glass were dense, with good adhesion to the substrate, and with occasional presence of larger pores and cracks. Delamination of the upper layer was observed in the coating with the BZMBS glass filler.

Oxidized textured stainless steel surface with passivation layer as a high temperature selective solar absorber

A nanocrystalline textured stainless steel (SS) surface passivated with an AlCr oxide layer is proposed for use as a high temperature solar selective absorbers (SSAs). The textured SS surface was prepared by oxidizing in air at 800 °C for 30 min. The heating resulted in outward diffusion of the SS substrate Mn atoms, their oxidation on the surface, and formation of octahedral Mn3O4 nanocrystals, which play a role of textured surface. The passivation AlCr oxide single layer was deposited on the textured surface using reactive RF magnetron sputtering to protect the SS from further oxidation. The solar absorptivity αs and thermal emissivity ε298K of the as-deposited SSAs were 0.84 and 0.165, respectively. In order to study high temperature stability, SSAs were heat treated under air conditions at 600–900 °C for 0.1–300 h. SSAs demonstrated thermal stability at 600 °C for at least 300 h and degradation of optical properties with performance criterion PC < 0.05 at 700, 800, and 900 °C for 300 h, 30 h, and 1 h, respectively. The increase in thickness of the surface Cr2O3 layer on SS substrate was identified as the main degradation mechanism of SSA optical performance. SSAs demonstrated a high activation energy of 330 ± 30 kJ/mol. The obtained data can be used to design high temperature SSAs for concentrating solar energy systems operating under vacuum or air conditions at 500 °C.

Hydrothermally synthesized copper telluride nanoparticles: First approach to flexible solid-state symmetric supercapacitor

Supercapacitors, with their high-power density, rapid charge–discharge rates, and long cycle life, have emerged as promising energy storage devices for numerous applications. Among the various materials explored for supercapacitor electrodes, copper-based chalcogenides have gathered significant attention due to their intriguing electrochemical properties and simple synthesis routes. While there have been thorough investigations in other fields, only a limited number of studies have focused on the specific application of copper telluride nanoparticles as supercapacitors. In this study, we present a novel approach utilizing hydrothermally synthesized copper telluride (Cu2-xTe) nanoparticles as binder-free electrodes on flexible stainless steel (SS) substrates. The Cu2-xTe nanoparticles, with their small particle (38 nm) and highly crystalline structure, enhance charge storage and promotes a pseudocapacitive behavior, resulting in a high specific capacitance [381 F/g (163 mF/cm2) at 2 mV/s] in a 2 M KCl electrolyte solution. Moreover, we studied and explained the distinct contributions of surface-controlled and diffusion-limited processes to the overall charge storage capacity of the electrode. Our pioneering effort includes the fabrication and analysis of flexible, symmetric solid-state supercapacitor devices utilizing Cu2-xTe electrodes with PVA-LiClO4 gel electrolyte. These devices demonstrate an energy density of 11 Wh/kg, a power density of 800 W/kg, and an impressive 85 % retention of cyclic stability after 5000 cycles.

Mixed phase iron oxides thin layers by atmospheric-pressure chemical vapor deposition method

This paper provides a simple method for producing a metal oxide thin layer methodology by atmospheric pressure chemical vapor deposition (APCVD) synthesis over stainless steel substrates. This methodology enables the formation of thin iron oxide layers at its performance at various temperatures of 330 °C, 430 °C, and 530 °C. The deposition arises from thermal decomposition of the iron organometallic precursor Fe3(CO)12, forming a thin layer of iron oxide is, by the ozone present in the reaction chamber promoting the deposition of the iron oxide particles over the substrate. The Raman characterization suggest that at 330 °C, a mixture of hematite and magnetite is predominant on the as deposited substrates, also hematite modes show to be more pronounced as the band at 300 cm-1 narrows. Conversely, magnetite is prominent at higher synthesis temperatures, exhibiting a more intense Eg5 mode at 680 cm-1. The particles exhibit a uniform morphology, with both metal oxide phases coexisting. The average diameter of the particles is 50 nanometers as scanning electronic microscopy shows in a transversal sample section.•The formation of particles is attributed to the combination of iron ions +2 and +3 in the deposition process and their interaction with oxygen in the given synthesis parameters at atmospheric pressure chemical vapor deposition (APCVD).

Microstructure evolution and tribological properties over a wide temperature range of Ni-based composite coatings with Ti3AlC2 addition

Ni60A alloy powders doped with varying concentrations (0, 10 wt% and 20 wt%) of Ti3AlC2 MAX phase were coated on S31008 NiCr stainless steel substrate using atmosphere plasma spraying technique in this work. Comparative investigation was conducted to examine the effects of Ti3AlC2 additions on the microstructure evolution, microhardness, and wide temperature range (room temperature to 800 oC) tribological performance of the composite coatings. The findings demonstrated that the composite coatings were composed of γ-Ni, intermetallic hard metal borides, Ti3AlC2 and TiC phases, without any noticeable oxide phases. The 20 wt% Ti3AlC2 additions to the Ni60A alloy coating exhibited minimum imperfections in microstructure with a porosity drop of 65.8 %, and the highest microhardness which was enhanced by 64 % to 924 HV0.515. After introducing of Ti3AlC2, the coefficient of friction decreased and appeared to distinguish itself by remaining minimal and stable at low-medium temperatures compared with an increase of more than 70 % at high temperatures. Ni60A-10 wt% Ti3AlC2 coating resulted in the lowest friction coefficient of approximately 0.45 from room temperature to 400 oC and it peaked to 0.78 at 800 oC, reducing by 19.6 % and 6 % compared to non-composite coating, respectively. The wear resistance of the composite coating was considerably improved with the increment of Ti3AlC2, and the coating with 20 wt% Ti3AlC2 showed the most significant reduction in wear rate: 18.5 % at room temperature, 45.2 % at 200 oC, 37.2 % at 400 oC, 60 % at 600 oC, 90.8 % at 800 oC. The lubricate layered Ti3AlC2 phases and the tribo-oxide film predominate composed of derivative NiO, Cr2O3 Al2O3 and TiO2 played a critical role in antifriction and wear resistance. The wear mechanisms were accordingly conducted as abrasion and adhesion wear at low-medium temperature and transferred into tribo-oxidation wear at elevated temperature.