Pub Date : 2025-12-31DOI: 10.1016/j.surfcoat.2025.133146
Yu-Lin Lee , Chih-Ching Tseng , Ren-Jei Chung , Ching-Yu Lin , Yu-Jui Fan , Po-Chun Chen
In this study, we developed a glucose sensor based on a nanoflower platinum (nfP) film prepared via electrodeposition. The nfP film exhibited excellent electrochemical performance, achieving a high glucose detection sensitivity of 81.9 μA cm−2 mM−1 and demonstrating strong selectivity in phosphate-buffered saline (PBS) electrolyte. Beyond glucose sensing, the nfP film enabled electrochemical monitoring of glucose consumption as an indirect means of detecting cell activity. Chronoamperometry was employed to quantify the concentrations of Escherichia coli (E. coli) and MCF-7 cancer cells by measuring glucose depletion in the solution. The presence of E. coli resulted in a decrease in glucose concentration, which was captured through reductions in the chronoamperometric current. As the E. coli concentration increased from 104 to 106 CFU/mL, the corresponding charge measured at the electrode decreased linearly, with a strong correlation (R2 = 0.999) described by the regression equation y = 755.5x – 2420.5. Similarly, MCF-7 cells exhibited a linear correlation (R2 = 0.943) within the range of 103 to 105 CFU/mL. Overall, this work presents a simple and effective electrochemical strategy for glucose detection and cell monitoring, demonstrating promising potential for practical biosensing applications involving both bacterial and cancer cell analysis.
{"title":"Electrodeposited nanoflower platinum films for high-sensitivity glucose sensing and cellular activity monitoring","authors":"Yu-Lin Lee , Chih-Ching Tseng , Ren-Jei Chung , Ching-Yu Lin , Yu-Jui Fan , Po-Chun Chen","doi":"10.1016/j.surfcoat.2025.133146","DOIUrl":"10.1016/j.surfcoat.2025.133146","url":null,"abstract":"<div><div>In this study, we developed a glucose sensor based on a nanoflower platinum (nfP) film prepared via electrodeposition. The nfP film exhibited excellent electrochemical performance, achieving a high glucose detection sensitivity of 81.9 μA cm<sup>−2</sup> mM<sup>−1</sup> and demonstrating strong selectivity in phosphate-buffered saline (PBS) electrolyte. Beyond glucose sensing, the nfP film enabled electrochemical monitoring of glucose consumption as an indirect means of detecting cell activity. Chronoamperometry was employed to quantify the concentrations of <em>Escherichia coli</em> (<em>E. coli</em>) and MCF-7 cancer cells by measuring glucose depletion in the solution. The presence of <em>E. coli</em> resulted in a decrease in glucose concentration, which was captured through reductions in the chronoamperometric current. As the <em>E. coli</em> concentration increased from 10<sup>4</sup> to 10<sup>6</sup> CFU/mL, the corresponding charge measured at the electrode decreased linearly, with a strong correlation (R<sup>2</sup> = 0.999) described by the regression equation y = 755.5x – 2420.5. Similarly, MCF-7 cells exhibited a linear correlation (R<sup>2</sup> = 0.943) within the range of 10<sup>3</sup> to 10<sup>5</sup> CFU/mL. Overall, this work presents a simple and effective electrochemical strategy for glucose detection and cell monitoring, demonstrating promising potential for practical biosensing applications involving both bacterial and cancer cell analysis.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133146"},"PeriodicalIF":6.1,"publicationDate":"2025-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145928884","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-31DOI: 10.1016/j.surfcoat.2025.133148
Zhiyong Zhang , Changsong Liu , Yongqiang Fu , Feng Guo , Dongzhou Jia , Jiarong Wang , Lei Cao , Xiaoqiang Wu , Xiaoxue Li
In this paper, we prepared series of DLC-Si films on 304 stainless steel by adjusting the flux of C6H18OSi2 (HMDSO) using the high-power pulse magnetron sputtering (HiPIMS) system. The effects of different Si contents on the tribology performance and electrochemical properties of DLC-Si films were evaluated. The results suggested that the film showed favorable tribological properties and corrosion resistance with 9.26 at.% Si content, and this can be attributed to the incorporation of Si elements changed its graphitization ratio, friction chemistry, and plastic transfer behavior. Furthermore, the formation of hydrated silica gel during the friction process resulted in the lowest coefficient of friction (0.084) and wear rate (2.124 × 10−7 mm3/(Nm)) in seawater. Furthermore, icorr of DLC film reduced three orders of magnitude (3.397 × 10−8 A/cm2) when compared to the 304 substrate, this is due to its inherent chemical inertness and the compact structure of films. The results suggested that the DLC-Si films with low friction coefficients and high corrosion resistance, could effectively prolong the service life of moving components in seawater environments. This provides a theoretical foundation for the application of these films in such environments.
{"title":"Achieving low friction and high corrosion resistance DLC-Si films by HiPIMS","authors":"Zhiyong Zhang , Changsong Liu , Yongqiang Fu , Feng Guo , Dongzhou Jia , Jiarong Wang , Lei Cao , Xiaoqiang Wu , Xiaoxue Li","doi":"10.1016/j.surfcoat.2025.133148","DOIUrl":"10.1016/j.surfcoat.2025.133148","url":null,"abstract":"<div><div>In this paper, we prepared series of DLC-Si films on 304 stainless steel by adjusting the flux of C<sub>6</sub>H<sub>18</sub>OSi<sub>2</sub> (HMDSO) using the high-power pulse magnetron sputtering (HiPIMS) system. The effects of different Si contents on the tribology performance and electrochemical properties of DLC-Si films were evaluated. The results suggested that the film showed favorable tribological properties and corrosion resistance with 9.26 at.% Si content, and this can be attributed to the incorporation of Si elements changed its graphitization ratio, friction chemistry, and plastic transfer behavior. Furthermore, the formation of hydrated silica gel during the friction process resulted in the lowest coefficient of friction (0.084) and wear rate (2.124 × 10<sup>−7</sup> mm<sup>3</sup>/(Nm)) in seawater. Furthermore, i<sub>corr</sub> of DLC film reduced three orders of magnitude (3.397 × 10<sup>−8</sup> A/cm<sup>2</sup>) when compared to the 304 substrate, this is due to its inherent chemical inertness and the compact structure of films. The results suggested that the DLC-Si films with low friction coefficients and high corrosion resistance, could effectively prolong the service life of moving components in seawater environments. This provides a theoretical foundation for the application of these films in such environments.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133148"},"PeriodicalIF":6.1,"publicationDate":"2025-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145928973","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-31DOI: 10.1016/j.surfcoat.2025.133142
Jianxiong Wu , Kou Du , Xuelei Fu , Hongbin Lin , Chao Zhang , Weidi Huang , Bing Xu , Junhui Zhang
Severe wear of 42CrMo steel easily causes unstable power transmission, overload-induced fracture, and even serious safety accidents. Ultrasonic surface rolling process (USRP) is an effective method to enhance the tribological performance of 42CrMo steel due to the gradient nanostructure and surface texture. However, there still lacks a comprehensive understanding about the improvement contribution of tribological performance from surface texture and gradient nanostructure induced by USRP. This study reflects that USRP can effectively generate a gradient nanostructure (~50 nm) and a plastic deformation layer (~500 μm) on the surface. The detailed formation mechanism of the gradient nanostructure is composed of the synergistic effect of lath martensite segregation and dislocation intersection. Moreover, the function of surface texture undergoes a transformation with the increase of surface-strengthening pressure during the wear process: from debris storage-assisted wear resistance function to edge effect-induced wear acceleration function. Under less than 1200 N, wear debris storage induced by texture and gradient nanostructures synergistically improves the tribological performance of 42CrMo steel. Under more than 1200 N, the edge effect caused by the sharp texture becomes more pronounced, further accelerating the wear. These phenomena reveal competitive behaviors between positive impact of gradient nanostructure on enhancing the friction performance and negative effect from the damage at the texture edges. It also leads to a transformation of the dominant wear mechanism with the increase of pressure: from the initial abrasive and oxidative wear to slight abrasive wear accompanied by friction-protective oxide film, and finally to severe abrasive and oxidative wear.
{"title":"Competitive effects of ultrasonic surface rolling-induced textures and nanocrystallization on wear behaviors of 42CrMo steel","authors":"Jianxiong Wu , Kou Du , Xuelei Fu , Hongbin Lin , Chao Zhang , Weidi Huang , Bing Xu , Junhui Zhang","doi":"10.1016/j.surfcoat.2025.133142","DOIUrl":"10.1016/j.surfcoat.2025.133142","url":null,"abstract":"<div><div>Severe wear of 42CrMo steel easily causes unstable power transmission, overload-induced fracture, and even serious safety accidents. Ultrasonic surface rolling process (USRP) is an effective method to enhance the tribological performance of 42CrMo steel due to the gradient nanostructure and surface texture. However, there still lacks a comprehensive understanding about the improvement contribution of tribological performance from surface texture and gradient nanostructure induced by USRP. This study reflects that USRP can effectively generate a gradient nanostructure (~50 nm) and a plastic deformation layer (~500 μm) on the surface. The detailed formation mechanism of the gradient nanostructure is composed of the synergistic effect of lath martensite segregation and dislocation intersection. Moreover, the function of surface texture undergoes a transformation with the increase of surface-strengthening pressure during the wear process: from debris storage-assisted wear resistance function to edge effect-induced wear acceleration function. Under less than 1200 N, wear debris storage induced by texture and gradient nanostructures synergistically improves the tribological performance of 42CrMo steel. Under more than 1200 N, the edge effect caused by the sharp texture becomes more pronounced, further accelerating the wear. These phenomena reveal competitive behaviors between positive impact of gradient nanostructure on enhancing the friction performance and negative effect from the damage at the texture edges. It also leads to a transformation of the dominant wear mechanism with the increase of pressure: from the initial abrasive and oxidative wear to slight abrasive wear accompanied by friction-protective oxide film, and finally to severe abrasive and oxidative wear.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133142"},"PeriodicalIF":6.1,"publicationDate":"2025-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145898175","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-31DOI: 10.1016/j.surfcoat.2025.133144
Juan David Matallana Guerrero , Siddha Sankalpa Sethi , Tarun Kumar Kundu , Siddhartha Das , Karabi Das
The viability of 5,5-dimethylhydantoin (DMH) and ethylenediaminetetraacetic acid (EDTA) as complexing agents in the electrolytic baths is systematically studied using experimental and theoretical approaches. The ZnNi alloy-based coatings were characterized using scanning electron microscopy (SEM), X-ray diffraction (XRD), and nano-indentation studies. Cyclic voltammetry (CV) studies were carried out to study the electrochemical behavior and deposition kinetics of the electrolytic baths with and without the presence of additives. Density functional theory (DFT) calculations indicate that in DMH-based baths, the dissociation energy required to release Ni from the additives is higher than that for Zn, whereas in EDTA baths, Zn dissociates more easily than Ni. The diffusivity of Ni in baths containing EDTA is higher than in baths containing DMH, leading to higher amounts of Ni in the coatings obtained from EDTA baths (~16 wt% Ni). Furthermore, the coatings' texture analysis reveals a change in preferred crystallographic texture from {110}〈001〉 to {001}〈100〉 as the concentration of DMH increases from 0.1 to 0.5 M in the baths, differing from the coatings obtained from EDTA baths at all concentrations which displays {110}〈001〉 components.
{"title":"Theoretical and experimental study of electroplated γ-Ni₂Zn₁₁ coatings from a non-aqueous electrolyte: effect of additives on the coating's microstructure, texture characteristics and mechanical properties","authors":"Juan David Matallana Guerrero , Siddha Sankalpa Sethi , Tarun Kumar Kundu , Siddhartha Das , Karabi Das","doi":"10.1016/j.surfcoat.2025.133144","DOIUrl":"10.1016/j.surfcoat.2025.133144","url":null,"abstract":"<div><div>The viability of 5,5-dimethylhydantoin (DMH) and ethylenediaminetetraacetic acid (EDTA) as complexing agents in the electrolytic baths is systematically studied using experimental and theoretical approaches. The Zn<img>Ni alloy-based coatings were characterized using scanning electron microscopy (SEM), X-ray diffraction (XRD), and nano-indentation studies. Cyclic voltammetry (CV) studies were carried out to study the electrochemical behavior and deposition kinetics of the electrolytic baths with and without the presence of additives. Density functional theory (DFT) calculations indicate that in DMH-based baths, the dissociation energy required to release Ni from the additives is higher than that for Zn, whereas in EDTA baths, Zn dissociates more easily than Ni. The diffusivity of Ni in baths containing EDTA is higher than in baths containing DMH, leading to higher amounts of Ni in the coatings obtained from EDTA baths (~16 wt% Ni). Furthermore, the coatings' texture analysis reveals a change in preferred crystallographic texture from {110}〈001〉 to {001}〈100〉 as the concentration of DMH increases from 0.1 to 0.5 M in the baths, differing from the coatings obtained from EDTA baths at all concentrations which displays {110}〈001〉 components.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133144"},"PeriodicalIF":6.1,"publicationDate":"2025-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145898147","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-31DOI: 10.1016/j.surfcoat.2025.133147
Lanxiang Li , Siwen Cui , Jingwen Li , Bin Zhang , Chaoyang Liu , Zhiliang Zhao , Dianbo Zhang , Yanjie Wang , Wenying Ai , Xiaoyan Guan , Tiebing Cui , Hongfang Wang , Junpeng Wang
Metal corrosion presents significant economic and safety challenges in industrial applications, highlighting the demand for energy-efficient and sustainable protection strategies. Herein, we developed a synergistic protection system by coupling a sandwich-structured triboelectric nanogenerator (TENG) with cetyltrimethylammonium bromide (CTAB) inhibitor, which achieves dual protection through electrochemical polarization and the protective barrier. Two different sandwich-structured TENGs were designed using the same materials, but with distinct layer assembly configurations. The optimal structure was ultimately selected for the effective implementation of cathodic protection. The electric field generated by TENG can enhance the migration and adsorption of CTAB cations, thereby facilitating the formation of compact hydrophobic films that effectively reduce contact with corrosive species. Microscopic images and photographs were utilized to observe the corrosion morphology of the metal surfaces after the immersion experiments. Additionally, the fitted parameters obtained from electrochemical measurements were analyzed to assess the performance of the synergistic anticorrosion system. EDS and XPS were employed to conduct compositional analysis and quantify the adsorption amount of CTAB cations on the metal surface, while the contact angle was used to characterize the surface wettability. These results confirm that even when CTAB is used at a concentration below the effective protection threshold and the TENG-powered cathodic protection provides insufficient power supply, their synergistic integration still enables a noticeable anticorrosion effect. This work establishes a novel anticorrosion method that combines self-powered TENG technology with corrosion inhibitors, thereby addressing the issues of energy consumption and excessive consumption of inhibitor materials.
{"title":"Self-powered triboelectric cathodic protection combined with CTAB inhibitor for synergistic enhancement of metal anticorrosion","authors":"Lanxiang Li , Siwen Cui , Jingwen Li , Bin Zhang , Chaoyang Liu , Zhiliang Zhao , Dianbo Zhang , Yanjie Wang , Wenying Ai , Xiaoyan Guan , Tiebing Cui , Hongfang Wang , Junpeng Wang","doi":"10.1016/j.surfcoat.2025.133147","DOIUrl":"10.1016/j.surfcoat.2025.133147","url":null,"abstract":"<div><div>Metal corrosion presents significant economic and safety challenges in industrial applications, highlighting the demand for energy-efficient and sustainable protection strategies. Herein, we developed a synergistic protection system by coupling a sandwich-structured triboelectric nanogenerator (TENG) with cetyltrimethylammonium bromide (CTAB) inhibitor, which achieves dual protection through electrochemical polarization and the protective barrier. Two different sandwich-structured TENGs were designed using the same materials, but with distinct layer assembly configurations. The optimal structure was ultimately selected for the effective implementation of cathodic protection. The electric field generated by TENG can enhance the migration and adsorption of CTAB cations, thereby facilitating the formation of compact hydrophobic films that effectively reduce contact with corrosive species. Microscopic images and photographs were utilized to observe the corrosion morphology of the metal surfaces after the immersion experiments. Additionally, the fitted parameters obtained from electrochemical measurements were analyzed to assess the performance of the synergistic anticorrosion system. EDS and XPS were employed to conduct compositional analysis and quantify the adsorption amount of CTAB cations on the metal surface, while the contact angle was used to characterize the surface wettability. These results confirm that even when CTAB is used at a concentration below the effective protection threshold and the TENG-powered cathodic protection provides insufficient power supply, their synergistic integration still enables a noticeable anticorrosion effect. This work establishes a novel anticorrosion method that combines self-powered TENG technology with corrosion inhibitors, thereby addressing the issues of energy consumption and excessive consumption of inhibitor materials.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133147"},"PeriodicalIF":6.1,"publicationDate":"2025-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145928889","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-31DOI: 10.1016/j.surfcoat.2025.133145
Chunyan He , Shuangjian Li , Zhongwu Liu , Jie Zhou , Qian Lin , Xiujuan Fan , Jinming Liu , Tingting Guo , Guifeng Tao , Jing Yang
Traditional thermal-sprayed Al2O3-3wt.%TiO2 (AT3) coatings and ion-deposited diamond-like carbon (DLC) films are currently research hotspots in the field of surface engineering. However, the differences between these two materials make their combination and synergistic interaction a key challenge in this field. To overcome this, we designed a dual-gradient transitional interlayer (in composition and structure) between an AT3 coating and a DLC film using a combined thermal spraying and ion deposition process. This approach enables the fabrication of a composite coating with superior comprehensive properties. The design of a structural gradient interlayer alleviated the internal stress between the bottom and top layers, thereby enhancing the mechanical properties of the coating. This results in a friction coefficient of 0.12 and a specific wear rate that decreases from 3.14 × 10−5 mm3·N−1·m−1 to 2.72 × 10−6 mm3·N−1·m−1. The corrosion resistance of the coating was significantly improved, the AT3/MTL/DLC coating exhibits a polarization resistance (Rp) of 4.178 × 106 Ω·cm2, surpassing the pure AT3 coating by two orders of magnitude. This study presents a novel protection strategy for wear-resistant and anti-corrosive moving components in marine environments, and it is anticipated to possess substantial application potential in extensive engineering fields.
{"title":"A dual-gradient transition layer design achieving “three things at one stroke” for thermal-sprayed ceramic/diamond-like carbon coatings: Microstructure, corrosion resistance, and tribological performance","authors":"Chunyan He , Shuangjian Li , Zhongwu Liu , Jie Zhou , Qian Lin , Xiujuan Fan , Jinming Liu , Tingting Guo , Guifeng Tao , Jing Yang","doi":"10.1016/j.surfcoat.2025.133145","DOIUrl":"10.1016/j.surfcoat.2025.133145","url":null,"abstract":"<div><div>Traditional thermal-sprayed Al<sub>2</sub>O<sub>3</sub>-3wt.%TiO<sub>2</sub> (AT3) coatings and ion-deposited diamond-like carbon (DLC) films are currently research hotspots in the field of surface engineering. However, the differences between these two materials make their combination and synergistic interaction a key challenge in this field. To overcome this, we designed a dual-gradient transitional interlayer (in composition and structure) between an AT3 coating and a DLC film using a combined thermal spraying and ion deposition process. This approach enables the fabrication of a composite coating with superior comprehensive properties. The design of a structural gradient interlayer alleviated the internal stress between the bottom and top layers, thereby enhancing the mechanical properties of the coating. This results in a friction coefficient of 0.12 and a specific wear rate that decreases from 3.14 × 10<sup>−5</sup> mm<sup>3</sup>·N<sup>−1</sup>·m<sup>−1</sup> to 2.72 × 10<sup>−6</sup> mm<sup>3</sup>·N<sup>−1</sup>·m<sup>−1</sup>. The corrosion resistance of the coating was significantly improved, the AT3/MTL/DLC coating exhibits a polarization resistance (R<sub>p</sub>) of 4.178 × 10<sup>6</sup> Ω·cm<sup>2</sup>, surpassing the pure AT3 coating by two orders of magnitude. This study presents a novel protection strategy for wear-resistant and anti-corrosive moving components in marine environments, and it is anticipated to possess substantial application potential in extensive engineering fields.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"521 ","pages":"Article 133145"},"PeriodicalIF":6.1,"publicationDate":"2025-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145926945","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-31DOI: 10.1016/j.surfcoat.2025.133141
Haiyan Liao , Haibo Ruan , Weijiu Huang , Jin Hu , Yuan Niu , Hao Peng , Xiangkong Xu , Xiaohan Deng , Tao Hao , Yongyao Su
To suppress ZrCr interdiffusion and improve the oxidation resistance of Cr-coated Zircaloy-4 in high-temperature steam, CrN (15.5 at.% N) and metallic Cr coatings were prepared by magnetron sputtering. Their oxidation behavior and microstructure evolution at 1200 °C and 1300 °C were investigated. The nanocrystalline CrN coating rapidly forms a dense Cr2O3 layer that retains N, thereby promoting the formation of Cr2N and alleviating stress to maintain Cr2O3 scale integrity. Temperature strongly affects the oxidized microstructure. At 1200 °C, the layered structure comprises Cr2O3/Cr2N/Cr/Zr-N(α-Zr(N) + ZrN), whereas it evolves to Cr2O3/Cr/ZrCr2/α-Zr(N) at 1300 °C. The in-situ formed ZrN layer during high-temperature oxidation acts as a critical diffusion barrier. Notably, in the Cr-N-coated sample, the ZrCr2 layer is only 265 nm thick at 1300 °C, compared with 2.0 μm in the metallic Cr-coated sample. These results indicate that the α-Zr(N) phase effectively retards interdiffusion and highlight the potential of CrN coatings for high-temperature steam environments.
{"title":"Enhanced oxidation resistance of CrN coated Zircaloy-4 in steam via a ZrN diffusion barrier formed during high-temperature exposure","authors":"Haiyan Liao , Haibo Ruan , Weijiu Huang , Jin Hu , Yuan Niu , Hao Peng , Xiangkong Xu , Xiaohan Deng , Tao Hao , Yongyao Su","doi":"10.1016/j.surfcoat.2025.133141","DOIUrl":"10.1016/j.surfcoat.2025.133141","url":null,"abstract":"<div><div>To suppress Zr<img>Cr interdiffusion and improve the oxidation resistance of Cr-coated Zircaloy-4 in high-temperature steam, Cr<img>N (15.5 at.% N) and metallic Cr coatings were prepared by magnetron sputtering. Their oxidation behavior and microstructure evolution at 1200 °C and 1300 °C were investigated. The nanocrystalline Cr<img>N coating rapidly forms a dense Cr<sub>2</sub>O<sub>3</sub> layer that retains N, thereby promoting the formation of Cr<sub>2</sub>N and alleviating stress to maintain Cr<sub>2</sub>O<sub>3</sub> scale integrity. Temperature strongly affects the oxidized microstructure. At 1200 °C, the layered structure comprises Cr<sub>2</sub>O<sub>3</sub>/Cr<sub>2</sub>N/Cr/Zr-N(α-Zr(N) + ZrN), whereas it evolves to Cr<sub>2</sub>O<sub>3</sub>/Cr/ZrCr<sub>2</sub>/α-Zr(N) at 1300 °C. The in-situ formed Zr<img>N layer during high-temperature oxidation acts as a critical diffusion barrier. Notably, in the Cr-N-coated sample, the ZrCr<sub>2</sub> layer is only 265 nm thick at 1300 °C, compared with 2.0 μm in the metallic Cr-coated sample. These results indicate that the α-Zr(N) phase effectively retards interdiffusion and highlight the potential of Cr<img>N coatings for high-temperature steam environments.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"521 ","pages":"Article 133141"},"PeriodicalIF":6.1,"publicationDate":"2025-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145926944","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-30DOI: 10.1016/j.surfcoat.2025.133125
Xiao Tao , Yunus Azakli , Linshan Yu , Adrian Leyland , Hanshan Dong , Allan Matthews , Haitao Zhao , Junheng Gao , Jian Chen
The carbide-free, carbon-supersaturated expanded austenite (γC) case in low-temperature carburized (LTC) AISI 316 (Fe-18Cr-11Ni-3Mo, wt%) austenitic stainless steel (SS) drawn extensive interests for its high hardness and good corrosion resistance. The addition of strong carbide-forming elements (e.g. Ti) in the substrate alloy would significantly improve the hardening of γC, but also tends to accelerate carbide formation that would deteriorate corrosion resistance. Nevertheless, increasing the Ni level would improve the stability of the austenitic structure and tends to prohibit carbide formation in the carburized surface, that could compensate with the Ti addition in matrix. The impacts of increasing Ni/Ti concentrations (either separately or combined) in Fe-Cr-Ni-Me (Me = strong carbide forming elements) austenitic matrix to the surface carburizing response and performance requires systematic examination. Following the above alloy-design concept, Fe-18Cr-18/35Ni(-2Ti) alloys containing approximately 18 wt% Cr and 18/35 wt% Ni, without and with ∼2 wt% Ti, are tentatively investigated after plasma carburizing at 470 and 520 °C for 15 h, respectively. The surface carbon uptake during carburizing and the resulting surface hardness reduce with increasing substrate Ni level, increase substantially with Ti addition in the substrate alloy. Both substrate Ni/Ti additions improve the corrosion resistance of the plasma carburized surfaces. Strikingly, when carburized at 470 °C/15 h, the γC case is significantly thicker and harder in Fe-18Cr-18Ni-2Ti (35 μm, 1009 HV0.3) than that in AISI 316 SS (25 μm, 450 HV0.3). Moreover, the carburized surfaces of high-Ni/Ti alloys exhibit sluggish carbide formation and improved corrosion resistance than those of AISI 316 SS. This study i) reveals the alloy-design criteria to enhancing hardening, while improving corrosion resistance, for γC, and ii) guides the development of carburizing process for specialty corrosion-resistant austenitic alloys.
{"title":"Influences of Ni and Ti concentrations on the carbon uptake, carbide formation, hardening and corrosion performance of the carbon-expanded austenite case in austenitic Fe-Cr-Ni-Ti alloys","authors":"Xiao Tao , Yunus Azakli , Linshan Yu , Adrian Leyland , Hanshan Dong , Allan Matthews , Haitao Zhao , Junheng Gao , Jian Chen","doi":"10.1016/j.surfcoat.2025.133125","DOIUrl":"10.1016/j.surfcoat.2025.133125","url":null,"abstract":"<div><div>The carbide-free, carbon-supersaturated expanded austenite (γ<sub>C</sub>) case in low-temperature carburized (LTC) AISI 316 (Fe-18Cr-11Ni-3Mo, wt%) austenitic stainless steel (SS) drawn extensive interests for its high hardness and good corrosion resistance. The addition of strong carbide-forming elements (e.g. Ti) in the substrate alloy would significantly improve the hardening of γ<sub>C</sub>, but also tends to accelerate carbide formation that would deteriorate corrosion resistance. Nevertheless, increasing the Ni level would improve the stability of the austenitic structure and tends to prohibit carbide formation in the carburized surface, that could compensate with the Ti addition in matrix. The impacts of increasing Ni/Ti concentrations (either separately or combined) in Fe-Cr-Ni-Me (Me = strong carbide forming elements) austenitic matrix to the surface carburizing response and performance requires systematic examination. Following the above alloy-design concept, Fe-18Cr-18/35Ni(-2Ti) alloys containing approximately 18 wt% Cr and 18/35 wt% Ni, without and with ∼2 wt% Ti, are tentatively investigated after plasma carburizing at 470 and 520 °C for 15 h, respectively. The surface carbon uptake during carburizing and the resulting surface hardness reduce with increasing substrate Ni level, increase substantially with Ti addition in the substrate alloy. Both substrate Ni/Ti additions improve the corrosion resistance of the plasma carburized surfaces. Strikingly, when carburized at 470 °C/15 h, the γ<sub>C</sub> case is significantly thicker and harder in Fe-18Cr-18Ni-2Ti (35 μm, 1009 HV<sub>0.3</sub>) than that in AISI 316 SS (25 μm, 450 HV<sub>0.3</sub>). Moreover, the carburized surfaces of high-Ni/Ti alloys exhibit sluggish carbide formation and improved corrosion resistance than those of AISI 316 SS. This study i) reveals the alloy-design criteria to enhancing hardening, while improving corrosion resistance, for γ<sub>C</sub>, and ii) guides the development of carburizing process for specialty corrosion-resistant austenitic alloys.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133125"},"PeriodicalIF":6.1,"publicationDate":"2025-12-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145928880","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Monel 400 cladding exhibits substantial potential as a premier material in marine applications owing to its superior mechanical strength and outstanding corrosion resistance. However, the detailed analysis of Monel 400 clad on the stainless steel (SS) 304 substrate in terms of grain microstructure, mechanical properties, and the corresponding mechanism remains unclear. Herein, a cold metal transfer (CMT) based wire arc additive manufacturing process (WAAM) was utilized to deposit a single layer of Monel 400 on SS 304. Microstructural analysis revealed the fragmented and elongated dendrites on the clad surface. In contrast, equiaxed austenite (γ) grains, bounded with a small delta ferrite (δ), were present on the SS 304 base substrate. EDS (Energy Dispersive Spectroscopy) analysis identified two types of intermetallic phases at the interface, namely FeNi and NiCr. XRD (X-ray Diffraction) results confirmed the presence of an FCC structure, along with the formation of new intermetallic phases at the interface. EBSD (Electron Backscatter Diffraction) analysis indicated that Continuous Dynamic Recrystallization (CDRX) and Geometric Dynamic Recrystallization (GDRX) predominated at the clad surface, while Discontinuous Dynamic Recrystallization (DDRX) was the primary mechanism within the SS 304 substrate. The quantitative analysis revealed grain sizes of 86 ± 5 μm and 9 ± 2 μm for the clad surface and base substrate, respectively. Mechanical analysis showed that the clad surface exhibits 25 % higher tensile strength than the interface and 55 % higher tensile strength than the base substrate. Moreover, delamination analysis confirmed the strong metallurgical bonding between the Monel 400 and SS 304. This study demonstrates the feasibility of cold metal transfer–based wire arc additive manufacturing (CMT-WAAM) for Monel 400 cladding on SS 304 with promising interfacial integrity and mechanical performance.
{"title":"Microstructure and mechanical performance of Monel 400 cladding on SS-304 using CMT-WAAM","authors":"Lalit Kumar Yadav , Joy Prakash Misra , Rajnesh Tyagi , Shubham Verma","doi":"10.1016/j.surfcoat.2025.133140","DOIUrl":"10.1016/j.surfcoat.2025.133140","url":null,"abstract":"<div><div>Monel 400 cladding exhibits substantial potential as a premier material in marine applications owing to its superior mechanical strength and outstanding corrosion resistance. However, the detailed analysis of Monel 400 clad on the stainless steel (SS) 304 substrate in terms of grain microstructure, mechanical properties, and the corresponding mechanism remains unclear. Herein, a cold metal transfer (CMT) based wire arc additive manufacturing process (WAAM) was utilized to deposit a single layer of Monel 400 on SS 304. Microstructural analysis revealed the fragmented and elongated dendrites on the clad surface. In contrast, equiaxed austenite (γ) grains, bounded with a small delta ferrite (δ), were present on the SS 304 base substrate. EDS (Energy Dispersive Spectroscopy) analysis identified two types of intermetallic phases at the interface, namely Fe<img>Ni and Ni<img>Cr. XRD (X-ray Diffraction) results confirmed the presence of an FCC structure, along with the formation of new intermetallic phases at the interface. EBSD (Electron Backscatter Diffraction) analysis indicated that Continuous Dynamic Recrystallization (CDRX) and Geometric Dynamic Recrystallization (GDRX) predominated at the clad surface, while Discontinuous Dynamic Recrystallization (DDRX) was the primary mechanism within the SS 304 substrate. The quantitative analysis revealed grain sizes of 86 ± 5 μm and 9 ± 2 μm for the clad surface and base substrate, respectively. Mechanical analysis showed that the clad surface exhibits 25 % higher tensile strength than the interface and 55 % higher tensile strength than the base substrate. Moreover, delamination analysis confirmed the strong metallurgical bonding between the Monel 400 and SS 304. This study demonstrates the feasibility of cold metal transfer–based wire arc additive manufacturing (CMT-WAAM) for Monel 400 cladding on SS 304 with promising interfacial integrity and mechanical performance.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133140"},"PeriodicalIF":6.1,"publicationDate":"2025-12-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145898176","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-29DOI: 10.1016/j.surfcoat.2025.133136
Shihao You , Xingwu Qiu , Ziyi Wang , Xianwen Shen , Yan Zhou , Boyang Shen , Zhongyi Liu , Yu Zhang , Hang Chen , Chao Meng
In this study, AlxNbTiVSi0.1 (x = 0.5, 0.75, 1, 1.25, 1.5) lightweight refractory high-entropy alloy (LRHEA) coatings were successfully fabricated on the surface of TC4 titanium alloy substrates by gas tungsten arc (GTA) cladding. The results indicated that AlxNbTiVSi0.1 LRHEA coatings were composed of BCC, TiNb, and (Nb, Ti)5Si3 phases. With increasing Al content, the fraction of the BCC phase increased, whereas both the size and fraction of TiNb phase decreased. The average hardness at the top of coatings increased with Al content, reaching a maximum of 842.55 HV0.5 for Al1.5NbTiVSi0.1 LRHEA coating. Wear tests demonstrated that the Al1NbTiVSi0.1 LRHEA coating exhibited optimal wear resistance at both room temperature and 600 °C, with mass loss rates of 2.01 × 10−5 mg/mm and 0.42 × 10−5 mg/mm, respectively. Furthermore, electrochemical tests further revealed that an increased Al content significantly improved the corrosion resistance. The Al1.5NbTiVSi0.1 LRHEA coating exhibited the highest corrosion potential (−207.56 mV) and the lowest corrosion current density (2.37 × 10−7 A/cm2). Moreover, with increasing Al content, the corrosion mechanism transformed from severe galvanic corrosion to slight pitting due to the formation of a protective passive film. This study provides valuable insights for the compositional design and performance optimization of LRHEA coatings.
{"title":"Effect of Al content on the microstructure, wear and corrosion resistance of AlxNbTiVSi0.1 lightweight refractory high-entropy alloy coatings by gas tungsten Arc cladding","authors":"Shihao You , Xingwu Qiu , Ziyi Wang , Xianwen Shen , Yan Zhou , Boyang Shen , Zhongyi Liu , Yu Zhang , Hang Chen , Chao Meng","doi":"10.1016/j.surfcoat.2025.133136","DOIUrl":"10.1016/j.surfcoat.2025.133136","url":null,"abstract":"<div><div>In this study, Al<sub>x</sub>NbTiVSi<sub>0.1</sub> (x = 0.5, 0.75, 1, 1.25, 1.5) lightweight refractory high-entropy alloy (LRHEA) coatings were successfully fabricated on the surface of TC4 titanium alloy substrates by gas tungsten arc (GTA) cladding. The results indicated that Al<sub>x</sub>NbTiVSi<sub>0.1</sub> LRHEA coatings were composed of BCC, Ti<img>Nb, and (Nb, Ti)<sub>5</sub>Si<sub>3</sub> phases. With increasing Al content, the fraction of the BCC phase increased, whereas both the size and fraction of Ti<img>Nb phase decreased. The average hardness at the top of coatings increased with Al content, reaching a maximum of 842.55 HV<sub>0.5</sub> for Al<sub>1.5</sub>NbTiVSi<sub>0.1</sub> LRHEA coating. Wear tests demonstrated that the Al<sub>1</sub>NbTiVSi<sub>0.1</sub> LRHEA coating exhibited optimal wear resistance at both room temperature and 600 °C, with mass loss rates of 2.01 × 10<sup>−5</sup> mg/mm and 0.42 × 10<sup>−5</sup> mg/mm, respectively. Furthermore, electrochemical tests further revealed that an increased Al content significantly improved the corrosion resistance. The Al<sub>1.5</sub>NbTiVSi<sub>0.1</sub> LRHEA coating exhibited the highest corrosion potential (−207.56 mV) and the lowest corrosion current density (2.37 × 10<sup>−7</sup> A/cm<sup>2</sup>). Moreover, with increasing Al content, the corrosion mechanism transformed from severe galvanic corrosion to slight pitting due to the formation of a protective passive film. This study provides valuable insights for the compositional design and performance optimization of LRHEA coatings.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"521 ","pages":"Article 133136"},"PeriodicalIF":6.1,"publicationDate":"2025-12-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145885339","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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