Pub Date : 2025-12-22DOI: 10.1016/j.surfcoat.2025.133099
Jiaping Han , Jingpeng Xia , Zhiqiang Jiang , Hao Zhang , Dongdong Zhang , Yan Liu , Carsten Blawert , Deliang Liu , Xiaopeng Lu , Yuquan Hao , Mikhail L. Zheludkevich , Hui Chen
A black ceramic coating was fabricated on Mg alloys via plasma electrolytic oxidation (PEO), NH4VO3 was used as black colorant while Nd2O3 rare earth nanoparticles (NPs) and phenol were employed to further enhance the properties. Results indicated that incorporation of Nd2O3 densified the PEO layer by sealing the open pores and discharge channels, resulting in comprehensive increase of the corrosion and wear resistance. The coatings presented stable corrosion property during 720 h of immersion in NaCl solution. Light absorption and emission properties were significantly improved after embedding colorant. A NPs-reinforced black PEO coating is suggested for long term protection of structural Mg alloys.
{"title":"Performance of Nd2O3 rare earth nanoparticle-incorporated black ceramic coatings on AZ31Mg alloys via plasma electrolytic oxidation","authors":"Jiaping Han , Jingpeng Xia , Zhiqiang Jiang , Hao Zhang , Dongdong Zhang , Yan Liu , Carsten Blawert , Deliang Liu , Xiaopeng Lu , Yuquan Hao , Mikhail L. Zheludkevich , Hui Chen","doi":"10.1016/j.surfcoat.2025.133099","DOIUrl":"10.1016/j.surfcoat.2025.133099","url":null,"abstract":"<div><div>A black ceramic coating was fabricated on Mg alloys via plasma electrolytic oxidation (PEO), NH<sub>4</sub>VO<sub>3</sub> was used as black colorant while Nd<sub>2</sub>O<sub>3</sub> rare earth nanoparticles (NPs) and phenol were employed to further enhance the properties. Results indicated that incorporation of Nd<sub>2</sub>O<sub>3</sub> densified the PEO layer by sealing the open pores and discharge channels, resulting in comprehensive increase of the corrosion and wear resistance. The coatings presented stable corrosion property during 720 h of immersion in NaCl solution. Light absorption and emission properties were significantly improved after embedding colorant. A NPs-reinforced black PEO coating is suggested for long term protection of structural Mg alloys.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"521 ","pages":"Article 133099"},"PeriodicalIF":6.1,"publicationDate":"2025-12-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145885338","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 : 2025-12-22DOI: 10.1016/j.surfcoat.2025.133111
Kun Lu , JiaJing Pan , YongPeng Fan , JiYuan Wang , ZhenHao Han , Zhou An , WeiRan Li , MuHan Zou
This study targets the issues of WC dissolution, grain coarsening, and the difficulty of simultaneously balancing wear and corrosion resistance in C276-based, WC-reinforced plasma arc cladded coatings. A Ti/B₄C multi-phase synergistic strengthening strategy was adopted, and a CFD–CA coupled model was used to quantitatively analyze the thermal–flow–solidification behavior in the 120–160 A current range, thereby determining a 140 A process window; accordingly, three coatings were prepared: W20 (C276 + 20 % WC), W20T (W20 + 10 % Ti), and W20TB (W20 + 5 % Ti + 5 % B₄C). The results show that the introduction of Ti generates in-situ TiC shells encapsulating the residual WC and dispersed TiC particles, which suppress WC dissolution and promote microstructural refinement; after further addition of B₄C, the solid solution of B and C lowers local misorientation (KAM). Compared with W20, the average microhardness of W20T and W20TB increases by about 1.2 times and 1.5 times, the wear volume rate decreases from 5.94 × 10−6 to 1.58 × 10−6 and 0.15 × 10−6 mm3·N−1·m−1, the friction coefficient drops from 0.54 to 0.23 and 0.21, and the corrosion resistance shows a slight decline, mainly due to micro-galvanic dissolution induced by Ti/C enrichment. The comprehensive strengthening mechanism derives from the pinning action of Ti/B/C solid-solution lattice distortion and dispersed precipitates on dislocations/grain boundaries, as well as the improvements brought by grain refinement and the increased proportion of high-angle grain boundaries. The study establishes a design pathway of “model-guided parameter selection—multiscale microstructural regulation—synergistic strengthening—performance trade-off,” providing a reference for the surface engineering of high-load, wear-service components of nickel-based alloys.
{"title":"Constructing highly wear-resistant plasma-clad C276/WC coatings via Ti/B₄C multi-phase synergy: Experiments and simulations","authors":"Kun Lu , JiaJing Pan , YongPeng Fan , JiYuan Wang , ZhenHao Han , Zhou An , WeiRan Li , MuHan Zou","doi":"10.1016/j.surfcoat.2025.133111","DOIUrl":"10.1016/j.surfcoat.2025.133111","url":null,"abstract":"<div><div>This study targets the issues of WC dissolution, grain coarsening, and the difficulty of simultaneously balancing wear and corrosion resistance in C276-based, WC-reinforced plasma arc cladded coatings. A Ti/B₄C multi-phase synergistic strengthening strategy was adopted, and a CFD–CA coupled model was used to quantitatively analyze the thermal–flow–solidification behavior in the 120–160 A current range, thereby determining a 140 A process window; accordingly, three coatings were prepared: W20 (C276 + 20 % WC), W20T (W20 + 10 % Ti), and W20TB (W20 + 5 % Ti + 5 % B₄C). The results show that the introduction of Ti generates in-situ TiC shells encapsulating the residual WC and dispersed TiC particles, which suppress WC dissolution and promote microstructural refinement; after further addition of B₄C, the solid solution of B and C lowers local misorientation (KAM). Compared with W20, the average microhardness of W20T and W20TB increases by about 1.2 times and 1.5 times, the wear volume rate decreases from 5.94 × 10<sup>−6</sup> to 1.58 × 10<sup>−6</sup> and 0.15 × 10<sup>−6</sup> mm<sup>3</sup>·N<sup>−1</sup>·m<sup>−1</sup>, the friction coefficient drops from 0.54 to 0.23 and 0.21, and the corrosion resistance shows a slight decline, mainly due to micro-galvanic dissolution induced by Ti/C enrichment. The comprehensive strengthening mechanism derives from the pinning action of Ti/B/C solid-solution lattice distortion and dispersed precipitates on dislocations/grain boundaries, as well as the improvements brought by grain refinement and the increased proportion of high-angle grain boundaries. The study establishes a design pathway of “model-guided parameter selection—multiscale microstructural regulation—synergistic strengthening—performance trade-off,” providing a reference for the surface engineering of high-load, wear-service components of nickel-based alloys.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"521 ","pages":"Article 133111"},"PeriodicalIF":6.1,"publicationDate":"2025-12-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145885878","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 : 2025-12-22DOI: 10.1016/j.surfcoat.2025.133110
Zhanlong Yang , Cong Sun , Dawei Wang , Yuan Hong , Yanquan Dai , Shuai Wang , Ye Tian
To achieve high-performance surface manufacturing of titanium alloys, most existing processing technologies adopt a “machining-first then finishing” stepwise mode, which results in redundant energy consumption and limited production efficiency. Meanwhile, to improve the comprehensive mechanical properties of titanium alloy surfaces and realize long-term service, there is an urgent need for surface strengthening and modification. Therefore, integrating the process integration concept with multi-element regulation, this study proposes a high-performance grinding method for Ti6Al4V via laser-induced C-N-B co- infiltration. By preplacing a detachable graphite + h-BN composite coating on the specimen surface, the laser-induced multi-element infiltration grinding process was carried out, successfully fabricating a multi-component strengthened cladding layer rich in TiC, TiN, and TiB phases on the Ti6Al4V surface. Compared with separate laser alloying and grinding (Group 2), the laser-induced multi-element infiltration grinding method exhibits significant advantages: the thermo-mechanical coupling effect during processing is more synergistic and prominent; the average surface roughness (Sa) is reduced by approximately 27.6 % compared with Group 2 and by about 21.3 % relative to conventional grinding (Group 3). Meanwhile, the precipitation quantity of strengthening phases in the cladding layer is significantly increased, and their distribution uniformity is greatly improved. In addition, this study clarifies the growth and evolution mechanisms of C-N-B multi-component strengthening phases, fills the research gap in the “machining-strengthening” integration theory under the synergistic effect of multi-elements, and provides theoretical support for the advanced manufacturing field of high-performance Ti6Al4V.
{"title":"Ti6Al4V surface evolution mechanism by laser-induced multi-element infiltration grinding","authors":"Zhanlong Yang , Cong Sun , Dawei Wang , Yuan Hong , Yanquan Dai , Shuai Wang , Ye Tian","doi":"10.1016/j.surfcoat.2025.133110","DOIUrl":"10.1016/j.surfcoat.2025.133110","url":null,"abstract":"<div><div>To achieve high-performance surface manufacturing of titanium alloys, most existing processing technologies adopt a “machining-first then finishing” stepwise mode, which results in redundant energy consumption and limited production efficiency. Meanwhile, to improve the comprehensive mechanical properties of titanium alloy surfaces and realize long-term service, there is an urgent need for surface strengthening and modification. Therefore, integrating the process integration concept with multi-element regulation, this study proposes a high-performance grinding method for Ti6Al4V via laser-induced C-N-B co- infiltration. By preplacing a detachable graphite + h-BN composite coating on the specimen surface, the laser-induced multi-element infiltration grinding process was carried out, successfully fabricating a multi-component strengthened cladding layer rich in TiC, TiN, and TiB phases on the Ti6Al4V surface. Compared with separate laser alloying and grinding (Group 2), the laser-induced multi-element infiltration grinding method exhibits significant advantages: the thermo-mechanical coupling effect during processing is more synergistic and prominent; the average surface roughness (Sa) is reduced by approximately 27.6 % compared with Group 2 and by about 21.3 % relative to conventional grinding (Group 3). Meanwhile, the precipitation quantity of strengthening phases in the cladding layer is significantly increased, and their distribution uniformity is greatly improved. In addition, this study clarifies the growth and evolution mechanisms of C-N-B multi-component strengthening phases, fills the research gap in the “machining-strengthening” integration theory under the synergistic effect of multi-elements, and provides theoretical support for the advanced manufacturing field of high-performance Ti6Al4V.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"521 ","pages":"Article 133110"},"PeriodicalIF":6.1,"publicationDate":"2025-12-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145841785","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 : 2025-12-22DOI: 10.1016/j.surfcoat.2025.133104
J. Müller , J. Swoboda , F. Burmeister , A. Fromm , M. Wirth , A. Killinger , S. Ulrich
High Power Impulse Magnetron Sputtering (HiPIMS) offers significant advantages over established sputtering techniques such as DC, MF, or RF sputtering. Thin films deposited with HiPIMS exhibit improved properties but often suffer from low deposition rates. In addition, reactive HiPIMS processes tend to arc. Superposition of different plasma excitations may help to overcome these limitations. We investigated the superposition of HiPIMS and RF on a single magnetron and studied voltage–current characteristics as well as the influence of pressure on process stability and cathode voltage for the reactive and non-reactive deposition of Aluminium in Ar/O2 discharge. We found that superimposing RF onto HiPIMS allows for stable operation at lower pressures and reduces arcing. Notably, the effect of the superimposed RF on peak current differs by mode: in reactive sputtering, the HiPIMS peak current is increased, while in non-reactive mode, the peak current is decreased. This is attributed to the different secondary electron emission in non-reactive and reactive mode.
{"title":"Continuous superposition of high power pulses and radio frequency power on a single magnetron target","authors":"J. Müller , J. Swoboda , F. Burmeister , A. Fromm , M. Wirth , A. Killinger , S. Ulrich","doi":"10.1016/j.surfcoat.2025.133104","DOIUrl":"10.1016/j.surfcoat.2025.133104","url":null,"abstract":"<div><div>High Power Impulse Magnetron Sputtering (HiPIMS) offers significant advantages over established sputtering techniques such as DC, MF, or RF sputtering. Thin films deposited with HiPIMS exhibit improved properties but often suffer from low deposition rates. In addition, reactive HiPIMS processes tend to arc. Superposition of different plasma excitations may help to overcome these limitations. We investigated the superposition of HiPIMS and RF on a single magnetron and studied voltage–current characteristics as well as the influence of pressure on process stability and cathode voltage for the reactive and non-reactive deposition of Aluminium in Ar/O2 discharge. We found that superimposing RF onto HiPIMS allows for stable operation at lower pressures and reduces arcing. Notably, the effect of the superimposed RF on peak current differs by mode: in reactive sputtering, the HiPIMS peak current is increased, while in non-reactive mode, the peak current is decreased. This is attributed to the different secondary electron emission in non-reactive and reactive mode.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"521 ","pages":"Article 133104"},"PeriodicalIF":6.1,"publicationDate":"2025-12-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145885330","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 : 2025-12-22DOI: 10.1016/j.surfcoat.2025.133087
Esteban Araya-Hermosilla , Javier Marqués-Henríquez , Rodrigo Araya-Hermosilla , Daniel Moncada , Francesco Picchioni , Marco Carlotti , Andrea Pucci , Franck Quero , Dario Zambrano , Andreas Rosenkranz
Improving the tribological performance of components and systems remains crucial to improve the resulting mechanical efficiency, durability, and sustainability. This study reports the development of composite coatings based on multilayer Ti3C2Tx (ML- Ti3C2Tx) and chemically modified polyketone (PKHEDA) for enhanced solid lubrication. In this regard, PKHEDA was synthesized via the Paal-Knorr reaction to improve MXenes' dispersion as well as coating's adhesion and chemical stability. Composite coatings with varying MXene-polymer ratios 1:3.3 (COM-1), 1:1.6 (COM-2), and 1:1 (COM-3) wt.-%, were spray-coated onto stainless-steel substrates and characterized using complementary materials characterization and tribo-testing. Our results demonstrate that PKHEDA effectively encapsulates ML- Ti3C2Tx, reducing its oxidation tendency and improving the overall coating integrity under mechanical stress. The tribological performance of the composite coatings was notably enhanced compared to pure Ti3C2Tx coatings and non-coated substrates, thus verifying a stable coefficient of friction and a reduction of the wear rate up to 87 %. The composite with a MXene-to-polymer ratio of 1:1.6 (COM-2) exhibited the best balance of load-bearing capacity, durability, and chemical resilience. These findings highlight the synergistic potential of ML-Ti3C2Tx/polyketone composites to develop high-performance, sustainable coatings for demanding tribological environments.
{"title":"Polyketone-modified Ti3C2Tx composite coatings for enhanced solid lubrication under elevated stress and oxidative environments","authors":"Esteban Araya-Hermosilla , Javier Marqués-Henríquez , Rodrigo Araya-Hermosilla , Daniel Moncada , Francesco Picchioni , Marco Carlotti , Andrea Pucci , Franck Quero , Dario Zambrano , Andreas Rosenkranz","doi":"10.1016/j.surfcoat.2025.133087","DOIUrl":"10.1016/j.surfcoat.2025.133087","url":null,"abstract":"<div><div>Improving the tribological performance of components and systems remains crucial to improve the resulting mechanical efficiency, durability, and sustainability. This study reports the development of composite coatings based on multilayer Ti<sub>3</sub>C<sub>2</sub>T<sub><em>x</em></sub> (ML- Ti<sub>3</sub>C<sub>2</sub>T<sub><em>x</em></sub>) and chemically modified polyketone (PKHEDA) for enhanced solid lubrication. In this regard, PKHEDA was synthesized via the Paal-Knorr reaction to improve MXenes' dispersion as well as coating's adhesion and chemical stability. Composite coatings with varying MXene-polymer ratios 1:3.3 (COM-1), 1:1.6 (COM-2), and 1:1 (COM-3) wt.-%, were spray-coated onto stainless-steel substrates and characterized using complementary materials characterization and tribo-testing. Our results demonstrate that PKHEDA effectively encapsulates ML- Ti<sub>3</sub>C<sub>2</sub>T<sub><em>x</em></sub>, reducing its oxidation tendency and improving the overall coating integrity under mechanical stress. The tribological performance of the composite coatings was notably enhanced compared to pure Ti<sub>3</sub>C<sub>2</sub>T<sub><em>x</em></sub> coatings and non-coated substrates, thus verifying a stable coefficient of friction and a reduction of the wear rate up to 87 %. The composite with a MXene-to-polymer ratio of 1:1.6 (COM-2) exhibited the best balance of load-bearing capacity, durability, and chemical resilience. These findings highlight the synergistic potential of ML-Ti<sub>3</sub>C<sub>2</sub>T<sub><em>x</em></sub>/polyketone composites to develop high-performance, sustainable coatings for demanding tribological environments.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"521 ","pages":"Article 133087"},"PeriodicalIF":6.1,"publicationDate":"2025-12-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145885333","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 : 2025-12-22DOI: 10.1016/j.surfcoat.2025.133107
Syed Sohail Akhtar , Abba A. Abubakar , Raihan A. Goriya , Ali Dolatabadi , Larry Pershin , Mohammad Izadinia , Ahmad A. Sorour , Javad Mostaghimi
Despite extensive investigations into cold spray technology across both high-pressure and low-pressure systems, most existing research on optimizing spray settings through trial-and-error experimentation has serious limitations in terms of time, deposition efficiency, and required mechanical properties. This paper presents a comprehensive simulation-based design framework that combines particle-laden flow simulations and finite element modeling under low-pressure and high-pressure cold spray conditions using both ‘Lagrangian Element’ and ‘Smoothed Particle Hydrodynamics’ numerical schemes. Simulations analyze the mechanical and thermal responses, namely equivalent plastic strain, temperature distribution, and von Mises stress, during particle-substrate interaction. The results show important correlations between cold spray parameters and particle deformation behavior in both spray modes. The study examines the impact of gas pressure (5–60 bar), temperature (400–1000 °C), and particle size (5–55 μm) on particle velocity and bonding properties. Experiments were conducted with pure Ni as the feedstock for high-pressure and a Ni/Al2O3 composite for low-pressure deposition. The generated deposition windows for both pressure regimes were experimentally confirmed and found to be very consistent with simulation predictions. Results from both numerical models and experiments show that particle kinetic energy and morphology have a considerable impact on plastic deformation and temperature evolution upon impact, determining deposition efficiency. The finite element simulation results demonstrate that material properties and spray conditions greatly influence deformation behavior, with softer substrates and HPCS conditions showing deeper penetration and higher thermal softening. A hybrid numerical approach is recommended for a more robust simulation of the cold spray process.
{"title":"Simulation-led design framework for cold spray deposition of metal structures considering high- and low-pressure conditions","authors":"Syed Sohail Akhtar , Abba A. Abubakar , Raihan A. Goriya , Ali Dolatabadi , Larry Pershin , Mohammad Izadinia , Ahmad A. Sorour , Javad Mostaghimi","doi":"10.1016/j.surfcoat.2025.133107","DOIUrl":"10.1016/j.surfcoat.2025.133107","url":null,"abstract":"<div><div>Despite extensive investigations into cold spray technology across both high-pressure and low-pressure systems, most existing research on optimizing spray settings through trial-and-error experimentation has serious limitations in terms of time, deposition efficiency, and required mechanical properties. This paper presents a comprehensive simulation-based design framework that combines particle-laden flow simulations and finite element modeling under low-pressure and high-pressure cold spray conditions using both ‘Lagrangian Element’ and ‘Smoothed Particle Hydrodynamics’ numerical schemes. Simulations analyze the mechanical and thermal responses, namely equivalent plastic strain, temperature distribution, and von Mises stress, during particle-substrate interaction. The results show important correlations between cold spray parameters and particle deformation behavior in both spray modes. The study examines the impact of gas pressure (5–60 bar), temperature (400–1000 °C), and particle size (5–55 μm) on particle velocity and bonding properties. Experiments were conducted with pure Ni as the feedstock for high-pressure and a Ni/Al<sub>2</sub>O<sub>3</sub> composite for low-pressure deposition. The generated deposition windows for both pressure regimes were experimentally confirmed and found to be very consistent with simulation predictions. Results from both numerical models and experiments show that particle kinetic energy and morphology have a considerable impact on plastic deformation and temperature evolution upon impact, determining deposition efficiency. The finite element simulation results demonstrate that material properties and spray conditions greatly influence deformation behavior, with softer substrates and HPCS conditions showing deeper penetration and higher thermal softening. A hybrid numerical approach is recommended for a more robust simulation of the cold spray process.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"521 ","pages":"Article 133107"},"PeriodicalIF":6.1,"publicationDate":"2025-12-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145885336","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 : 2025-12-22DOI: 10.1016/j.surfcoat.2025.133108
Chen Hua , Yantong Man , Taihong Huang , Rongfeng Zhou , Peng Song , Yanhong Zhuang , Tao Wang , Xiping Xiong , Qingshan Yang , Ruixiong Zhai , Tao Ma
With the increasing demand for large temperature drops in hot-section components, ultra-thick thermal barrier coatings (TBCs) have gained increasing interest. A major challenge is achieving both mechanical robustness and low thermal conductivity in such thick layers. To address this issue, a gradient porosity design was introduced. Ultra-thick (1300 μm) YSZ TBCs were fabricated by atmospheric plasma spraying (APS) using gradient porous (GP) structure. Controlled porosity distribution was realized through a “dual-powder feeding + gradient deposition” process. The GP coating exhibited porosity and hardness gradients, which enhanced bonding strength, fracture toughness, and reduced thermal conductivity (1.05 W·m−1·K−1 at 1200 °C). Thermal shock tests revealed 34 cycles for the GP coating and 348 for the high porous (HP) coating, and the GP design narrowed the lifetime gap from 38-fold to 10-fold. Crack evolution followed a delayed failure mechanism of “crack growth–stress release–lifetime extension.” These results demonstrate that tailoring porosity gradients provides an effective strategy for improving the performance and service lifetime of ultra-thick TBCs.
{"title":"Superpower of porosity gradient: Synergistic enhancement of mechanical and thermal properties in ultra-thick TBCs","authors":"Chen Hua , Yantong Man , Taihong Huang , Rongfeng Zhou , Peng Song , Yanhong Zhuang , Tao Wang , Xiping Xiong , Qingshan Yang , Ruixiong Zhai , Tao Ma","doi":"10.1016/j.surfcoat.2025.133108","DOIUrl":"10.1016/j.surfcoat.2025.133108","url":null,"abstract":"<div><div>With the increasing demand for large temperature drops in hot-section components, ultra-thick thermal barrier coatings (TBCs) have gained increasing interest. A major challenge is achieving both mechanical robustness and low thermal conductivity in such thick layers. To address this issue, a gradient porosity design was introduced. Ultra-thick (1300 μm) YSZ TBCs were fabricated by atmospheric plasma spraying (APS) using gradient porous (GP) structure. Controlled porosity distribution was realized through a “dual-powder feeding + gradient deposition” process. The GP coating exhibited porosity and hardness gradients, which enhanced bonding strength, fracture toughness, and reduced thermal conductivity (1.05 W·m<sup>−1</sup>·K<sup>−1</sup> at 1200 °C). Thermal shock tests revealed 34 cycles for the GP coating and 348 for the high porous (HP) coating, and the GP design narrowed the lifetime gap from 38-fold to 10-fold. Crack evolution followed a delayed failure mechanism of “crack growth–stress release–lifetime extension.” These results demonstrate that tailoring porosity gradients provides an effective strategy for improving the performance and service lifetime of ultra-thick TBCs.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"521 ","pages":"Article 133108"},"PeriodicalIF":6.1,"publicationDate":"2025-12-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145841696","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 : 2025-12-22DOI: 10.1016/j.surfcoat.2025.133109
Mohammadreza Lalegani Dezaki , Kah Leng , Vikram Hastak , Nicholas Curry , Nicolas Correa Villanueva , Benjamin Evans , Tanvir Hussain
This work investigates the fabrication and microstructural evolution of tungsten–copper (WCu) functionally graded material (FGM) coatings produced using a shrouded axial-injection atmospheric plasma spray (APS) process. The central novelty of this study lies in the use of an inert-gas shrouded axial-injection APS system, which markedly suppresses in-flight oxidation and enables deposition of W-rich layers, overcoming a major limitation of conventional APS for refractory metals and allowing the formation of a continuous WCu compositional gradient. The resulting architecture exhibits a controlled transition from a Cu-rich region at the substrate interface to a W-rich layer at the coating surface. Microstructural characterisation by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and quantitative XRD revealed phase-pure W and Cu without evidence of intermetallic formation, together with a well-defined spatial gradient in elemental distribution. Through systematic adjustment of stand-off distance, gas composition, and plasma net power, it was observed that elevated net power and reduced stand-off distance improved melting efficiency and splat deformation, leading to significantly enhanced bonding and reduced porosity, particularly in W-rich sections where deposition is most sensitive to thermal input. Porosity analysis demonstrated that coatings produced under higher plasma power exhibited enhanced consolidation, with porosity decreasing from ∼2 % to ∼0.2 % in W-rich regions of the FGM after sub-solidus heat treatment at 650 °C in an argon atmosphere. Heat treatment further promoted diffusion-assisted healing of crack defects. Microhardness values reflected the compositional gradient, ranging from ∼125 HV in Cu-rich zones to ∼310 HV in W-rich regions. These findings establish shrouded APS as a viable, oxidation-controlled method for producing graded WCu coatings and provide the processing foundation for future mechanical, thermal, and functional assessment in high-temperature and plasma-facing applications.
{"title":"Functionally graded tungsten–copper coatings produced by axial injection shrouded atmospheric plasma spray","authors":"Mohammadreza Lalegani Dezaki , Kah Leng , Vikram Hastak , Nicholas Curry , Nicolas Correa Villanueva , Benjamin Evans , Tanvir Hussain","doi":"10.1016/j.surfcoat.2025.133109","DOIUrl":"10.1016/j.surfcoat.2025.133109","url":null,"abstract":"<div><div>This work investigates the fabrication and microstructural evolution of tungsten–copper (W<img>Cu) functionally graded material (FGM) coatings produced using a shrouded axial-injection atmospheric plasma spray (APS) process. The central novelty of this study lies in the use of an inert-gas shrouded axial-injection APS system, which markedly suppresses in-flight oxidation and enables deposition of W-rich layers, overcoming a major limitation of conventional APS for refractory metals and allowing the formation of a continuous W<img>Cu compositional gradient. The resulting architecture exhibits a controlled transition from a Cu-rich region at the substrate interface to a W-rich layer at the coating surface. Microstructural characterisation by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and quantitative XRD revealed phase-pure W and Cu without evidence of intermetallic formation, together with a well-defined spatial gradient in elemental distribution. Through systematic adjustment of stand-off distance, gas composition, and plasma net power, it was observed that elevated net power and reduced stand-off distance improved melting efficiency and splat deformation, leading to significantly enhanced bonding and reduced porosity, particularly in W-rich sections where deposition is most sensitive to thermal input. Porosity analysis demonstrated that coatings produced under higher plasma power exhibited enhanced consolidation, with porosity decreasing from ∼2 % to ∼0.2 % in W-rich regions of the FGM after sub-solidus heat treatment at 650 °C in an argon atmosphere. Heat treatment further promoted diffusion-assisted healing of crack defects. Microhardness values reflected the compositional gradient, ranging from ∼125 HV in Cu-rich zones to ∼310 HV in W-rich regions. These findings establish shrouded APS as a viable, oxidation-controlled method for producing graded W<img>Cu coatings and provide the processing foundation for future mechanical, thermal, and functional assessment in high-temperature and plasma-facing applications.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"521 ","pages":"Article 133109"},"PeriodicalIF":6.1,"publicationDate":"2025-12-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145841703","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 : 2025-12-22DOI: 10.1016/j.surfcoat.2025.133105
Yongchun Zou , Jiashuo Sun , Jiacheng Wang , Junji Xuan , Shuqi Wang , Guoliang Chen , Liwei Zhang , Yaming Wang
Additively manufactured porous titanium alloys are widely used in aerospace and battery fabrication field due to their excellent structural controllability and high strength. However, residual oxide films and unmelted adherent particles on surfaces during additive manufacturing degrade mechanical properties, limiting their broader application. Consequently, this work employs an environmental and efficient electrolyte plasma polishing (EPPo) technique to polish additively manufactured Ti-6Al-4 V porous materials. The surface microstructure of specimen under different polishing time was investigated by scanning electron microscopy (SEM), laser scanning microscope (LSM), transmission electron microscopy (TEM), X-ray photoelectron spectroscopy (XPS) and 3D X-ray Microscope (XRM). Results indicate that when the specimen is polished for 30 min, achieving the best quality of surface. In terms of mechanical property, ultimate tensile strength of the Ti-6Al-4 V increased from 769 ± 25 MPa to 875 ± 15 MPa. According to the in-situ XRM tensile technology, the reduced surface roughness of polished specimen makes it less prone to stress concentration, delaying the initiation of surface cracks and enhancing mechanical properties. Hence, EPPo exhibits significant potential for polishing additively manufactured porous materials.
{"title":"Electrolyte plasma polishing: A strategy for surface and mechanical enhancement of additively manufactured Ti-6Al-4 V porous materials","authors":"Yongchun Zou , Jiashuo Sun , Jiacheng Wang , Junji Xuan , Shuqi Wang , Guoliang Chen , Liwei Zhang , Yaming Wang","doi":"10.1016/j.surfcoat.2025.133105","DOIUrl":"10.1016/j.surfcoat.2025.133105","url":null,"abstract":"<div><div>Additively manufactured porous titanium alloys are widely used in aerospace and battery fabrication field due to their excellent structural controllability and high strength. However, residual oxide films and unmelted adherent particles on surfaces during additive manufacturing degrade mechanical properties, limiting their broader application. Consequently, this work employs an environmental and efficient electrolyte plasma polishing (EPPo) technique to polish additively manufactured Ti-6Al-4 V porous materials. The surface microstructure of specimen under different polishing time was investigated by scanning electron microscopy (SEM), laser scanning microscope (LSM), transmission electron microscopy (TEM), X-ray photoelectron spectroscopy (XPS) and 3D X-ray Microscope (XRM). Results indicate that when the specimen is polished for 30 min, achieving the best quality of surface. In terms of mechanical property, ultimate tensile strength of the Ti-6Al-4 V increased from 769 ± 25 MPa to 875 ± 15 MPa. According to the <em>in-situ</em> XRM tensile technology, the reduced surface roughness of polished specimen makes it less prone to stress concentration, delaying the initiation of surface cracks and enhancing mechanical properties. Hence, EPPo exhibits significant potential for polishing additively manufactured porous materials.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"521 ","pages":"Article 133105"},"PeriodicalIF":6.1,"publicationDate":"2025-12-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145885340","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 : 2025-12-21DOI: 10.1016/j.surfcoat.2025.133090
Yu Cao , Xueyun Li , Baogou Wu , Zefan Xu , Xiaohu Bing , Qian Ren , Long Wang
Porous polymer foams with engineered surface structures are of great interest for superhydrophobic and self-cleaning applications. However, most existing surface modification techniques rely on complex processing routes and provide limited control over surface porosity and morphology. In this work, we propose a simple and sustainable strategy that integrates interfacial design with supercritical carbon dioxide (scCO2) foaming. Bilayers of poly(lactic acid) (PLA) and PLA/thermoplastic polyurethane (TPU) were constructed, in which dispersed TPU domains acted as heterogeneous nucleation sites, thereby facilitating the formation of porous surfaces. The morphology and wettability of the foams were further tailored through TPU content, hot-pressing temperature, and foaming conditions. Subsequent modification with fluorinated silica nanoparticles imparted robust superhydrophobicity (water contact angle >150°, sliding angle <5°) and durable self-cleaning ability even after repeated contamination. This environmentally friendly method thus provides a scalable route to multifunctional foams and highlights the potential of interfacial design for sustainable polymer materials.
{"title":"Superhydrophobic and self-cleaning PLA/TPU foams via interfacial design and supercritical CO2 foaming","authors":"Yu Cao , Xueyun Li , Baogou Wu , Zefan Xu , Xiaohu Bing , Qian Ren , Long Wang","doi":"10.1016/j.surfcoat.2025.133090","DOIUrl":"10.1016/j.surfcoat.2025.133090","url":null,"abstract":"<div><div>Porous polymer foams with engineered surface structures are of great interest for superhydrophobic and self-cleaning applications. However, most existing surface modification techniques rely on complex processing routes and provide limited control over surface porosity and morphology. In this work, we propose a simple and sustainable strategy that integrates interfacial design with supercritical carbon dioxide (scCO<sub>2</sub>) foaming. Bilayers of poly(lactic acid) (PLA) and PLA/thermoplastic polyurethane (TPU) were constructed, in which dispersed TPU domains acted as heterogeneous nucleation sites, thereby facilitating the formation of porous surfaces. The morphology and wettability of the foams were further tailored through TPU content, hot-pressing temperature, and foaming conditions. Subsequent modification with fluorinated silica nanoparticles imparted robust superhydrophobicity (water contact angle >150°, sliding angle <5°) and durable self-cleaning ability even after repeated contamination. This environmentally friendly method thus provides a scalable route to multifunctional foams and highlights the potential of interfacial design for sustainable polymer materials.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"521 ","pages":"Article 133090"},"PeriodicalIF":6.1,"publicationDate":"2025-12-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145841695","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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