Pub Date : 2025-12-03DOI: 10.1016/j.surfcoat.2025.133023
Yunwei Zhu , Lixin Wei
To improve the performance of Ni-based coatings, Ni–W–TiN nanocomposite coatings with micro-pitted surfaces were fabricated on #45 steel by three electrodeposition techniques: pulse electrodeposition (PE), jet electrodeposition (JE), and ultrasonic-assisted jet electrodeposition (UAJE). Coatings obtained by UAJE showed the densest microstructure, the smoothest surface (RMS roughness ≈ 90 nm), the highest microhardness (659.1 Hv at 3 A·dm−2), and the lowest wear mass loss (3.1 mg). Compared with PE and JE, UAJE coatings also exhibited markedly improved tribological behavior, with a minimum friction coefficient of 0.47. XRD and TEM analyses confirmed enhanced crystallinity and uniform dispersion of TiN nanoparticles in the UAJE coatings. In 3.5 wt% NaCl solution, UAJE coatings achieved the lowest corrosion current density (5.146 μA·cm−2) and corrosion rate (0.061 mm·year−1), and SEM observations after corrosion revealed only slight surface degradation. These results demonstrate that UAJE is an efficient route to produce dense, durable Ni–W–TiN coatings with superior mechanical, tribological, and corrosion-resistant properties.
{"title":"The influence of deposition methods on the structure and properties of Ni-W-TiN nano-composite coatings with micro-pitted shapes","authors":"Yunwei Zhu , Lixin Wei","doi":"10.1016/j.surfcoat.2025.133023","DOIUrl":"10.1016/j.surfcoat.2025.133023","url":null,"abstract":"<div><div>To improve the performance of Ni-based coatings, Ni–W–TiN nanocomposite coatings with micro-pitted surfaces were fabricated on #45 steel by three electrodeposition techniques: pulse electrodeposition (PE), jet electrodeposition (JE), and ultrasonic-assisted jet electrodeposition (UAJE). Coatings obtained by UAJE showed the densest microstructure, the smoothest surface (RMS roughness ≈ 90 nm), the highest microhardness (659.1 Hv at 3 A·dm<sup>−2</sup>), and the lowest wear mass loss (3.1 mg). Compared with PE and JE, UAJE coatings also exhibited markedly improved tribological behavior, with a minimum friction coefficient of 0.47. XRD and TEM analyses confirmed enhanced crystallinity and uniform dispersion of TiN nanoparticles in the UAJE coatings. In 3.5 wt% NaCl solution, UAJE coatings achieved the lowest corrosion current density (5.146 μA·cm<sup>−2</sup>) and corrosion rate (0.061 mm·year<sup>−1</sup>), and SEM observations after corrosion revealed only slight surface degradation. These results demonstrate that UAJE is an efficient route to produce dense, durable Ni–W–TiN coatings with superior mechanical, tribological, and corrosion-resistant properties.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"520 ","pages":"Article 133023"},"PeriodicalIF":6.1,"publicationDate":"2025-12-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145790654","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}
We report the fabrication of ultrathin (10 nm) Cu2O films via a superimposed high-power impulse magnetron sputtering (HiPIMS) process, combining HiPIMS and middle-frequency (MF) pulses to enable precise control over film properties, thus promoting sustainable manufacturing goals. The Cu2O layers exhibited stable p-type conductivity above an oxygen flow ratio (fO2) of 17.5 %. To enhance interfacial quality, a NiOx overlayer was introduced by sol-gel deposition, forming an all-inorganic Cu2O/NiOx double-layer hole transport layer (HTL) for p-i-n perovskite solar cells (PSCs). This architecture effectively mitigates interfacial defect states at the Cu2O + NiOx/perovskite, improves carrier extraction, and boosts device stability. Optimized devices incorporating Cu2O films deposited at fO2 = 35 % achieved a power conversion efficiency of 20.15 %. Remarkably, after 1000 h of storage in a glove box, the devices retained 99.4 % of their initial efficiency. These results establish HiPIMS-deposited Cu2O as a scalable and robust building block for high-performance inorganic HTLs, advancing both efficiency and long-term stability in perovskite photovoltaic, aligning with clean and efficient energy technologies.
{"title":"HiPIMS-engineered Cu2O/NiOx double-layer hole transport layers for high-efficiency and stable p-i-n perovskite solar cells","authors":"Yin-Hung Chen , Shikha Akshay Joshi , Zhong-En Shi , Chao-Kuang Wen , Tung-Han Chuang , Chi-Wei Lin , Sheng-Chi Chen , Chih-Ping Chen","doi":"10.1016/j.surfcoat.2025.133024","DOIUrl":"10.1016/j.surfcoat.2025.133024","url":null,"abstract":"<div><div>We report the fabrication of ultrathin (10 nm) Cu<sub>2</sub>O films via a superimposed high-power impulse magnetron sputtering (HiPIMS) process, combining HiPIMS and middle-frequency (MF) pulses to enable precise control over film properties, thus promoting sustainable manufacturing goals. The Cu<sub>2</sub>O layers exhibited stable p-type conductivity above an oxygen flow ratio (f<sub>O2</sub>) of 17.5 %. To enhance interfacial quality, a NiO<sub>x</sub> overlayer was introduced by sol-gel deposition, forming an all-inorganic Cu<sub>2</sub>O/NiO<sub>x</sub> double-layer hole transport layer (HTL) for p-i-n perovskite solar cells (PSCs). This architecture effectively mitigates interfacial defect states at the Cu<sub>2</sub>O + NiO<sub>x</sub>/perovskite, improves carrier extraction, and boosts device stability. Optimized devices incorporating Cu<sub>2</sub>O films deposited at f<sub>O2</sub> = 35 % achieved a power conversion efficiency of 20.15 %. Remarkably, after 1000 h of storage in a glove box, the devices retained 99.4 % of their initial efficiency. These results establish HiPIMS-deposited Cu<sub>2</sub>O as a scalable and robust building block for high-performance inorganic HTLs, advancing both efficiency and long-term stability in perovskite photovoltaic, aligning with clean and efficient energy technologies.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"520 ","pages":"Article 133024"},"PeriodicalIF":6.1,"publicationDate":"2025-12-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145736990","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 : 2025-12-02DOI: 10.1016/j.surfcoat.2025.133025
Hou-Chin Cha , Shih-Han Cheng , Chia-Feng Li , Ssu-Yung Chung , Pin-Hao Zhao , Yun-Ming Sung , Yu-Ching Huang
Organic photovoltaics (OPVs) have emerged as promising power sources for the next generation of self-powered electronics and Internet-of-Things (IoT) systems, yet their industrial translation is limited by slow processing, poor interface control, and reduced efficiency under low-light conditions. Here, we demonstrate a scalable fabrication strategy that unites slot-die coating, intense pulsed light (IPL) annealing, and interfacial molecular engineering to produce high-performance inverted OPVs optimized for indoor energy harvesting. The ZnO electron transport layer (ETL) prepared by IPL achieves full crystallization within seconds, reducing processing time by a factor of seven compared to conventional thermal annealing. Surface modification of ZnO with a polyethyleneimine ethoxylated (PEIE) interlayer further aligns energy levels, passivates oxygen defects, and enhances charge extraction. The combined process yields an indoor power conversion efficiency (PCE) of 14 % at 300 lx, compared to 10 % for unmodified devices, while maintaining full compatibility with sheet-to-sheet slot-die coating at low substrate temperatures (60 °C). This integrated approach establishes a rapid, low-cost, and industrially scalable route for fabricating efficient indoor OPVs, bridging the gap between laboratory-scale optimization and large-scale energy harvesting technologies.
{"title":"Ultrafast processed electron transport layers enable high-efficiency slot-die coated indoor organic photovoltaics","authors":"Hou-Chin Cha , Shih-Han Cheng , Chia-Feng Li , Ssu-Yung Chung , Pin-Hao Zhao , Yun-Ming Sung , Yu-Ching Huang","doi":"10.1016/j.surfcoat.2025.133025","DOIUrl":"10.1016/j.surfcoat.2025.133025","url":null,"abstract":"<div><div>Organic photovoltaics (OPVs) have emerged as promising power sources for the next generation of self-powered electronics and Internet-of-Things (IoT) systems, yet their industrial translation is limited by slow processing, poor interface control, and reduced efficiency under low-light conditions. Here, we demonstrate a scalable fabrication strategy that unites slot-die coating, intense pulsed light (IPL) annealing, and interfacial molecular engineering to produce high-performance inverted OPVs optimized for indoor energy harvesting. The ZnO electron transport layer (ETL) prepared by IPL achieves full crystallization within seconds, reducing processing time by a factor of seven compared to conventional thermal annealing. Surface modification of ZnO with a polyethyleneimine ethoxylated (PEIE) interlayer further aligns energy levels, passivates oxygen defects, and enhances charge extraction. The combined process yields an indoor power conversion efficiency (PCE) of 14 % at 300 lx, compared to 10 % for unmodified devices, while maintaining full compatibility with sheet-to-sheet slot-die coating at low substrate temperatures (60 °C). This integrated approach establishes a rapid, low-cost, and industrially scalable route for fabricating efficient indoor OPVs, bridging the gap between laboratory-scale optimization and large-scale energy harvesting technologies.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"520 ","pages":"Article 133025"},"PeriodicalIF":6.1,"publicationDate":"2025-12-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145682844","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 : 2025-12-02DOI: 10.1016/j.surfcoat.2025.133012
Camelia Gabor , Vasile-Adrian Surdu , Ioana Borsan , Mihai Alin Pop , Filipe Vaz , Daniel Munteanu
The properties of a certain compound developed as a thin film can be influenced either by modifying the composition (mass ratio of the constituent elements) or, for a certain composition, by modifying the structural architecture. TiN compound, developed as a thin film, is well known, especially for its mechanical and tribological properties. For its stoichiometric aspect, it was found that modifying the structural design of the compound can expand its application area (from the perspective of thermal, electrical, optical properties). It is of particular interest to investigate the consequences of these structural architectural modifications taking into account the potential reduction in mechanical and tribological performance.
This study focuses on the preparation of nanostructured thin films and the tailoring of their properties by employing inclined and zigzag-like growth architectures. To achieve this, TiN thin films were deposited on stainless steel and silicon substrates using Oblique Angle Deposition (OAD) with a DC reactive magnetron sputtering system.
The mechanical and tribological properties of the films were found to be strongly influenced by their roughness and porosity values evolution, which resulted from the specific characteristics of the OAD geometry. As the deposition configuration shifted from conventional growth geometry (normal incidence) to OAD with inclined and zigzag geometries, both surface porosity and roughness values increased significantly due to the shadowing effect and comparatively low thermalization degrees. This led to a noticeable decrease in hardness and Young's modulus values, friction coefficient and wear rates, along with a reduced scratch resistance of the thin films. However, the values obtained were consistent with those reported in the literature, confirming the thin films' good applicability and suitability for a variety of applications. Hardness/Young's modulus values varied from about 27/260 GPa for the samples grown in the conventional geometry, reducing to approximately 13/210 GPa and about 10/190 GPa for the inclined and zigzag grown TiN films, respectively. The same reduction trend was also observed in the adhesion behaviour, where a decrease of about 50 % was observed for the critical loads (Lc2 and Lc3) when going from conventional to inclined and from this last to zigzag growth geometries. Finally, and keeping this tendency to a slight degradation of the mechanical and tribological behaviour, the friction coefficient, μ, increased from 0.20 for the conventional grown TiN sample to about 0.69 and 0.81 for the inclined and zigzag grown TiN sets.
{"title":"The influence of the structural design on the mechanical and tribological properties of TiN thin films prepared by reactive magnetron sputtering","authors":"Camelia Gabor , Vasile-Adrian Surdu , Ioana Borsan , Mihai Alin Pop , Filipe Vaz , Daniel Munteanu","doi":"10.1016/j.surfcoat.2025.133012","DOIUrl":"10.1016/j.surfcoat.2025.133012","url":null,"abstract":"<div><div>The properties of a certain compound developed as a thin film can be influenced either by modifying the composition (mass ratio of the constituent elements) or, for a certain composition, by modifying the structural architecture. TiN compound, developed as a thin film, is well known, especially for its mechanical and tribological properties. For its stoichiometric aspect, it was found that modifying the structural design of the compound can expand its application area (from the perspective of thermal, electrical, optical properties). It is of particular interest to investigate the consequences of these structural architectural modifications taking into account the potential reduction in mechanical and tribological performance.</div><div>This study focuses on the preparation of nanostructured thin films and the tailoring of their properties by employing inclined and zigzag-like growth architectures. To achieve this, TiN thin films were deposited on stainless steel and silicon substrates using Oblique Angle Deposition (OAD) with a DC reactive magnetron sputtering system.</div><div>The mechanical and tribological properties of the films were found to be strongly influenced by their roughness and porosity values evolution, which resulted from the specific characteristics of the OAD geometry. As the deposition configuration shifted from conventional growth geometry (normal incidence) to OAD with inclined and zigzag geometries, both surface porosity and roughness values increased significantly due to the shadowing effect and comparatively low thermalization degrees. This led to a noticeable decrease in hardness and Young's modulus values, friction coefficient and wear rates, along with a reduced scratch resistance of the thin films. However, the values obtained were consistent with those reported in the literature, confirming the thin films' good applicability and suitability for a variety of applications. Hardness/Young's modulus values varied from about 27/260 GPa for the samples grown in the conventional geometry, reducing to approximately 13/210 GPa and about 10/190 GPa for the inclined and zigzag grown TiN films, respectively. The same reduction trend was also observed in the adhesion behaviour, where a decrease of about 50 % was observed for the critical loads (Lc<sub>2</sub> and Lc<sub>3</sub>) when going from conventional to inclined and from this last to zigzag growth geometries. Finally, and keeping this tendency to a slight degradation of the mechanical and tribological behaviour, the friction coefficient, μ, increased from 0.20 for the conventional grown TiN sample to about 0.69 and 0.81 for the inclined and zigzag grown TiN sets.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"520 ","pages":"Article 133012"},"PeriodicalIF":6.1,"publicationDate":"2025-12-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145682838","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 : 2025-12-01DOI: 10.1016/j.surfcoat.2025.133014
Yunlong Lei , Kang Yang , Minmin Xu , Shihong Zhang , Baohong Tong , Xia Liu , Yang Yang
Plasma nitriding was employed to fabricate nitrided layers on the surface of AlCoCrMoNi high-entropy alloy coatings. The high-temperature wear and hot corrosion behaviors of the nitrided coatings were systematically evaluated and compared with those of the as-sprayed counterparts. The results reveal that nitriding significantly enhances the coating hardness, increasing from 606.6 HV0.3 in the as-sprayed state to 1005.96 HV0.3 after nitriding. Correspondingly, the nitrided coating exhibits markedly improved wear resistance. During high-temperature wear, the formation of Cr- and Mo-rich oxide films enables the coating nitrided for 16 h to achieve the lowest wear rate (5.61 × 10−7 mm3/N·m). The wear mechanism of the as-sprayed coating is mainly characterized by oxidative wear accompanied by slight abrasive wear, whereas the nitrided coating predominantly undergoes oxidative wear. Hot corrosion tests further demonstrate that the coating nitrided for 24 h exhibits the best corrosion resistance. The formation of a continuous and dense Al2O3 film, together with an underlying Cr-rich layer, effectively suppresses the inward diffusion of oxygen. However, excessive nitriding duration leads to spallation of the nitrided layer during hot corrosion, thereby diminishing its long-term protective capability.
{"title":"High-temperature wear and hot corrosion mechanisms of nitrided AlCoCrMoNi high-entropy alloy coatings","authors":"Yunlong Lei , Kang Yang , Minmin Xu , Shihong Zhang , Baohong Tong , Xia Liu , Yang Yang","doi":"10.1016/j.surfcoat.2025.133014","DOIUrl":"10.1016/j.surfcoat.2025.133014","url":null,"abstract":"<div><div>Plasma nitriding was employed to fabricate nitrided layers on the surface of AlCoCrMoNi high-entropy alloy coatings. The high-temperature wear and hot corrosion behaviors of the nitrided coatings were systematically evaluated and compared with those of the as-sprayed counterparts. The results reveal that nitriding significantly enhances the coating hardness, increasing from 606.6 HV<sub>0.3</sub> in the as-sprayed state to 1005.96 HV<sub>0.3</sub> after nitriding. Correspondingly, the nitrided coating exhibits markedly improved wear resistance. During high-temperature wear, the formation of Cr- and Mo-rich oxide films enables the coating nitrided for 16 h to achieve the lowest wear rate (5.61 × 10<sup>−7</sup> mm<sup>3</sup>/N·m). The wear mechanism of the as-sprayed coating is mainly characterized by oxidative wear accompanied by slight abrasive wear, whereas the nitrided coating predominantly undergoes oxidative wear. Hot corrosion tests further demonstrate that the coating nitrided for 24 h exhibits the best corrosion resistance. The formation of a continuous and dense Al<sub>2</sub>O<sub>3</sub> film, together with an underlying Cr-rich layer, effectively suppresses the inward diffusion of oxygen. However, excessive nitriding duration leads to spallation of the nitrided layer during hot corrosion, thereby diminishing its long-term protective capability.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"520 ","pages":"Article 133014"},"PeriodicalIF":6.1,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145682784","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 : 2025-12-01DOI: 10.1016/j.surfcoat.2025.133010
Leonardo Piccolo , Leonardo Cecotto , Luca Donazzolo , Artur Hoxha , Francesco Fabbro , Silvano Rech , Saber Amin Yavari , Sara Bagherifard
In response to escalating hygiene concerns, we propose a novel strategy to reduce bacterial adhesion on consumer-grade plastic surfaces (e.g. consumer electronics). Herein, we develop, for the first time in an industrial environment, a process chain using infrared ultrafast laser texturing to create controlled nanotextures that can influence bacterial colonization on plastic surfaces. First, four distinct nanotextures are developed through femtosecond laser patterning on steel at a pulse energy of 0.62, 0.25, and 0.29 μJ. Secondly, high-resolution injection molding using variothermal molding technology is exploited for the precise fabrication of nanotextured polymer. Detailed surface characterization through scanning electron microscopy and atomic force microscopy was carried out to characterize the obtained nanotextures. The nanomorphology performance was assessed through bacterial adhesion characterization, analyzing the surface early interaction with Staphylococcus aureus. The results show that the process can produce nanotexture with periodicity down to 270 nm, roughness (Sa) up to 110 nm and surface sharpness (Sdq – root mean square gradient) up to 1.5, providing promising indications of a 60 % reduction in adhering bacteria. The results testify the potential of the developed process chain to be used as a scalable, accurate, environmentally friendly and flexible nanotexturing approach against bacterial adhesion on polymer surfaces.
{"title":"A process chain leveraging femtosecond laser induced nanotextures towards mitigating Staphylococcus aureus adhesion on plastic surfaces","authors":"Leonardo Piccolo , Leonardo Cecotto , Luca Donazzolo , Artur Hoxha , Francesco Fabbro , Silvano Rech , Saber Amin Yavari , Sara Bagherifard","doi":"10.1016/j.surfcoat.2025.133010","DOIUrl":"10.1016/j.surfcoat.2025.133010","url":null,"abstract":"<div><div>In response to escalating hygiene concerns, we propose a novel strategy to reduce bacterial adhesion on consumer-grade plastic surfaces (e.g. consumer electronics). Herein, we develop, for the first time in an industrial environment, a process chain using infrared ultrafast laser texturing to create controlled nanotextures that can influence bacterial colonization on plastic surfaces. First, four distinct nanotextures are developed through femtosecond laser patterning on steel at a pulse energy of 0.62, 0.25, and 0.29 μJ. Secondly, high-resolution injection molding using variothermal molding technology is exploited for the precise fabrication of nanotextured polymer. Detailed surface characterization through scanning electron microscopy and atomic force microscopy was carried out to characterize the obtained nanotextures. The nanomorphology performance was assessed through bacterial adhesion characterization, analyzing the surface early interaction with <em>Staphylococcus aureus</em>. The results show that the process can produce nanotexture with periodicity down to 270 nm, roughness (Sa) up to 110 nm and surface sharpness (Sdq – root mean square gradient) up to 1.5, providing promising indications of a 60 % reduction in adhering bacteria. The results testify the potential of the developed process chain to be used as a scalable, accurate, environmentally friendly and flexible nanotexturing approach against bacterial adhesion on polymer surfaces.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"520 ","pages":"Article 133010"},"PeriodicalIF":6.1,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145682780","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 : 2025-12-01DOI: 10.1016/j.surfcoat.2025.133011
Jaehyeon Kim , N. Rahul , Sang Won Lee , Min-Suk Oh
Conventional AlSi coated steels rely on Al2O3 passive films for corrosion and heat resistance; however, prolonged high-temperature exposure often results in Fe diffusion, intermetallic layer growth, and Fe2O3 formation, which compromise their protective capabilities. This study addresses these limitations by enhancing the high-temperature corrosion resistance of AlSi coated steel through Cr thin-film deposition via physical vapor deposition followed by heat treatment. Specifically, a 300-nm Cr thin film was deposited on commercial AlSi coated steel and heat treated at 600 °C, resulting in the formation of AlCr and CrSi alloy phases at the surface. Microstructural analyses demonstrated that the Cr layer and its alloy phases improved surface stability after thermal exposure, and strengthened adhesion between coating and substrate. The root mean square roughness (Rrms) for uncoated specimens increased markedly after exposure, whereas the Cr-coated and heat-treated specimens showed almost no increase. Adhesion was improved, as the peeling area in tape tests dropped from 91.5 % for Cr-only specimens to just 7.7 % after heat treatment. Thermogravimetric, electrochemical, and salt spray tests confirmed that ASC-600 specimens had the lowest oxidation weight gain and best corrosion resistance. TEM confirmed that dense Cr2O3 and α-Al2O3 films acted as barriers, highlighting the effectiveness of this approach for durable industrial coatings.
{"title":"Enhanced high-temperature corrosion resistance of AlSi coated steel via Cr thin-film deposition and alloy phase formation","authors":"Jaehyeon Kim , N. Rahul , Sang Won Lee , Min-Suk Oh","doi":"10.1016/j.surfcoat.2025.133011","DOIUrl":"10.1016/j.surfcoat.2025.133011","url":null,"abstract":"<div><div>Conventional Al<img>Si coated steels rely on Al<sub>2</sub>O<sub>3</sub> passive films for corrosion and heat resistance; however, prolonged high-temperature exposure often results in Fe diffusion, intermetallic layer growth, and Fe<sub>2</sub>O<sub>3</sub> formation, which compromise their protective capabilities. This study addresses these limitations by enhancing the high-temperature corrosion resistance of Al<img>Si coated steel through Cr thin-film deposition via physical vapor deposition followed by heat treatment. Specifically, a 300-nm Cr thin film was deposited on commercial Al<img>Si coated steel and heat treated at 600 °C, resulting in the formation of Al<img>Cr and Cr<img>Si alloy phases at the surface. Microstructural analyses demonstrated that the Cr layer and its alloy phases improved surface stability after thermal exposure, and strengthened adhesion between coating and substrate. The root mean square roughness (Rrms) for uncoated specimens increased markedly after exposure, whereas the Cr-coated and heat-treated specimens showed almost no increase. Adhesion was improved, as the peeling area in tape tests dropped from 91.5 % for Cr-only specimens to just 7.7 % after heat treatment. Thermogravimetric, electrochemical, and salt spray tests confirmed that ASC-600 specimens had the lowest oxidation weight gain and best corrosion resistance. TEM confirmed that dense Cr<sub>2</sub>O<sub>3</sub> and α-Al<sub>2</sub>O<sub>3</sub> films acted as barriers, highlighting the effectiveness of this approach for durable industrial coatings.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"520 ","pages":"Article 133011"},"PeriodicalIF":6.1,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145682845","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 : 2025-11-30DOI: 10.1016/j.surfcoat.2025.133007
Mingju Chen , Hang Liang , Guanghai Bai , Biao Chen , William Yi Wang , Jun Wang , Jinshan Li
Chromium (Cr) coatings on Zircaloy alloys are a leading candidate for accident tolerant fuel (ATF) cladding, where their performance under normal and loss-of-coolant accident (LOCA) conditions is governed by microstructure and defects. This work systematically investigates the effect of substrate bias (−30 V, −70 V, and −110 V) on the microstructure and mechanical properties of Cr coatings. Results demonstrate that increasing bias promotes significant grain coarsening within the coatings while concurrently reducing the density of internal defects. This phenomenon is attributed to the enhanced adatom surface diffusion induced by higher bias, which progressively mitigates the shadowing effect during deposition. Based on these findings, a mechanistic model elucidating the relationship between bias and coating growth evolution is established, providing a valuable reference for the practical design and optimization of Cr coatings for advanced nuclear fuel cladding applications.
{"title":"Effect of substrate bias on the microstructure, defect evolution and mechanical properties of Cr coatings during magnetron sputtering","authors":"Mingju Chen , Hang Liang , Guanghai Bai , Biao Chen , William Yi Wang , Jun Wang , Jinshan Li","doi":"10.1016/j.surfcoat.2025.133007","DOIUrl":"10.1016/j.surfcoat.2025.133007","url":null,"abstract":"<div><div>Chromium (Cr) coatings on Zircaloy alloys are a leading candidate for accident tolerant fuel (ATF) cladding, where their performance under normal and loss-of-coolant accident (LOCA) conditions is governed by microstructure and defects. This work systematically investigates the effect of substrate bias (−30 V, −70 V, and −110 V) on the microstructure and mechanical properties of Cr coatings. Results demonstrate that increasing bias promotes significant grain coarsening within the coatings while concurrently reducing the density of internal defects. This phenomenon is attributed to the enhanced adatom surface diffusion induced by higher bias, which progressively mitigates the shadowing effect during deposition. Based on these findings, a mechanistic model elucidating the relationship between bias and coating growth evolution is established, providing a valuable reference for the practical design and optimization of Cr coatings for advanced nuclear fuel cladding applications.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"520 ","pages":"Article 133007"},"PeriodicalIF":6.1,"publicationDate":"2025-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145682781","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}
Some applications of duplex stainless steels (DSS) demand wear resistance. To meet this requirement, innovative surface treatments are being implemented. The aim of this paper is to study the effects of laser shock peening without coating (LSPwC) on the microstructure of DSS SAF 2507 and its related tribological behavior. For this purpose, residual stress, roughness, microhardness and microstructure were evaluated. Tribological ball-on-disk tests were performed at room temperature, without lubricant and at constants speed and load using alumina balls as counterpart. LSPwC induces surface oxidation and compressive residual stresses (CRS), but it does not produce appreciable changes in roughness, microhardness or microstructure. During sliding, oxide particles caused an abrasive wear mechanism which is more pronounced in the AR material. The LSPwC material exhibits lower COF, weight loss and specific wear rate than the AR one. This could be rationalized by the earlier establishment of a protective CRS field in LSPwC material.
双相不锈钢（DSS）的一些应用要求具有耐磨性。为了满足这一要求，正在实施创新的表面处理。研究了无涂层激光冲击强化（LSPwC）对DSS SAF 2507显微组织及其摩擦学行为的影响。为此，对残余应力、粗糙度、显微硬度和显微组织进行了评价。摩擦球盘试验在室温下进行，无润滑剂，在恒定的速度和负载下，使用氧化铝球作为对应物。LSPwC诱导表面氧化和压缩残余应力（CRS），但不产生明显的粗糙度、显微硬度或微观结构的变化。在滑动过程中，氧化物颗粒引起磨料磨损机制，这在AR材料中更为明显。与AR材料相比，LSPwC材料具有更低的COF、重量损失和比磨损率。这可以通过早期在LSPwC材料中建立保护性CRS场来合理化。
{"title":"Influence of laser shock processing without coating on the microstructure and tribological behavior of super duplex stainless steel","authors":"Josefina Dib , Renata Strubbia , Carlos Rubio González , Gilberto Gómez Rosas , Nadia Álvarez , Miguel Vicente Álvarez , Silvina Hereñú","doi":"10.1016/j.surfcoat.2025.133002","DOIUrl":"10.1016/j.surfcoat.2025.133002","url":null,"abstract":"<div><div>Some applications of duplex stainless steels (DSS) demand wear resistance. To meet this requirement, innovative surface treatments are being implemented. The aim of this paper is to study the effects of laser shock peening without coating (LSPwC) on the microstructure of DSS SAF 2507 and its related tribological behavior. For this purpose, residual stress, roughness, microhardness and microstructure were evaluated. Tribological ball-on-disk tests were performed at room temperature, without lubricant and at constants speed and load using alumina balls as counterpart. LSPwC induces surface oxidation and compressive residual stresses (CRS), but it does not produce appreciable changes in roughness, microhardness or microstructure. During sliding, oxide particles caused an abrasive wear mechanism which is more pronounced in the AR material. The LSPwC material exhibits lower COF, weight loss and specific wear rate than the AR one. This could be rationalized by the earlier establishment of a protective CRS field in LSPwC material.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"520 ","pages":"Article 133002"},"PeriodicalIF":6.1,"publicationDate":"2025-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145682846","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 : 2025-11-30DOI: 10.1016/j.surfcoat.2025.133009
Kiran Judd , Kyle Tsaknopoulos , Caroline Dowling , Thomas L. Christiansen , Danielle Cote
Titanium alloys, such as Ti-6Al-4V, are advantageous due to their high strength-to-weight ratio and excellent corrosion resistance. High pressure cold spray additive manufacturing (CSAM) and coating/repair processes have provided low-cost methods for new part production and restoration of damaged components. However, Ti-6Al-4V cold spray has presented challenges due to the alloy's high yield strength and increased resistance to plastically deform during deposition. Consequently, this study aspires to optimize the cold spray deposition process of virgin and recycled Ti-6Al-4V feedstock powders through tailored particle thermal treatments. Powder heat treatment parameters were informed and developed from limited results within literature. Feedstock powder and cold spray deposit characterization methods included chemical analysis, scanning electron microscopy (SEM), X-ray diffraction (XRD), particle size distribution analysis (PSD), Karl Fischer Titration moisture content analysis, powder particle compression testing, optical microscopy, porosity quantification, Vickers microindentation, and nanoindentation. Results indicate that heat treating both virgin and recycled Ti-6Al-4V powders prior to deposition can achieve reduced strength in the powder by promoting an α' → α + β phase transformation, thereby enhancing cold spray performance. Improved cold spray performance was verified by an observed increase in coating density with no reduction in bulk mechanical properties. This work demonstrates that heat-treatment of Ti-6Al-4V powder is possible without irreversible sintering and can be successfully utilized to improve cold spray deposition through increased plastic deformation and particle flattening.
{"title":"Thermal treatments of recycled and virgin Ti-6Al-4V feedstock powders for improved cold spray deposition","authors":"Kiran Judd , Kyle Tsaknopoulos , Caroline Dowling , Thomas L. Christiansen , Danielle Cote","doi":"10.1016/j.surfcoat.2025.133009","DOIUrl":"10.1016/j.surfcoat.2025.133009","url":null,"abstract":"<div><div>Titanium alloys, such as Ti-6Al-4V, are advantageous due to their high strength-to-weight ratio and excellent corrosion resistance. High pressure cold spray additive manufacturing (CSAM) and coating/repair processes have provided low-cost methods for new part production and restoration of damaged components. However, Ti-6Al-4V cold spray has presented challenges due to the alloy's high yield strength and increased resistance to plastically deform during deposition. Consequently, this study aspires to optimize the cold spray deposition process of virgin and recycled Ti-6Al-4V feedstock powders through tailored particle thermal treatments. Powder heat treatment parameters were informed and developed from limited results within literature. Feedstock powder and cold spray deposit characterization methods included chemical analysis, scanning electron microscopy (SEM), X-ray diffraction (XRD), particle size distribution analysis (PSD), Karl Fischer Titration moisture content analysis, powder particle compression testing, optical microscopy, porosity quantification, Vickers microindentation, and nanoindentation. Results indicate that heat treating both virgin and recycled Ti-6Al-4V powders prior to deposition can achieve reduced strength in the powder by promoting an α' → α + β phase transformation, thereby enhancing cold spray performance. Improved cold spray performance was verified by an observed increase in coating density with no reduction in bulk mechanical properties. This work demonstrates that heat-treatment of Ti-6Al-4V powder is possible without irreversible sintering and can be successfully utilized to improve cold spray deposition through increased plastic deformation and particle flattening.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"520 ","pages":"Article 133009"},"PeriodicalIF":6.1,"publicationDate":"2025-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145682842","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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