Surface & Coatings Technology最新文献_第9页

Research on the interface bonding mechanism and lifespan model of BIPV bonded structures BIPV键合结构界面键合机理及寿命模型研究

IF 6.1 2区材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS

Surface & Coatings Technology

Pub Date : 2026-02-15 Epub Date: 2026-01-12 DOI: 10.1016/j.surfcoat.2026.133164

Yonghua Zhu , Fugui Ha , Runze Zhang , Yunchuan Xie , Zhen Liu

Thermoplastic polyolefin (TPO) is widely used in automotive, waterproofing, and electrical applications due to its excellent mechanical properties, weather resistance, and chemical corrosion resistance. With the advancing refinement of solar technology, building-integrated photovoltaics (BIPV) urgently require enhanced bonding strength and durability at the adhesive interface between the TPO base layer and silicone adhesive. This study proposes a modification strategy using plasma treatment to alter the surface chemistry of TPO and improve its interaction with silicone adhesive, thereby constructing a robust and durable bonded interface. Furthermore, a computational model for predicting the service life of adhesive joints under complex external field coupling was established. The results demonstrate that the bonding strength at the interface increased from 0.23 MPa for untreated TPO to 1.25 MPa for plasma-modified TPO, while the lap shear strength improved from 0.42 MPa to 1.84 MPa. Numerical simulations and aging tests were employed to develop a generalized Eyring model for predicting the service life of the adhesive structure under combined stress-humidity-thermal conditions. The model achieved an accuracy of 98%, and the predicted service life of the joint under 45 °C and 30% RH was 18.17 years, meeting practical application requirements. This research provides theoretical support for the design of bonding strength and durability in BIPV interfaces, the formulation of engineering maintenance strategies, and the optimization of lifetime prediction standards, thereby contributing to the long-term safe operation of BIPV under the dual‑carbon goals.

热塑性聚烯烃（TPO）因其优异的机械性能、耐候性和耐化学腐蚀性而广泛应用于汽车、防水和电气应用。随着太阳能技术的不断完善，建筑集成光伏（BIPV）迫切需要提高TPO基材与有机硅胶粘剂粘合界面的粘合强度和耐久性。本研究提出了一种利用等离子体处理改变TPO表面化学性质并改善其与有机硅粘合剂相互作用的改性策略，从而构建坚固耐用的粘合界面。在此基础上，建立了复杂外场耦合作用下粘接寿命预测的计算模型。结果表明：等离子体改性TPO的界面结合强度从0.23 MPa提高到1.25 MPa，搭接剪切强度从0.42 MPa提高到1.84 MPa；通过数值模拟和老化试验，建立了粘接结构在应力-湿-热复合条件下使用寿命的广义Eyring模型。该模型的预测精度达到98%，在45°C、30% RH条件下，预测接头的使用寿命为18.17年，满足实际应用要求。本研究为BIPV界面的粘结强度和耐久性设计、工程维护策略的制定、寿命预测标准的优化提供理论支持，有助于BIPV在双碳目标下的长期安全运行。

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引用次数: 0

Competitive effects of ultrasonic surface rolling-induced textures and nanocrystallization on wear behaviors of 42CrMo steel 超声表面轧制诱导织构和纳米晶化对42CrMo钢磨损行为的竞争影响

IF 6.1 2区材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS

Surface & Coatings Technology

Pub Date : 2026-02-15 Epub Date: 2025-12-31 DOI: 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.

42CrMo钢的严重磨损容易造成电力传输不稳定、超载断裂，甚至严重的安全事故。超声波表面轧制工艺（USRP）是提高42CrMo钢摩擦学性能的一种有效方法，因为它具有梯度纳米结构和表面织构。然而，对于USRP诱导的表面织构和梯度纳米结构对摩擦学性能的改善贡献，目前还缺乏全面的认识。研究表明，USRP可以有效地在表面生成梯度纳米结构（~50 nm）和塑性变形层（~500 μm）。梯度纳米结构的详细形成机制是板条马氏体偏析和位错相交的协同作用。在磨损过程中，随着表面强化压力的增大，表面织构的功能发生了转变，从碎屑储存辅助的耐磨功能向边缘效应诱导的磨损加速功能转变。在小于1200 N的条件下，织构和梯度纳米结构诱导的磨损屑沉积协同提高了42CrMo钢的摩擦学性能。在1200n以上时，尖锐的织构所产生的边缘效应更加明显，进一步加速磨损。这些现象揭示了梯度纳米结构对增强摩擦性能的积极影响和对织构边缘损伤的消极影响之间的竞争行为。随着压力的增加，主导磨损机制发生转变：从最初的磨粒和氧化磨损到轻微的磨粒磨损并伴有保护摩擦的氧化膜，最后到严重的磨粒和氧化磨损。

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引用次数: 0

Study on the microstructure and current-carrying frictional behaviors of reactively synthesized TiO2-x/Cu/C composite coating 反应合成TiO2-x/Cu/C复合涂层的微观结构及载流摩擦行为研究

IF 6.1 2区材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS

Surface & Coatings Technology

Pub Date : 2026-02-15 Epub Date: 2026-01-04 DOI: 10.1016/j.surfcoat.2026.133154

Zekun Li , Peng Wang , Guozheng Ma , Haidou Wang , Da Zeng , Yiliang Gan , Junhong Jia

Ceramic/metal composite coating that integrate superior electrical conductivity, minimal friction coefficients and exceptional wear resistance hold significant importance in current-carrying sliding contact system. In this study, the TiO_2-x/Cu composite coating is prepared by one-step reaction using plasma spraying, and then carbon microspheres are synthesized in situ within the coating defects through hydrothermal reaction at different temperatures, fabricating the TiO_2-x/Cu/C composite coating. Results show that higher hydrothermal temperature improves the graphitization degree of carbon microspheres, and the morphology changes from aggregation to a larger spherical shape as the temperature is elevated from 160 °C to 200 °C, whereas the size of carbon microspheres decreases and severe aggregation occurs at 220 °C. Although the microhardness of the TiO_2-x/Cu/C composite coating decreases owing to the increase in surface structural defects, it increases with increasing temperature. Moreover, the electrical conductivity of the TiO_2-x/Cu/C composite coating is improved by a factor of ten compared to the TiO_2-x/Cu coating. Relatively speaking, the TiO_2-x/Cu/C composite coating exhibits optimal friction reduction and wear resistance at 200 °C, with the friction coefficient and wear rate reaching their minimum observed level. At a lower temperature of 160 °C under dry sliding condition, the composite coating is susceptible to severe adhesive wear, abrasive wear and fatigue wear simultaneously, with wear intensifying under the action of electrical current. Excitingly, a synergistic improvement in friction and wear resistance is observed for the composite coating at higher temperatures (notably 180 °C and 200 °C), regardless of dry sliding or electrical current application.

陶瓷/金属复合涂层具有优异的导电性、极小的摩擦系数和优异的耐磨性，在载流滑动触点系统中具有重要意义。本研究采用等离子喷涂一步反应法制备TiO2-x/Cu复合涂层，然后在涂层缺陷处通过不同温度的水热反应原位合成碳微球，制备TiO2-x/Cu/C复合涂层。结果表明：水热温度越高，碳微球的石墨化程度越高，随着温度从160℃升高到200℃，碳微球的形貌由聚集变为较大的球形，而在220℃时，碳微球尺寸减小，发生严重的聚集；TiO2-x/Cu/C复合涂层的显微硬度随着表面结构缺陷的增加而降低，但随着温度的升高而升高。此外，与TiO2-x/Cu/C涂层相比，TiO2-x/Cu/C复合涂层的导电性提高了十倍。相对而言，TiO2-x/Cu/C复合涂层在200℃时表现出最佳的摩擦减量和耐磨性，摩擦系数和磨损率达到了观测到的最低水平。在较低温度160℃干滑动条件下，复合涂层容易同时发生严重的粘着磨损、磨粒磨损和疲劳磨损，且在电流作用下磨损加剧。令人兴奋的是，在高温下（特别是180°C和200°C），无论干滑动或电流应用，复合涂层的摩擦和耐磨性都有协同改善。

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引用次数: 0

Enhancement of depth and properties of laser quenching strengthening layer in F92 steel by prefabricating light trapping texture 预制光捕获织构增强F92钢激光淬火强化层的深度和性能

IF 6.1 2区材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS

Surface & Coatings Technology

Pub Date : 2026-02-15 Epub Date: 2026-01-03 DOI: 10.1016/j.surfcoat.2026.133149

Peikai Luo , Guangqi Xu , Ming Zhou , Guolong Wu , Siwei Du , Haoran Sun , Yulei Feng , Yiwu Wu

F92 steel is widely used for critical components such as valves and power generation equipment, where improved surface hardness and wear resistance are required for enhanced durability. Conventional quenching methods can increase hardness; however, they often suffer from limited effective hardening depth and poor dimensional controllability. In this study, a laser quenching strategy assisted by a laser textured light trapping surface texture is proposed to enhance the depth and properties of the quenching-strengthened layer in F92 steel. The results show that, under the synergistic effect, the surface reflectivity was significantly reduced from 50.0 % in the original sample to 5.7 %, greatly improving the laser energy absorption efficiency and increasing the quenching depth from 1.0 mm to 2.5 mm. After laser quenching with surface texture, the samples exhibited finer grains, lower residual austenite content, higher dislocation density, and the formation of oxygen solid solution in matrix, compared with water quenched and directly laser quenched samples. The hardness of the sample with the light trapping texture increased to 952.8 HV_0.5 after laser quenching, while the wear rate decreased to 4.13 × 10⁻⁵ mm³·N⁻¹·m⁻¹. Overall, the laser quenched sample with light trapping surface texture exhibited the best hardness and wear resistance, providing a new approach for the surface strengthening of materials such as F92 steel.

F92钢广泛用于阀门和发电设备等关键部件，这些部件需要提高表面硬度和耐磨性以增强耐用性。常规淬火方法可提高硬度；但其有效硬化深度有限，尺寸可控性差。为了提高F92钢淬火强化层的深度和性能，提出了一种利用激光织构光捕获表面织构辅助的激光淬火策略。结果表明：在协同作用下，表面反射率从原始样品的50.0%显著降低到5.7%，激光能量吸收效率大大提高，淬火深度从1.0 mm增加到2.5 mm；经过表面织构的激光淬火后，样品的晶粒更细，残余奥氏体含量更低，位错密度更高，基体中形成了氧固溶体。激光淬火后，具有光捕获织体的样品硬度提高到952.8 HV0.5，而磨损率下降到4.13 × 10−5 mm3·N−1·m−1。综上所述，具有光捕获表面织构的激光淬火样品具有最佳的硬度和耐磨性，为F92钢等材料的表面强化提供了新的途径。

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引用次数: 0

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 非水电解液电镀γ-Ni₂Zn₁₁镀层的理论与实验研究：添加剂对镀层微观结构、织构特征和力学性能的影响

IF 6.1 2区材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS

Surface & Coatings Technology

Pub Date : 2026-02-15 Epub Date: 2025-12-31 DOI: 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.

采用实验和理论方法系统地研究了5,5-二甲基海因（DMH）和乙二胺四乙酸（EDTA）作为络合剂在电解液中的活性。采用扫描电子显微镜（SEM）、x射线衍射（XRD）和纳米压痕研究对ZnNi合金基涂层进行了表征。采用循环伏安法（CV）研究了添加和不添加添加剂时电解液的电化学行为和沉积动力学。密度泛函理论（DFT）计算表明，在dmh溶液中，从添加剂中释放Ni所需的解离能高于Zn，而在EDTA溶液中，Zn比Ni更容易解离。镍在含有EDTA的镀液中的扩散率高于含有DMH的镀液，导致EDTA镀液中镍的含量更高（~16 wt% Ni）。此外，涂层的织构分析显示，当DMH浓度从0.1 M增加到0.5 M时，涂层的首选晶体结构从{110}< 001 >变化到{001}< 100 >，这与EDTA在所有浓度下显示{110}< 001 >组分的涂层不同。

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引用次数: 0

Laser-driven, precision manufacturing of hierarchical structure surfaces enables tunable superhydrophobic/hydrophilic properties 激光驱动，分层结构表面的精密制造实现了可调的超疏水/亲水性

IF 6.1 2区材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS

Surface & Coatings Technology

Pub Date : 2026-02-15 Epub Date: 2026-01-03 DOI: 10.1016/j.surfcoat.2026.133151

Wei Wu , Kangsen Li , Changning Bai , Chi Fai Cheung , Chunjin Wang

This study demonstrates a laser-driven precision manufacturing approach for tunable wettability surfaces by direct conversion of polyimide films into laser-induced graphene (LIG) with hierarchical microstructures. By precisely controlling Ytterbium fiber laser parameters, the reversible transition between superhydrophilic (contact angle ≈ 15°) and superhydrophobic (contact angle ≈ 155°, hysteresis < 5°) states is achieved. Comprehensive characterizations reveal that the non-monotonic wettability transition results from the synergistic evolution of carbonization degree, surface chemistry, and hierarchical roughness. The grid-like LIG structures fabricated at 70 W power exhibited optimal superhydrophobicity due to their unique combination of high sp² carbon content, minimal oxygen content, moderate surface roughness (Sa = 15.27 μm), high fractal dimension (Df = 2.35), and optimal feature aspect ratio (1:4.2). The process exhibited excellent reproducibility (contact angle standard deviation <±2° across 10 samples) and environmental stability (contact angle remained >150° after 30 days of ambient exposure). This approach enables rapid, mask-free fabrication of functional surfaces with tunable wettability for applications in anti-icing, liquid transport, and microfluidic devices.

本研究展示了一种激光驱动的精密制造方法，通过将聚酰亚胺薄膜直接转化为具有分层微结构的激光诱导石墨烯（LIG），来制造可调润湿性表面。通过精确控制镱光纤激光器参数，实现了超亲水性（接触角≈15°）和超疏水性（接触角≈155°，迟滞<； 5°）态之间的可逆转变。综合表征表明，非单调润湿性转变是炭化程度、表面化学和分层粗糙度协同演化的结果。在70 W功率下制备的网格状LIG结构具有高sp2碳含量、低氧含量、中等表面粗糙度（Sa = 15.27 μm）、高分形维数（Df = 2.35）和最佳特征长宽比（1:4.2）的独特组合，具有最佳的超疏水性。该工艺具有出色的重现性（10个样品的接触角标准偏差为±2°）和环境稳定性（接触角在环境暴露30天后保持为150°）。这种方法可以快速、无掩膜地制造具有可调润湿性的功能表面，用于防冰、液体输送和微流体装置。

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引用次数: 0

Aggregating-flow-guiding synergy in micro-channel tool: A surface engineering strategy for enhanced lubrication and wear resistance 微通道工具中的聚集导流协同作用：一种增强润滑和耐磨性的表面工程策略

IF 6.1 2区材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS

Surface & Coatings Technology

Pub Date : 2026-02-15 Epub Date: 2026-01-13 DOI: 10.1016/j.surfcoat.2026.133192

Feilong Du , Fang Dai , Cheng Chen , Hengyu Ma , Tao Zhou , Hongfei Yao , Xuefeng Zhao , Lin He

Addressing the critical challenges of localized high temperatures and accelerated wear during minimum quantity lubrication (MQL) milling, this study proposes an innovative surface engineering strategy by developing a novel micro-channel tool (MCT). A micro-channel design framework, integrating computational fluid dynamics (CFD) and heat transfer theory, is established to facilitate the creation of functional surface structures on the tool rake face. A coupled simulation model investigates systematically the influence of structural parameters—including cross-sectional shape, distribution pattern, and dimension—on interfacial cooling and lubrication performance. By introducing the cross-sectional area (S_cs) of individual microchannels and the channel proportion factor (λ_c) as quantitative evaluation metrics, we elucidate the underlying mechanism of lubrication enhancement, thereby optimizing the channel configuration. Experimental validation confirms the performance enhancement effect of the external shrink (SH) microchannel. This structure connects the microgroove near the cutting edge to the tool's inner side and incorporates rectangular cross-sections with a 6° inclination. Compared to the original micro-groove tool (INT), the MCT reduces cutting force and temperature by 9.88% and 11.21%, respectively. It simultaneously improves the machined surface quality (with surface roughness Ra decreased by 10%) and extends tool service life by 18.2%. The SH-type microchannel appears to exert aggregating and flow-guiding effects, which actively manipulate the oil mist flow and thereby promote the formation of a stable lubricating film at the tool-chip interface. SEM-EDS analysis indicates that the microchannel-enabled film contributes to reduced adhesive and oxidation wear. This work establishes a pioneering “functional surface-lubricating film-wear resistance” collaborative optimization paradigm, offering a theoretical foundation for active thermal and tribological management in the high-efficiency machining of difficult-to-machine materials.

针对最小量润滑（MQL）铣削过程中局部高温和加速磨损的关键挑战，本研究提出了一种创新的表面工程策略，即开发一种新型微通道工具（MCT）。结合计算流体力学（CFD）和传热理论，建立了一种微通道设计框架，以促进工具前刀面功能表面结构的创建。耦合仿真模型系统地研究了结构参数（包括截面形状、分布模式和尺寸）对界面冷却和润滑性能的影响。通过引入单个微通道的横截面积（Scs）和通道比例因子（λc）作为定量评价指标，我们阐明了增强润滑的潜在机制，从而优化了通道结构。实验验证了外收缩微通道的性能增强效果。这种结构将切削边缘附近的微槽连接到工具的内侧，并包含6°倾斜的矩形横截面。与原始微槽刀具（INT）相比，MCT的切削力和切削温度分别降低了9.88%和11.21%。同时提高了加工表面质量（表面粗糙度Ra降低了10%），延长了刀具使用寿命18.2%。sh型微通道具有聚集和导流作用，主动操纵油雾流动，促进刀屑界面稳定润滑膜的形成。SEM-EDS分析表明，微通道薄膜有助于减少粘着和氧化磨损。这项工作建立了一个开创性的“功能性表面润滑膜-耐磨性”协同优化范例，为难加工材料的高效加工中的主动热学和摩擦学管理提供了理论基础。

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引用次数: 0

Osteoconductive composite coating of gelatin/β-TCP on Mg-Zn-Ca alloy using AC-EPD for bone regeneration 明胶/β-TCP在Mg-Zn-Ca合金上的骨导电复合涂层

IF 6.1 2区材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS

Surface & Coatings Technology

Pub Date : 2026-02-15 Epub Date: 2026-01-07 DOI: 10.1016/j.surfcoat.2026.133166

Manisha Behera , Agnès Denys , Fabrice Allain , Cosmin Gruescu , Annabel Braem , Rajashekhara Shabadi

Surface modification of magnesium (Mg) alloys offers a promising strategy to overcome their intrinsically rapid degradation and mechanical instability in physiological environments. This will address the key challenges in orthopedic and tissue engineering implants. In this study, we coated as-cast Mg-0.3Zn-0.2Ca (CZ03) alloy with an osteoconductive composite of gelatin and β-tricalcium phosphate (β-TCP) using alternating current electrophoretic deposition (AC-EPD) to address these challenges. Optimized AC-EPD parameters yielded uniform, crack-free coatings with an average thickness of ∼8 μm. FTIR analysis indicated structural interactions within the gelatin matrix during AC-EPD, consistent with enhanced coating stability without external crosslinkers. in simulated body fluid (SBF) revealed that the composite coating significantly reduced the corrosion rate by 80 % and produced a positive shift in corrosion potential, compared to the uncoated alloy. In vitro studies with MC3T3-E1 cells demonstrated significantly improved cell viability and proliferation over 6 days, while RAW-Blue™ macrophage assays revealed reduced secreted embryonic alkaline phosphatase (SEAP) activity, suggesting favourable immunomodulation. Overall, AC-EPD–derived gelatin/β-TCP coatings enhanced corrosion resistance, cytocompatibility, and immunomodulatory performance of Mg alloys, supporting their potential as biodegradable orthopedic implants.

镁合金的表面改性为克服其在生理环境中固有的快速降解和机械不稳定性提供了一种很有前途的策略。这将解决骨科和组织工程植入物的关键挑战。在本研究中，我们使用交流电电泳沉积（AC-EPD）技术将明胶和β-磷酸三钙（β-TCP）的骨导电复合材料涂覆在铸态Mg-0.3Zn-0.2Ca （CZ03）合金上，以解决这些问题。优化后的AC-EPD涂层均匀、无裂纹，平均厚度为~ 8 μm。FTIR分析表明，在AC-EPD过程中，明胶基质内部存在结构相互作用，这与没有外部交联剂的情况下涂层稳定性增强相一致。在模拟体液（SBF）中，与未涂覆合金相比，复合涂层显著降低了80%的腐蚀速率，并产生了正的腐蚀电位变化。MC3T3-E1细胞的体外研究表明，在6天内，MC3T3-E1细胞的活力和增殖能力显著提高，而RAW-Blue™巨噬细胞实验显示，分泌的胚胎碱性磷酸酶（SEAP）活性降低，表明有利的免疫调节。总的来说，ac - epd衍生明胶/β-TCP涂层增强了镁合金的耐腐蚀性、细胞相容性和免疫调节性能，支持了镁合金作为可生物降解骨科植入物的潜力。

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引用次数: 0

Role of Zn spraying amount and diffusion in governing the corrosion resistance of aluminum microchannel heat-exchange tubes 喷锌量和扩散对铝微通道换热管耐蚀性的影响

IF 6.1 2区材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS

Surface & Coatings Technology

Pub Date : 2026-02-15 Epub Date: 2026-01-09 DOI: 10.1016/j.surfcoat.2026.133168

Qiang Lu , Shenshen Cui , Dezhi Li , Haochang Chen , Feng Li , Bao Yue , Haishen Wang , Haixia Deng , Qudong Wang

The service life of aluminum alloy microchannel tubes is often severely limited by corrosion under aggressive environments. In this study, it is revealed that the Zn distribution formed in arc-sprayed coatings after brazing does not decrease monotonically with depth, but instead exhibits a distinctive subsurface concentration peak located at ∼10–22 μm beneath the surface. This unique diffusion feature fundamentally alters the corrosion mechanism: the Zn-rich subsurface layer acts as an internal sacrificial anode that preferentially dissolves, while the corrosion products retained within this region form a locally occluded, partially blocking layer that hinders ionic transport and slows further penetration into the substrate. As a result, compared with uncoated tubes, Zn-coated tubes display more uniform laminar corrosion morphologies and significantly reduced penetration depths. Moreover, the protective performance is highly sensitive to the spraying amount: insufficient Zn deposition causes heterogeneous laminar corrosion, whereas excessive Zn deposition accelerates depletion of the diffusion layer. Comprehensive analysis identifies an optimal Zn spraying amount of ∼8 g/m², which balances diffusion depth, coating uniformity, and sacrificial anode effects, thereby markedly extending the service life of aluminum alloy microchannel heat-exchange tubes.

在恶劣环境下，铝合金微通道管的使用寿命往往受到腐蚀的严重限制。本研究发现，钎焊后电弧喷涂涂层中锌的分布并不是随着深度单调减少，而是在表面以下~ 10-22 μm处呈现出明显的亚表面浓度峰。这种独特的扩散特性从根本上改变了腐蚀机制：富锌亚表层充当内部牺牲阳极，优先溶解，而保留在该区域的腐蚀产物形成局部阻塞，部分阻塞层，阻碍离子传输，减缓进一步渗透到基材中。结果表明，与未镀锌管相比，镀锌管表现出更均匀的层状腐蚀形态，并显著降低了渗透深度。此外，保护性能对喷涂量高度敏感，锌沉积不足会导致非均匀层状腐蚀，而锌沉积过多会加速扩散层的耗竭。综合分析发现，最佳喷锌量为~ 8 g/m2，可以平衡扩散深度、涂层均匀性和牺牲阳极效应，从而显著延长铝合金微通道换热管的使用寿命。

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引用次数: 0

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 Ni和Ti浓度对Fe-Cr-Ni-Ti奥氏体合金碳膨胀奥氏体碳吸收、碳化物形成、硬化和腐蚀性能的影响

IF 6.1 2区材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS

Surface & Coatings Technology

Pub Date : 2026-02-15 Epub Date: 2025-12-30 DOI: 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 (γ_C) 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_C, 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_C case is significantly thicker and harder in Fe-18Cr-18Ni-2Ti (35 μm, 1009 HV_0.3) than that in AISI 316 SS (25 μm, 450 HV_0.3). 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 γ_C, and ii) guides the development of carburizing process for specialty corrosion-resistant austenitic alloys.

低温渗碳（LTC） AISI 316 （Fe-18Cr-11Ni-3Mo, wt%）奥氏体不锈钢（SS）中无碳化物、碳过饱和膨胀奥氏体（γC）壳体因其高硬度和良好的耐腐蚀性而受到广泛关注。在基体合金中加入强碳化物形成元素（如Ti）会显著改善γ - c的硬化，但也倾向于加速碳化物的形成，从而降低耐腐蚀性。然而，增加Ni水平可以提高奥氏体组织的稳定性，并倾向于阻止渗碳表面形成碳化物，这可以通过基体中添加Ti来补偿。Fe-Cr-Ni-Me（强碳化物形成元素）奥氏体基体中Ni/Ti浓度（单独或联合）的增加对表面渗碳响应和性能的影响需要系统的研究。根据上述合金设计概念，在470°C和520°C等离子渗碳15小时后，对Fe-18Cr-18/35Ni（-2Ti）合金进行了初步研究，Fe-18Cr-18/35Ni（-2Ti）合金的Cr含量约为18 wt%， Ni含量为18/ 35wt %， Ti含量为~ 2 wt%。渗碳过程中的表面碳吸收量和表面硬度随基体Ni含量的增加而降低，随基体合金中Ti含量的增加而显著增加。在基体中添加Ni/Ti均可提高等离子渗碳表面的耐腐蚀性。当渗碳温度为470°C/15 h时，Fe-18Cr-18Ni-2Ti （35 μm, 1009 HV0.3）的γ - C层明显比AISI 316 SS （25 μm, 450 HV0.3）的γ - C层更厚、更硬。此外，高ni /Ti合金渗碳表面碳化物形成缓慢，耐蚀性较AISI 316 SS有所提高。本研究1)揭示了强化γ - c硬化同时提高耐蚀性的合金设计准则，2)指导了特种耐蚀奥氏体合金渗碳工艺的发展。

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