Pub Date : 2026-01-10DOI: 10.1016/j.surfcoat.2026.133185
Yangguang Cheng , Hao Yi , Junwei Yang , Huajun Cao , Runsheng Li
This study investigates the integration of ultrasonic vibration (UV) into Cored Wire Arc Additive Manufacturing (CWAAM) for fabricating WC/316 L stainless steel composite coatings, aiming to leverage the synergistic effects of the UV energy field and arc thermal-force field to refine the microstructure and improve wear performance. Results demonstrate that UV application significantly refined the grain structure, reducing the average grain size from 105.4 μm to 57.9 μm, and promoted a more uniform distribution of WC particles and precipitated phases. This microstructural improvement led to enhanced solid solution strengthening and increased microhardness from 395.2 ± 17.4 HV to 454.2 ± 11.9 HV. Tribological tests revealed a substantial improvement in wear resistance, with the average friction coefficient decreased by 14.06% and the wear volume reduced by 27.58% under UV treatment. Furthermore, both adhesive and abrasive wear were mitigated, while the local effect of oxidative wear becomes more pronounced. These findings confirm that UV-assisted CWAAM effectively enhances the mechanical properties and wear performance of WC/316 L composite coatings, providing a viable approach for producing high-performance wear-resistant surfaces.
{"title":"Ultrasonic vibration-assisted cored wire arc additive manufacturing of WC-reinforced 316 L composite coatings: Microstructure and wear performance","authors":"Yangguang Cheng , Hao Yi , Junwei Yang , Huajun Cao , Runsheng Li","doi":"10.1016/j.surfcoat.2026.133185","DOIUrl":"10.1016/j.surfcoat.2026.133185","url":null,"abstract":"<div><div>This study investigates the integration of ultrasonic vibration (UV) into Cored Wire Arc Additive Manufacturing (CWAAM) for fabricating WC/316 L stainless steel composite coatings, aiming to leverage the synergistic effects of the UV energy field and arc thermal-force field to refine the microstructure and improve wear performance. Results demonstrate that UV application significantly refined the grain structure, reducing the average grain size from 105.4 μm to 57.9 μm, and promoted a more uniform distribution of WC particles and precipitated phases. This microstructural improvement led to enhanced solid solution strengthening and increased microhardness from 395.2 ± 17.4 HV to 454.2 ± 11.9 HV. Tribological tests revealed a substantial improvement in wear resistance, with the average friction coefficient decreased by 14.06% and the wear volume reduced by 27.58% under UV treatment. Furthermore, both adhesive and abrasive wear were mitigated, while the local effect of oxidative wear becomes more pronounced. These findings confirm that UV-assisted CWAAM effectively enhances the mechanical properties and wear performance of WC/316 L composite coatings, providing a viable approach for producing high-performance wear-resistant surfaces.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133185"},"PeriodicalIF":6.1,"publicationDate":"2026-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145980004","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 : 2026-01-09DOI: 10.1016/j.surfcoat.2026.133172
Anke Dalke , Minh Ngoc Le , Saeed M. Jafarpour , Sonia P. Brühl , Horst Biermann
This study investigates how the nitrogen fraction (fN) in N₂-H₂ feed gas affects the microstructure, mechanical, wear and corrosion properties of AISI 316L stainless steel treated at 460 °C for 5 h by active screen plasma nitrocarburizing (ASPNC) using a plasma-activated carbon screen as the carbon source. Investigation includes glow discharge optical emission spectroscopy (GDOES), X-ray diffraction (XRD), scanning electron microscopy (SEM) and atomic force microscopy (AFM) to characterize the elemental composition, phase composition, and surface topography of the expanded austenite layers across five different nitrogen fractions (0 ≤ fN ≤ 1). A transitional regime at fN = 0.5 showed maximum nitrogen uptake, minimal carbon content, and the thickest expanded austenite layer, though accompanied by highest defect density. Mechanical testing indicate that hardness and wear resistance reach a peak at fN = 0.5 (Martens hardness HM = 3.27 GPa), while higher nitrogen fractions (fN ≥ 0.9) lead to decreased hardness due to nitride-induced brittleness. Electrochemical polarization in 0.05 M H₂SO₄ reveal that corrosion resistance deteriorates with increasing fN, particularly at fN = 0.5, where nitride precipitates, grain boundary defects, and chromium depletion impair passive film stability. Treatments at low nitrogen fraction (fN ≤ 0.1) offer an optimal balance between corrosion resistance and mechanical performance, suitable for applications requiring both wear and corrosion protection. In contrast, high nitrogen conditions (fN ≥ 0.5) enhance wear resistance but are susceptible to corrosion, emphasizing the importance of tailoring plasma parameters to optimize AISI 316L performance for specific industrial applications.
{"title":"Impact of nitrogen fraction in N2-H2 plasma nitrocarburizing on mechanical, tribological, and corrosion performance of AISI 316L","authors":"Anke Dalke , Minh Ngoc Le , Saeed M. Jafarpour , Sonia P. Brühl , Horst Biermann","doi":"10.1016/j.surfcoat.2026.133172","DOIUrl":"10.1016/j.surfcoat.2026.133172","url":null,"abstract":"<div><div>This study investigates how the nitrogen fraction (<em>f</em><sub><em>N</em></sub>) in N₂-H₂ feed gas affects the microstructure, mechanical, wear and corrosion properties of AISI 316L stainless steel treated at 460 °C for 5 h by active screen plasma nitrocarburizing (ASPNC) using a plasma-activated carbon screen as the carbon source. Investigation includes glow discharge optical emission spectroscopy (GDOES), X-ray diffraction (XRD), scanning electron microscopy (SEM) and atomic force microscopy (AFM) to characterize the elemental composition, phase composition, and surface topography of the expanded austenite layers across five different nitrogen fractions (0 ≤ <em>f</em><sub><em>N</em></sub> ≤ 1). A transitional regime at <em>f</em><sub><em>N</em></sub> = 0.5 showed maximum nitrogen uptake, minimal carbon content, and the thickest expanded austenite layer, though accompanied by highest defect density. Mechanical testing indicate that hardness and wear resistance reach a peak at <em>f</em><sub><em>N</em></sub> = 0.5 (Martens hardness HM = 3.27 GPa), while higher nitrogen fractions (<em>f</em><sub><em>N</em></sub> ≥ 0.9) lead to decreased hardness due to nitride-induced brittleness. Electrochemical polarization in 0.05 M H₂SO₄ reveal that corrosion resistance deteriorates with increasing <em>f</em><sub><em>N</em></sub>, particularly at <em>f</em><sub><em>N</em></sub> = 0.5, where nitride precipitates, grain boundary defects, and chromium depletion impair passive film stability. Treatments at low nitrogen fraction (<em>f</em><sub><em>N</em></sub> ≤ 0.1) offer an optimal balance between corrosion resistance and mechanical performance, suitable for applications requiring both wear and corrosion protection. In contrast, high nitrogen conditions (<em>f</em><sub><em>N</em></sub> ≥ 0.5) enhance wear resistance but are susceptible to corrosion, emphasizing the importance of tailoring plasma parameters to optimize AISI 316L performance for specific industrial applications.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133172"},"PeriodicalIF":6.1,"publicationDate":"2026-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145980002","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 : 2026-01-09DOI: 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.
{"title":"Role of Zn spraying amount and diffusion in governing the corrosion resistance of aluminum microchannel heat-exchange tubes","authors":"Qiang Lu , Shenshen Cui , Dezhi Li , Haochang Chen , Feng Li , Bao Yue , Haishen Wang , Haixia Deng , Qudong Wang","doi":"10.1016/j.surfcoat.2026.133168","DOIUrl":"10.1016/j.surfcoat.2026.133168","url":null,"abstract":"<div><div>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/m<sup>2</sup>, which balances diffusion depth, coating uniformity, and sacrificial anode effects, thereby markedly extending the service life of aluminum alloy microchannel heat-exchange tubes.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133168"},"PeriodicalIF":6.1,"publicationDate":"2026-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145979925","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 : 2026-01-09DOI: 10.1016/j.surfcoat.2026.133180
Sumeyya Ayca , Ibrahim Dincer
This study analyzes hydrogen production using photoelectrochemical (PEC) water splitting methods for Ga-doped ZnO electrodes coated on stainless steel. Physical electrochemistry, electrochemical impedance, hydrogen production, X-ray diffraction (XRD), and scanning electron microscopy (SEM) analyses are performed on uncoated, undoped ZnO-coated, and Ga-doped ZnO-coated electrodes. The parameters of the best-coated electrode obtained by chronoamperometry (CA) analysis are as follows: the electrode is immersed in a dip-coating bath for 4 s, is coated five times, and has a doping ratio of 1%. The Tafel slope obtained from the Tafel graph of the 1% Ga-doped ZnO electrode is 0.15 V/dec, and the change in current density is 1.05 × 10−7 A/cm2. According to the electrochemical impedance spectroscopy (EIS) data, the solution resistance (Rs), polarization resistance (Rp), and constant phase element (CPE) of the 1% Ga-doped ZnO electrode are 0.4862 Ω·cm2, 0.0785 Ω·cm2, and 2.031 × 10−3 Ω−1·s·cm−2, respectively. The slope value obtained from the Mott–Schottky graph is also 3.45 × 10−4. The hydrogen production rate obtained from CA analysis over a half-hour period is 6 ml/cm2. The energy efficiency is 2.3%, the exergy efficiency is 2.36%, and the applied bias photon-to-current efficiency (ABPE) is 0.75%. This study demonstrates higher hydrogen evolution reaction (HER) activity and overall efficiency than comparable studies in the literature. This study is the first in the literature to illustrate the dip-coating of Ga-doped ZnO electrodes onto stainless steel, the optimization of coating number and duration parameters, and the reporting of direct hydrogen production quantities. Thus, the study fills a gap in the literature in terms of both methodological innovation and performance, offering an applicable and scalable approach for sustainable hydrogen production.
{"title":"Green hydrogen production by an improved photoelectrochemical process with Ga-doped ZnO photoanodes on stainless steel substrates","authors":"Sumeyya Ayca , Ibrahim Dincer","doi":"10.1016/j.surfcoat.2026.133180","DOIUrl":"10.1016/j.surfcoat.2026.133180","url":null,"abstract":"<div><div>This study analyzes hydrogen production using photoelectrochemical (PEC) water splitting methods for Ga-doped ZnO electrodes coated on stainless steel. Physical electrochemistry, electrochemical impedance, hydrogen production, X-ray diffraction (XRD), and scanning electron microscopy (SEM) analyses are performed on uncoated, undoped ZnO-coated, and Ga-doped ZnO-coated electrodes. The parameters of the best-coated electrode obtained by chronoamperometry (CA) analysis are as follows: the electrode is immersed in a dip-coating bath for 4 s, is coated five times, and has a doping ratio of 1%. The Tafel slope obtained from the Tafel graph of the 1% Ga-doped ZnO electrode is 0.15 V/dec, and the change in current density is 1.05 × 10<sup>−7</sup> A/cm<sup>2</sup>. According to the electrochemical impedance spectroscopy (EIS) data, the solution resistance (Rs), polarization resistance (Rp), and constant phase element (CPE) of the 1% Ga-doped ZnO electrode are 0.4862 Ω·cm<sup>2</sup>, 0.0785 Ω·cm<sup>2</sup>, and 2.031 × 10<sup>−3</sup> Ω<sup>−1</sup>·s·cm<sup>−2</sup>, respectively. The slope value obtained from the Mott–Schottky graph is also 3.45 × 10<sup>−4</sup>. The hydrogen production rate obtained from CA analysis over a half-hour period is 6 ml/cm<sup>2</sup>. The energy efficiency is 2.3%, the exergy efficiency is 2.36%, and the applied bias photon-to-current efficiency (ABPE) is 0.75%. This study demonstrates higher hydrogen evolution reaction (HER) activity and overall efficiency than comparable studies in the literature. This study is the first in the literature to illustrate the dip-coating of Ga-doped ZnO electrodes onto stainless steel, the optimization of coating number and duration parameters, and the reporting of direct hydrogen production quantities. Thus, the study fills a gap in the literature in terms of both methodological innovation and performance, offering an applicable and scalable approach for sustainable hydrogen production.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133180"},"PeriodicalIF":6.1,"publicationDate":"2026-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145979998","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 : 2026-01-09DOI: 10.1016/j.surfcoat.2026.133179
Marzieh Ebrahimi , Ahmad Kermanpur , Mahshid Kharaziha , Mathew T. Mathew
The present study investigates the effects of plasma electrolytic oxidation (PEO) followed by physical vapor deposition (PVD) on the corrosion behavior and biological performance of Ti-6Al-4V gyroid scaffolds fabricated by laser powder bed fusion (LPBF). A porous TiO2 layer was first developed via PEO, after which multilayered Nb/NbN coatings were deposited using PVD in various configurations of single and double Nb/NbN layers. While a single Nb/NbN layer maintained the surface morphology of the PEO-treated sample, the deposition of two Nb/NbN layers decreased the PEO-induced micropore size and resulted in micro/nano-porous features. PEO-TiO2/PVD-2layers Nb/NbN coating exhibited about a 57% reduction in maximum pore size and a 94% decrease in average porosity compared with the PEO-treated sample. The two-layer Nb/NbN coating showed a higher corrosion current density than PEO alone (4.20 × 10−7 A·cm−2 vs. 1.30 × 10−8 A·cm−2), yet still outperformed both the single-layer Nb/NbN coating (1.51 × 10−6 A·cm−2) and the untreated sample (8.68 × 10−7 A·cm−2). Changing surface topography of samples via PEO/PVD increased their hydrophilicity, thereby promoting in vitro bioactivity of Ti-6Al-4V gyroid scaffolds. Moreover, depending on coating configurations, PEO/PVD showed improved biological performance on Ti-6Al-4V scaffolds. Notably, PEO-treated Ti-6Al-4V gyroid scaffolds coated with two Nb/NbN layers exhibited enhanced MG63 cell viability, reaching 107 ± 6% (relative to control) by day 7, as well as improved cell attachment compared with the untreated scaffold. Furthermore, PEO/PVD treatment, particularly in samples coated with two Nb/NbN layers, reduced bacterial adhesion on the surface. In overall, deposition of a PEO-TiO2/PVD-2layers Nb/NbN multilayer coating presents an innovative approach for surface engineering of 3D-printed Ti-6Al-4V gyroid scaffolds.
{"title":"Synergistic surface modification of LPBF-fabricated Ti-6Al-4V gyroid scaffolds using PEO and Nb/NbN multilayers: Towards antibacterial and bioactive performances","authors":"Marzieh Ebrahimi , Ahmad Kermanpur , Mahshid Kharaziha , Mathew T. Mathew","doi":"10.1016/j.surfcoat.2026.133179","DOIUrl":"10.1016/j.surfcoat.2026.133179","url":null,"abstract":"<div><div>The present study investigates the effects of plasma electrolytic oxidation (PEO) followed by physical vapor deposition (PVD) on the corrosion behavior and biological performance of Ti-6Al-4V gyroid scaffolds fabricated by laser powder bed fusion (LPBF). A porous TiO<sub>2</sub> layer was first developed via PEO, after which multilayered Nb/NbN coatings were deposited using PVD in various configurations of single and double Nb/NbN layers. While a single Nb/NbN layer maintained the surface morphology of the PEO-treated sample, the deposition of two Nb/NbN layers decreased the PEO-induced micropore size and resulted in micro/nano-porous features. PEO-TiO<sub>2</sub>/PVD-2layers Nb/NbN coating exhibited about a 57% reduction in maximum pore size and a 94% decrease in average porosity compared with the PEO-treated sample. The two-layer Nb/NbN coating showed a higher corrosion current density than PEO alone (4.20 × 10<sup>−7</sup> A·cm<sup>−2</sup> vs. 1.30 × 10<sup>−8</sup> A·cm<sup>−2</sup>), yet still outperformed both the single-layer Nb/NbN coating (1.51 × 10<sup>−6</sup> A·cm<sup>−2</sup>) and the untreated sample (8.68 × 10<sup>−7</sup> A·cm<sup>−2</sup>). Changing surface topography of samples via PEO/PVD increased their hydrophilicity, thereby promoting in vitro bioactivity of Ti-6Al-4V gyroid scaffolds. Moreover, depending on coating configurations, PEO/PVD showed improved biological performance on Ti-6Al-4V scaffolds. Notably, PEO-treated Ti-6Al-4V gyroid scaffolds coated with two Nb/NbN layers exhibited enhanced MG63 cell viability, reaching 107 ± 6% (relative to control) by day 7, as well as improved cell attachment compared with the untreated scaffold. Furthermore, PEO/PVD treatment, particularly in samples coated with two Nb/NbN layers, reduced bacterial adhesion on the surface. In overall, deposition of a PEO-TiO<sub>2</sub>/PVD-2layers Nb/NbN multilayer coating presents an innovative approach for surface engineering of 3D-printed Ti-6Al-4V gyroid scaffolds.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"523 ","pages":"Article 133179"},"PeriodicalIF":6.1,"publicationDate":"2026-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146090276","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 : 2026-01-09DOI: 10.1016/j.surfcoat.2026.133182
Eugenia L. Dalibón , Andrea Abreu-García , A. Justina Maskavizan , Javier Izquierdo , Ricardo M. Souto , Sonia P. Brühl
PVD AlCrN coatings are extensively used to improve the steel performance in severe wear and corrosion conditions. In this study, AISI 420 martensitic stainless steel was coated with a commercial AlCrN coating (Alcrona®, Oerlikon Balzers). Prior to deposition, the steel was plasma nitrided for 5 h in a semi-industrial facility. Surface characterization was conducted by X-ray diffraction (XRD), nanoindentation, microhardness, optical microscopy, and scanning electron microscopy coupled with focus ion beam milling (SEM-FIB). The long-term corrosion behavior was analyzed using Salt Spray test, open circuit potential and electrochemical impedance spectroscopy (EIS) measurements. Single and duplex coating systems were studied and compared with the uncoated systems, plasma nitrided steel and quenched & tempered steel. The coating thickness was approximately 4 μm, while the thickness of the nitrided compound layer was between 12 and 13 μm, with a nitriding penetration depth of 28 μm. The nitriding pretreatment enhanced adhesion of the coating in the duplex system. AlCrN significantly improved wear resistance of the substrates in Pin on disk tests under Hertzian pressures higher than 1 GPa. The coating was hard enough to withstand the sand for both coated systems in abrasive wear tests. It was not worn through in both type of wear tests, so nitriding treatment had no influence in wear resistance. In the salt spray chamber, the nitrided sample experienced homogeneous distribution of pits rather than localized pitting corrosion, whereas the samples with the AlCrN coating showed good protection. The AlCrN-coated samples exhibited barrier properties immediately after immersion; however, electrolyte penetration through pores and defects in the chloride-containing medium compromised their long-term corrosion resistance, especially for previously nitrided substrates.
{"title":"Wear and corrosion behavior of AISI 420 stainless steel coated with PVD AlCrN","authors":"Eugenia L. Dalibón , Andrea Abreu-García , A. Justina Maskavizan , Javier Izquierdo , Ricardo M. Souto , Sonia P. Brühl","doi":"10.1016/j.surfcoat.2026.133182","DOIUrl":"10.1016/j.surfcoat.2026.133182","url":null,"abstract":"<div><div>PVD AlCrN coatings are extensively used to improve the steel performance in severe wear and corrosion conditions. In this study, AISI 420 martensitic stainless steel was coated with a commercial AlCrN coating (Alcrona®, Oerlikon Balzers). Prior to deposition, the steel was plasma nitrided for 5 h in a semi-industrial facility. Surface characterization was conducted by X-ray diffraction (XRD), nanoindentation, microhardness, optical microscopy, and scanning electron microscopy coupled with focus ion beam milling (SEM-FIB). The long-term corrosion behavior was analyzed using Salt Spray test, open circuit potential and electrochemical impedance spectroscopy (EIS) measurements. Single and duplex coating systems were studied and compared with the uncoated systems, plasma nitrided steel and quenched & tempered steel. The coating thickness was approximately 4 μm, while the thickness of the nitrided compound layer was between 12 and 13 μm, with a nitriding penetration depth of 28 μm. The nitriding pretreatment enhanced adhesion of the coating in the duplex system. AlCrN significantly improved wear resistance of the substrates in Pin on disk tests under Hertzian pressures higher than 1 GPa. The coating was hard enough to withstand the sand for both coated systems in abrasive wear tests. It was not worn through in both type of wear tests, so nitriding treatment had no influence in wear resistance. In the salt spray chamber, the nitrided sample experienced homogeneous distribution of pits rather than localized pitting corrosion, whereas the samples with the AlCrN coating showed good protection. The AlCrN-coated samples exhibited barrier properties immediately after immersion; however, electrolyte penetration through pores and defects in the chloride-containing medium compromised their long-term corrosion resistance, especially for previously nitrided substrates.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133182"},"PeriodicalIF":6.1,"publicationDate":"2026-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145979560","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 : 2026-01-08DOI: 10.1016/j.surfcoat.2026.133173
Yi Wang, Yonggang Guo, Qing Zhang, Xinchao Wang, Zhongpu Wang, Zichao Guo, Dongjin Cui
As the core component of the flour mill, the grinding roller has a significant impact on the flour quality and processing efficiency. Currently, the wear resistance of grinding rollers is primarily enhanced through alloy composition optimization and heat treatment strengthening, however, the improvement achieved by these methods remains limited. In this study, based on the solid solution strengthening and grain refinement effects of Mo and Ti in the alloy layer of the grinding roller surface, FeCoNiCrMo-TiC, FeCoNiCrMo-TiB₂, and FeCoNiCrMo-TiN coatings were prepared using plasma spraying. The microstructure, mechanical and tribological properties of the coatings were comprehensively characterized using XRD, XPS, SEM, EDS, microhardness testing, universal testing machine, and wear resistance testing. The results indicate that all coatings consisted of ceramic particles and FCC and BCC matrix solid solution phases. Compared with the FeCoNiCrMo coating, the FeCoNiCrMo-TiC coating exhibited a porosity reduction of 84%, while its hardness and bonding strength increased by 38% and 51%, respectively. These improvements are primarily attributed to the grain refinement and interfacial strengthening induced by TiC. Furthermore, compared with the substrate material, the friction coefficients of FeCoNiCrMo-TiC, FeCoNiCrMo-TiB₂, and FeCoNiCrMo-TiN coatings decreased by 18%, 9%, and 3%, respectively, and the corresponding wear rates were reduced by 33%, 23%, and 17%. Comprehensive analysis indicate that the FeCoNiCrMo-TiC composite coating possesses excellent tribological properties, mainly due to the synergistic effect of multiple hardening and strengthening mechanisms resulting from the addition of TiC ceramic particles, with wear mechanisms of abrasive wear and oxidative wear.
{"title":"Microstructure evolution and tribological properties of plasma sprayed FeCoNiCrMo-TiX composite coatings","authors":"Yi Wang, Yonggang Guo, Qing Zhang, Xinchao Wang, Zhongpu Wang, Zichao Guo, Dongjin Cui","doi":"10.1016/j.surfcoat.2026.133173","DOIUrl":"10.1016/j.surfcoat.2026.133173","url":null,"abstract":"<div><div>As the core component of the flour mill, the grinding roller has a significant impact on the flour quality and processing efficiency. Currently, the wear resistance of grinding rollers is primarily enhanced through alloy composition optimization and heat treatment strengthening, however, the improvement achieved by these methods remains limited. In this study, based on the solid solution strengthening and grain refinement effects of Mo and Ti in the alloy layer of the grinding roller surface, FeCoNiCrMo-TiC, FeCoNiCrMo-TiB₂, and FeCoNiCrMo-TiN coatings were prepared using plasma spraying. The microstructure, mechanical and tribological properties of the coatings were comprehensively characterized using XRD, XPS, SEM, EDS, microhardness testing, universal testing machine, and wear resistance testing. The results indicate that all coatings consisted of ceramic particles and FCC and BCC matrix solid solution phases. Compared with the FeCoNiCrMo coating, the FeCoNiCrMo-TiC coating exhibited a porosity reduction of 84%, while its hardness and bonding strength increased by 38% and 51%, respectively. These improvements are primarily attributed to the grain refinement and interfacial strengthening induced by TiC. Furthermore, compared with the substrate material, the friction coefficients of FeCoNiCrMo-TiC, FeCoNiCrMo-TiB₂, and FeCoNiCrMo-TiN coatings decreased by 18%, 9%, and 3%, respectively, and the corresponding wear rates were reduced by 33%, 23%, and 17%. Comprehensive analysis indicate that the FeCoNiCrMo-TiC composite coating possesses excellent tribological properties, mainly due to the synergistic effect of multiple hardening and strengthening mechanisms resulting from the addition of TiC ceramic particles, with wear mechanisms of abrasive wear and oxidative wear.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133173"},"PeriodicalIF":6.1,"publicationDate":"2026-01-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145979555","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 : 2026-01-07DOI: 10.1016/j.surfcoat.2026.133171
João Vitor Piovesan Dalla NORA , Douglas Rodrigues de RODRIGUES , Morvan da Silva FRANCO , Vinicius Waechter DIAS , Fernando Michelon MARQUES , Rafael Menezes NUNES , Alexandre da Silva ROCHA
Plasma nitriding of continuous cooling bainitic steel DIN 18 MnCrSiMo6–4 has been previously studied to enhance its surface properties without compromising core hardness. However, the potential of plasma nitrocarburizing for this specific advanced steel remains largely unexplored, despite its promise of superior tribological performance. In this context, this article aims to evaluate the response to plasma nitrocarburizing of DIN 18 MnCrSiMo6–4 continuously cooled bainitic steel compared to plasma nitriding. Plasma thermochemical treatments were carried out in N2 - H2 - CH4 atmosphere, varying CH4 content from 0 vol%, for plasma nitriding, to 3 and 5 vol% for plasma ferritic nitrocarburizing. The N2 content was fixed at 75 vol% and H2 was used in balance for all treatments. Microstructure, roughness, hardness, phase and micro-abrasive wear resistance of the samples were investigated after plasma treatments. The experimental findings indicate a decrease in the thickness of the white layer, and an enhancement in surface hardness and roughness as the CH4 content increases. Furthermore, there is an increased formation of Fe23N phase, which correlates with an elevated concentration of CH4 in the system. Plasma nitrocarburizing with 3 vol% CH4 exhibited reduced worn volume and minor crater depths than white layer thickness for the longest micro-abrasive tests. Plasma nitrocarburizing significantly improved wear resistance while preserving core hardness of DIN 18MnCrSiMo6–4 bainitic steel surface properties.
{"title":"Investigation on plasma nitriding and nitrocarburizing of a continuous cooling bainitic steel","authors":"João Vitor Piovesan Dalla NORA , Douglas Rodrigues de RODRIGUES , Morvan da Silva FRANCO , Vinicius Waechter DIAS , Fernando Michelon MARQUES , Rafael Menezes NUNES , Alexandre da Silva ROCHA","doi":"10.1016/j.surfcoat.2026.133171","DOIUrl":"10.1016/j.surfcoat.2026.133171","url":null,"abstract":"<div><div>Plasma nitriding of continuous cooling bainitic steel DIN 18 MnCrSiMo6–4 has been previously studied to enhance its surface properties without compromising core hardness. However, the potential of plasma nitrocarburizing for this specific advanced steel remains largely unexplored, despite its promise of superior tribological performance. In this context, this article aims to evaluate the response to plasma nitrocarburizing of DIN 18 MnCrSiMo6–4 continuously cooled bainitic steel compared to plasma nitriding. Plasma thermochemical treatments were carried out in N<sub>2</sub> - H<sub>2</sub> - CH<sub>4</sub> atmosphere, varying CH<sub>4</sub> content from 0 vol%, for plasma nitriding, to 3 and 5 vol% for plasma ferritic nitrocarburizing. The N<sub>2</sub> content was fixed at 75 vol% and H<sub>2</sub> was used in balance for all treatments. Microstructure, roughness, hardness, phase and micro-abrasive wear resistance of the samples were investigated after plasma treatments. The experimental findings indicate a decrease in the thickness of the white layer, and an enhancement in surface hardness and roughness as the CH<sub>4</sub> content increases. Furthermore, there is an increased formation of Fe<sub>23</sub>N phase, which correlates with an elevated concentration of CH<sub>4</sub> in the system. Plasma nitrocarburizing with 3 vol% CH<sub>4</sub> exhibited reduced worn volume and minor crater depths than white layer thickness for the longest micro-abrasive tests. Plasma nitrocarburizing significantly improved wear resistance while preserving core hardness of DIN 18MnCrSiMo6–4 bainitic steel surface properties.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133171"},"PeriodicalIF":6.1,"publicationDate":"2026-01-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145928881","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}
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.
{"title":"Osteoconductive composite coating of gelatin/β-TCP on Mg-Zn-Ca alloy using AC-EPD for bone regeneration","authors":"Manisha Behera , Agnès Denys , Fabrice Allain , Cosmin Gruescu , Annabel Braem , Rajashekhara Shabadi","doi":"10.1016/j.surfcoat.2026.133166","DOIUrl":"10.1016/j.surfcoat.2026.133166","url":null,"abstract":"<div><div>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. <em>In vitro</em> 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.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133166"},"PeriodicalIF":6.1,"publicationDate":"2026-01-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145979597","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 : 2026-01-07DOI: 10.1016/j.surfcoat.2026.133153
Tianxiang Lin , Meiyan Feng , Guofu Lian , Zhigang Zeng , Changrong Chen
To investigate the impact of ultrasonic energy on microstructural evolution, mechanical performance, and corrosion behavior in high-entropy alloy composites synthesized via laser cladding, CoCrFeMnNiSi1.6-WC3 coatings were deposited on AISI 1045 steel through an ultrasound-enhanced laser processing method. Results demonstrate that the phase composition of the coatings remains unchanged under varying ultrasonic frequencies, consistently comprising FCC, BCC, silicide, and carbide phases. As the ultrasonic frequency increases, the coating microstructure is significantly refined. At 15 kHz, dendritic structures exhibit the finest morphology and most uniform distribution. Under ultrasonic excitation, WC refractory particles were efficiently fragmented and homogeneously dispersed throughout the matrix, thereby playing a pivotal role in enhancing the coating's overall performance. The microhardness of the coatings initially increases with ultrasonic frequency, reaching a maximum of 876.2 HV0.5 at 15 kHz—302 % higher than that of the substrate and 12 % higher than that of the non-ultrasonically treated W0U0 coating. Similarly, wear resistance first improves and then declines with frequency. At 15 kHz, the friction coefficient and wear rate reach their lowest values—0.543 and 0.02247mm3, respectively—representing reductions of 7.97 % and 14.7 % compared to the W0U0 coating. Increasing ultrasonic frequency markedly mitigates both adhesive and abrasive wear, while simultaneously stabilizing the friction coefficient fluctuations. Corrosion resistance also shows a non-monotonic trend with frequency. At an ultrasonic frequency of 15 kHz, the coating demonstrates the peak corrosion potential (−0.402 V) alongside the minimal corrosion current density (5.516 × 10−8 A/cm2), signifying the development of a highly stable, dense passive film that affords superior corrosion resistance. These findings offer both experimental evidence and theoretical insight into the optimization of high-entropy alloy composite coatings via ultrasound-assisted laser cladding.
{"title":"Ultrasonic-assisted laser cladding of CoCrFeMnNiSi1.6-WC3 composite coatings: Frequency effect","authors":"Tianxiang Lin , Meiyan Feng , Guofu Lian , Zhigang Zeng , Changrong Chen","doi":"10.1016/j.surfcoat.2026.133153","DOIUrl":"10.1016/j.surfcoat.2026.133153","url":null,"abstract":"<div><div>To investigate the impact of ultrasonic energy on microstructural evolution, mechanical performance, and corrosion behavior in high-entropy alloy composites synthesized via laser cladding, CoCrFeMnNiSi1.6-WC3 coatings were deposited on AISI 1045 steel through an ultrasound-enhanced laser processing method. Results demonstrate that the phase composition of the coatings remains unchanged under varying ultrasonic frequencies, consistently comprising FCC, BCC, silicide, and carbide phases. As the ultrasonic frequency increases, the coating microstructure is significantly refined. At 15 kHz, dendritic structures exhibit the finest morphology and most uniform distribution. Under ultrasonic excitation, WC refractory particles were efficiently fragmented and homogeneously dispersed throughout the matrix, thereby playing a pivotal role in enhancing the coating's overall performance. The microhardness of the coatings initially increases with ultrasonic frequency, reaching a maximum of 876.2 HV0.5 at 15 kHz—302 % higher than that of the substrate and 12 % higher than that of the non-ultrasonically treated W0U0 coating. Similarly, wear resistance first improves and then declines with frequency. At 15 kHz, the friction coefficient and wear rate reach their lowest values—0.543 and 0.02247mm<sup>3</sup>, respectively—representing reductions of 7.97 % and 14.7 % compared to the W0U0 coating. Increasing ultrasonic frequency markedly mitigates both adhesive and abrasive wear, while simultaneously stabilizing the friction coefficient fluctuations. Corrosion resistance also shows a non-monotonic trend with frequency. At an ultrasonic frequency of 15 kHz, the coating demonstrates the peak corrosion potential (−0.402 V) alongside the minimal corrosion current density (5.516 × 10<sup>−8</sup> A/cm<sup>2</sup>), signifying the development of a highly stable, dense passive film that affords superior corrosion resistance. These findings offer both experimental evidence and theoretical insight into the optimization of high-entropy alloy composite coatings via ultrasound-assisted laser cladding.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"522 ","pages":"Article 133153"},"PeriodicalIF":6.1,"publicationDate":"2026-01-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145928883","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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