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Volume 16
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Coatings, Volume 16, Issue 4 (April 2026) – 60 articles

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27 pages, 5310 KB  
Review
Research Progress of Non-Invasive Magnetic Resonance Imaging in Lithium-Ion Battery Detection
by Wen Jiang, Yunyi Deng, Wentao Li, Jilong Song, Songtao Che and Kai Wang
Coatings 2026, 16(4), 453; https://doi.org/10.3390/coatings16040453 (registering DOI) - 9 Apr 2026
Abstract
Non-invasive magnetic resonance imaging (MRI), as an extension of nuclear magnetic resonance (NMR) technology, enables detailed characterization of lithium-ion batteries (LIBs) in model systems. This review summarizes the fundamental principles of MRI and its applications in liquid/solid electrolytes, electrodes, and limited commercial diagnostics. [...] Read more.
Non-invasive magnetic resonance imaging (MRI), as an extension of nuclear magnetic resonance (NMR) technology, enables detailed characterization of lithium-ion batteries (LIBs) in model systems. This review summarizes the fundamental principles of MRI and its applications in liquid/solid electrolytes, electrodes, and limited commercial diagnostics. Key capabilities include quantifying ion diffusion coefficients and mobility numbers in electrolytes, visualizing dendrite growth in lithium metal, and tracking lithium distribution in porous electrodes such as graphite and LiCoO2. However, spatial and temporal resolution (typically 10–100 μm with acquisition times ranging from minutes to hours) and metal-induced shielding effects severely limit direct imaging in complete commercial batteries. Indirect methods like magnetic field imaging (MFI) show potential for defect detection. Future work should focus on sequence optimization and multimodal fusion, while emphasizing MRI’s primary role in fundamental research rather than conventional industrial testing. Full article
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47 pages, 3670 KB  
Review
Toxicological and Environmental Risk Assessment of Biopolymeric Coatings for Horticultural Produce: A Comprehensive Review on Biosafety, Degradation, and Ecological Risks
by Aldenora dos Santos Vasconcelos, Lorena Vieira Bentolila de Aguiar, Vítor Alves Pessoa, Iracimar Batista do Carmo, Larissa Batista do Nascimento Soares, Giovanna Lima-Silva, Daiane Barão Pereira, Patrick Cruz do Nascimento, Josilene Lima Serra Pereira, Ceci Sales-Campos, Larissa Ramos Chevreuil, Walter José Martínez-Burgos and Roberta Pozzan
Coatings 2026, 16(4), 452; https://doi.org/10.3390/coatings16040452 - 9 Apr 2026
Abstract
The increasing adoption of biopolymeric and nanostructured coatings for horticultural produce has emerged as a sustainable strategy to mitigate postharvest losses and extend shelf life. However, while their technological performance has been extensively documented, comprehensive and integrative assessments of biosafety, potential human health [...] Read more.
The increasing adoption of biopolymeric and nanostructured coatings for horticultural produce has emerged as a sustainable strategy to mitigate postharvest losses and extend shelf life. However, while their technological performance has been extensively documented, comprehensive and integrative assessments of biosafety, potential human health implications, and environmental risks profiles are still insufficiently explored. This review critically analyzes recent advances in polysaccharide, protein, and lipid-based coatings, including nanoenabled systems incorporating metallic nanoparticles and bioactive agents. The mechanisms underlying gas barrier properties, antimicrobial activity, and preservation efficacy are discussed alongside degradation pathways in composting, soil, and aquatic environments. Particular attention is given to nanoparticle release, migration potential, gastrointestinal fate, and toxicological endpoints such as oxidative stress, genotoxicity, endocrine disruption, and immunomodulation. Ecotoxicological evidence across trophic levels, from microorganisms and invertebrates to fish and amphibians, is examined, highlighting sublethal and mechanistic biomarkers relevant to environmental risk assessment. Regulatory frameworks from major agencies are also compared to contextualize current safety standards and limitations. Overall, although biopolymeric coatings represent promising alternatives to conventional plastics, their life-cycle impacts, transformation products, and nano-related uncertainties require comprehensive, multilevel risk evaluation to ensure truly sustainable and safe postharvest applications. Full article
(This article belongs to the Special Issue Innovative Coating Technologies for Preservation and Safety of Horticultural Produce)
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26 pages, 6283 KB  
Article
Surface Defect Detection in Liquid Crystal Display Polariser Coating Manufacturing Based on an Enhanced YOLOv10-N Approach
by Jiayue Zhang, Shanhui Liu, Minghui Chen, Kezhan Zhang, Yinfeng Li, Ming Peng and Yeting Teng
Coatings 2026, 16(4), 451; https://doi.org/10.3390/coatings16040451 - 8 Apr 2026
Abstract
To address the issues of uneven grayscale distribution, weak defect features, and small target scales on the coating surface of LCD polarizers during manufacturing, an improved YOLOv10-N-based method is proposed for surface defect detection. First, a polarizer coating defect dataset is constructed based [...] Read more.
To address the issues of uneven grayscale distribution, weak defect features, and small target scales on the coating surface of LCD polarizers during manufacturing, an improved YOLOv10-N-based method is proposed for surface defect detection. First, a polarizer coating defect dataset is constructed based on the LCD polarizer coating process and the characteristics of coating defects. Adaptive median filtering is then employed for image denoising, while a particle-swarm-optimization-based improved histogram equalization method is adopted for image enhancement. Next, the Scale-aware Pyramid Pooling (SCPP) module is introduced into the C2f module of the backbone network to construct the C2f_SCPP feature extraction module, thereby improving the model’s ability to detect coating defects with different morphologies through multi-scale semantic feature fusion. In addition, rotation-equivariant convolution PreCM is incorporated into the SPPF module of the backbone network to build the SPPF_PreCM module, which effectively suppresses feature redundancy and scale conflicts while strengthening the representation of tiny defects. Finally, while retaining the original Distribution Focal Loss (DFL) branch of YOLOv10, WIoU is used to replace CIoU as the IoU loss term in bounding box regression, thereby improving localization accuracy and accelerating model convergence during training. Experimental results show that, compared with YOLOv10-N, the proposed method improves mAP@0.5 and mAP@0.5:0.95 by 1.8 and 2.8 percentage points, respectively, demonstrating its effectiveness for polarizer coating defect detection. However, its generalization capability under diverse production environments, varying illumination conditions, and complex noise scenarios still requires further investigation. Full article
(This article belongs to the Section High-Energy Beam Surface Engineering and Coatings)
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23 pages, 3026 KB  
Article
3D NiMnCo Electrocatalysts with Cauliflower Curd-Shaped Microspherical Morphology for an Efficient and Sustainable HER in Alkaline Freshwater/Seawater Media
by Sukomol Barua, Aldona Balčiūnaitė, Daina Upskuvienė, Jūrate Vaičiūnienė, Loreta Tamašauskaitė-Tamašiūnaitė and Eugenijus Norkus
Coatings 2026, 16(4), 450; https://doi.org/10.3390/coatings16040450 - 8 Apr 2026
Abstract
Electrocatalytic seawater splitting is an ideal strategy for the large-scale production of green hydrogen. Compared to scarce freshwater, oceanic seawater electrolysis represents a game-changer for the hydrogen economy. Herein, we report a cost-effective one-step synthesis of binder-free, self-supported 3D nickel–manganese–cobalt (NiMnCo) coatings on [...] Read more.
Electrocatalytic seawater splitting is an ideal strategy for the large-scale production of green hydrogen. Compared to scarce freshwater, oceanic seawater electrolysis represents a game-changer for the hydrogen economy. Herein, we report a cost-effective one-step synthesis of binder-free, self-supported 3D nickel–manganese–cobalt (NiMnCo) coatings on titanium (Ti) substrates and evaluated their electrocatalytic performance for the hydrogen evolution reactions (HERs) in alkaline media (1.0 M KOH), simulated seawater (SSW, 1.0 M KOH + 0.5 M NaCl) and alkaline natural seawater (ASW, 1.0 M KOH + natural seawater). These ternary coatings were electrodeposited on Ti substrates using an electrochemical deposition method via a dynamic hydrogen bubble template (DHBT) technique. The optimized ternary NiMnCo/Ti-2 electrocatalyst exhibited an enhanced HER activity in both alkaline and seawater media, achieving an ultra-low overpotential of 29, 59 and 66 mV to reach the benchmark current density of 10 mA cm−2 in SSW, ASW and 1.0 M KOH, respectively. This efficient 3D ternary NiMnCo/Ti-2 electrocatalyst demonstrated stable long-term performance at a constant potential of −0.23 V (vs. RHE) and a constant current density of 10 mA cm−2 for 50 h without any significant degradation. Furthermore, it exhibited long-term stability in alkaline electrolyte and simulated seawater during multi-step chronopotentiometric testing at variable current densities from 20 mA cm−2 to 100 mA cm−2 for 18 h. This superior performance can be attributed to its unique intermetallic structure and multi-component composition, which provides good Cl− resistance, electrochemical stability and synergistic effects among its constituents. Therefore, the optimized NiMnCo/Ti-2 electrocatalyst is a promising candidate for practical seawater electrolysis aiming at green hydrogen production. Full article
(This article belongs to the Special Issue Advanced Coatings for Enhanced Electrochemical Catalysis and Energy Storage Technologies)
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14 pages, 981 KB  
Article
Modeling and Computational Analysis of Failure Mechanism of Photocatalytic Anti-Corrosion Materials Driven by Multi-Source Environmental Data
by Yanwei Tong, Hui Xu and Shuyuan Jia
Coatings 2026, 16(4), 449; https://doi.org/10.3390/coatings16040449 - 8 Apr 2026
Abstract
Photocatalytic anti-corrosion materials are an emerging intelligent protective material that has been widely used in marine and offshore engineering in recent years. However, its failure mechanism under multi-factor coupling is complex, and it is difficult for traditional methods to achieve accurate life prediction [...] Read more.
Photocatalytic anti-corrosion materials are an emerging intelligent protective material that has been widely used in marine and offshore engineering in recent years. However, its failure mechanism under multi-factor coupling is complex, and it is difficult for traditional methods to achieve accurate life prediction and mechanism analysis. This article takes submarine pipelines as the research object and designs an innovative multi-source environmental data-driven method combined with deep learning (DL), aiming to establish an intelligent prediction model for the failure of the material. This article first systematically collects the multi-source heterogeneous data of materials during service; on this basis, this article constructs a hybrid DL model. Firstly, a multi-scale multimodal image feature fusion network (MMFCT) based on the combination of convolutional neural network (CNN) and Transformer is adopted to automatically extract corrosion features from microscopic images and capture the dynamic correlation between environmental temporal data and performance degradation; then, the Sparrow Search Algorithm (SSA) was constructed to optimize the BP neural network (BPNN) model for predicting the ultimate bearing capacity of submarine corroded pipelines. Simulation experiments show that the proposed method achieves accurate prediction of material remaining life and key performance degradation paths. The corrosion recognition precision reaches 94.7%, and the bearing capacity prediction error remains below 3.1%. Full article
(This article belongs to the Section Surface Engineering for Energy Harvesting, Conversion, and Storage)
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19 pages, 3111 KB  
Review
A Review of Carbonation of C-S-H: From Atomic Structure to Macroscopic Behavior
by Yi Zhao and Junjie Wang
Coatings 2026, 16(4), 448; https://doi.org/10.3390/coatings16040448 - 8 Apr 2026
Abstract
Calcium–silicate–hydrate (C-S-H), the primary binding phase governing cement paste cohesion, undergoes progressive physicochemical transformation upon carbonation—a process that critically dictates concrete durability in atmospheric environments. When CO2 penetrates the porous cement matrix, it triggers a cascade of degradation mechanisms: calcium leaching decalcifies [...] Read more.
Calcium–silicate–hydrate (C-S-H), the primary binding phase governing cement paste cohesion, undergoes progressive physicochemical transformation upon carbonation—a process that critically dictates concrete durability in atmospheric environments. When CO2 penetrates the porous cement matrix, it triggers a cascade of degradation mechanisms: calcium leaching decalcifies the C-S-H structure, inducing polymerization of silicate chains from dimeric to longer-chain configurations, while concurrent precipitation of calcium carbonate and amorphous silica gel fundamentally reconstitutes the nanoscale architecture. These nanoscale alterations propagate to macroscopic property evolution, manifesting as initial strength and stiffness gains due to pore-filling carbonation products followed by eventual deterioration as the cohesive binding network deteriorates. This review synthesizes current understanding of carbonation-induced structural evolution, examining the coupled influences of environmental parameters—CO2 concentration, relative humidity, and temperature—alongside C-S-H intrinsic chemistry (Ca/Si ratio, aluminum substitution, and alkali content) on reaction kinetics and material performance. However, significant knowledge gaps persist: predictive models for in-service carbonation rates remain elusive due to the disconnect between idealized laboratory conditions and the heterogeneous, cracked reality of field concrete; the causal linkage between nanoscale C-S-H alteration and macroscale cracking patterns along with physical performance is poorly resolved, and most mechanistic studies rely on synthetic C-S-H, neglecting the compositional complexity of real Portland cement systems. We further propose emerging protection strategies, including surface barrier coatings and low-carbon alternative binders (geopolymers, calcium sulfoaluminate cements, carbon-negative materials such as recycled cement), which demonstrate enhanced carbonation resistance. Future research priorities include developing effective coating barriers for carbonation protection, developing operando characterization techniques for real-time reaction monitoring, deploying machine learning algorithms to bridge atomistic simulations with structural-scale predictions, and establishing long-term field performance databases to validate laboratory-derived degradation models. Full article
(This article belongs to the Special Issue Advanced Coating Barriers for the Protection of Reinforced Concrete and Pavement, 3rd Edition)
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19 pages, 3874 KB  
Article
Real-Time pH Monitoring in Microreactor Channels Using Sol–Gel Thin-Film Coatings
by Elizabeta Forjan, Marijan-Pere Marković and Domagoj Vrsaljko
Coatings 2026, 16(4), 447; https://doi.org/10.3390/coatings16040447 - 8 Apr 2026
Abstract
Sol–gel-based optical functional sensor coatings were developed for real-time monitoring of multiphase saponification reactions in microreactors. Various pH-sensitive indicator mixtures, including bromocresol green and bromocresol purple (BCG and BCP) and methyl red–methyl orange, were incorporated into sol–gel coatings and evaluated on test plates [...] Read more.
Sol–gel-based optical functional sensor coatings were developed for real-time monitoring of multiphase saponification reactions in microreactors. Various pH-sensitive indicator mixtures, including bromocresol green and bromocresol purple (BCG and BCP) and methyl red–methyl orange, were incorporated into sol–gel coatings and evaluated on test plates across pH range of 2–12. Coatings with BCG and BCP 1:3 demonstrated the most pronounced color change at high pH (11–12), with distinct hue (H) transitions providing a reliable measure of local pH. These optimized coatings were integrated into microreactor channels to track the passage of oil and NaOH slugs under varying flow rates. Hue analysis produced reproducible plateaus corresponding to NaOH-rich (H = 50°) and oil-rich (H = 41°) phases, enabling droplet-level resolution of slug flow and detection of flow-regime transitions. The sensor response was fully reversible, highlighting the robustness and reusability of the coatings. Unlike previous high-resolution fluorescence-based systems, this approach relies on simple visible-light imaging and low-cost data extraction, leaving the reaction chemistry unaltered. The results demonstrate that sol–gel coatings coupled with hue-based analysis provide a practical, noninvasive, and real-time monitoring strategy for multiphase reactions in microreactors, with potential for implementation in industrial or IoT-enabled process control systems. Full article
(This article belongs to the Special Issue Advances in 3D Printing for Functional Coatings and Materials)
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23 pages, 6242 KB  
Article
Microstructure and Mechanical Properties of Narrow-Gap Laser Wire-Fed Welded S32101 Duplex Stainless Steel Thick-Plate Joints
by Yuetong Liu, Jinjie Wang, Juan Fu and Feiyun Wang
Coatings 2026, 16(4), 446; https://doi.org/10.3390/coatings16040446 - 7 Apr 2026
Abstract
Duplex stainless steel is widely used in nuclear power, the chemical industry, coastal infrastructure, and other fields due to its excellent mechanical properties, physical properties, and corrosion resistance. This paper focuses on the narrow-gap groove laser welding with wire filling conducted on 25 [...] Read more.
Duplex stainless steel is widely used in nuclear power, the chemical industry, coastal infrastructure, and other fields due to its excellent mechanical properties, physical properties, and corrosion resistance. This paper focuses on the narrow-gap groove laser welding with wire filling conducted on 25 mm S32101 duplex stainless steel. It analyzes the microstructural features of various regions within the welded joint and evaluates its mechanical properties and corrosion resistance. Research indicates that the thermal cycle effect during multi-layer and multi-pass welding significantly affects the microstructure and properties of the joint. Austenite in the weld seam area mainly precipitates along the dendrite boundaries; in the overlap area of the weld beads, due to the secondary thermal cycle effect, the austenite content significantly increases to 56.2%, and the grain size is refined; in the heat-affected zone (HAZ) near the seam, austenite appears in stripes, and its content decreases to 39.4%. Mechanical property tests reveal that the welded joint exhibits an average tensile strength of 705 MPa, surpassing that of the base material. The corrosion resistance of the weld zone closely mirrors that of the base material, yet the corrosion resistance of the heat-affected zone (HAZ) is diminished due to the reduction in austenite content and the potential precipitation of harmful phases. Full article
(This article belongs to the Special Issue Laser-Based Additive Manufacturing and Surface Engineering for Advanced Coatings)
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15 pages, 16359 KB  
Article
Two-Dimensional rGO-Supported Mo2S3 Catalysts with Tunable Electronic Structure for Efficient Electrochemical Water Splitting
by Mrunal Bhosale, Aditya A. Patil and Chan-Wook Jeon
Coatings 2026, 16(4), 445; https://doi.org/10.3390/coatings16040445 - 7 Apr 2026
Abstract
The rational design of cost-effective and highly active electrocatalysts for overall water splitting remains a critical challenge for sustainable hydrogen production. Herein, we report a two-dimensional reduced graphene oxide (rGO)-supported Mo2S3 nanohybrid catalyst with a tunable electronic structure engineered through [...] Read more.
The rational design of cost-effective and highly active electrocatalysts for overall water splitting remains a critical challenge for sustainable hydrogen production. Herein, we report a two-dimensional reduced graphene oxide (rGO)-supported Mo2S3 nanohybrid catalyst with a tunable electronic structure engineered through interfacial coupling. The intimate integration of Mo2S3 nanoflakes with conductive rGO nanosheet facilitates rapid electron transport, enhanced active site exposure, and optimized adsorption energetics for reaction intermediates. Structural and spectroscopic analyses confirm strong electronic interaction between Mo2S3 and rGO, leading to modulated charge density distribution and improved intrinsic catalytic activity. Electrochemical evaluations reveal significantly reduced overpotentials for oxygen evolution reaction (OER) with 166 mV overpotential at 10 mA cm−2 current density, along with favorable Tafel kinetics with 38.1 mV dec−1 and long-term operational stability in alkaline electrolyte. The rGO-Mo2S3-2||Pt-C cell delivers 10 mA cm−2 at 1.64 V, indicating efficient alkaline water splitting. The enhanced performance is attributed to synergistic effects arising from electronic modulation, enhanced active sites, and accelerated interfacial charge transfer. Full article
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19 pages, 6753 KB  
Article
Influence of a CaNa2(EDTA) Additive on Plasma Electrolytic Oxidation of Zirlo Alloy and the Properties of the Resulting Coatings
by Wei Li, Guohua Yan, Qianna Zhang and Yingliang Cheng
Coatings 2026, 16(4), 444; https://doi.org/10.3390/coatings16040444 - 7 Apr 2026
Abstract
The plasma electrolytic oxidation (PEO) of Zirlo alloy was carried out in a phosphate electrolyte with CaNa2(EDTA) as an additive (0–15 g/L) to improve its corrosion and wear resistance. The PEO behavior, microstructure, phase composition, and performance of coatings were characterized [...] Read more.
The plasma electrolytic oxidation (PEO) of Zirlo alloy was carried out in a phosphate electrolyte with CaNa2(EDTA) as an additive (0–15 g/L) to improve its corrosion and wear resistance. The PEO behavior, microstructure, phase composition, and performance of coatings were characterized as a function of the concentration of the additive. The results indicate that the addition of CaNa2(EDTA) promotes coating growth and improves the coating structure and phase composition. When the additive concentration is 5–10 g/L, the coating shows an improved thickness, and denser microstructure. The coatings consist of m-ZrO2 and t-ZrO2 as the main crystalline phases, as well as amorphous materials with Ca and P. The t-ZrO2 phase content rises sharply when CaNa2(EDTA) is added into the electrolyte (81.3% t-ZrO2 is obtained under the condition with 10 g/L CaNa2(EDTA)). Potentiodynamic polarization tests demonstrate that PEO treatment significantly enhances the corrosion resistance of Zirlo alloy. Under the condition of 5 g/L CaNa2(EDTA), the corrosion current density of the coating decreases by two orders of magnitude compared to the substrate, achieving the best corrosion resistance. Friction and wear tests also show that the coating obtained at 5 g/L CaNa2(EDTA) exhibits the shallowest wear scar and the lowest wear rate, demonstrating optimal wear resistance. This study shows the novelty of obtaining high-quality PEO coatings on Zirlo alloy based on Ca and P incorporation. Full article
(This article belongs to the Special Issue Plasma Electrolytic Oxidation (PEO) Coatings—3rd Edition)
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4 pages, 151 KB  
Editorial
Surface Modification for Improving the Performance of Engineering Components
by Annalisa Fortini and Mattia Merlin
Coatings 2026, 16(4), 443; https://doi.org/10.3390/coatings16040443 - 7 Apr 2026
Viewed by 35
Abstract
In the manufacturing industry, mechanical and structural elements are essential and are often located in harsh operational environments where they must withstand the synergic effects of wear, corrosion, fatigue, and elevated temperatures [...] Full article
(This article belongs to the Special Issue Surface Modification for Improving the Performance of Engineering Components)
17 pages, 6962 KB  
Article
Effect of Ta on Microstructure, Mechanical Properties, and Soft Magnetic Performance of Fe-Based Amorphous Coatings Prepared by High-Speed Laser Cladding
by Haibo Huang, Xiaoqiang Yao, Jiangtong Yu, Yong Huang, Jintao Li and Xiaoqiang Wang
Coatings 2026, 16(4), 442; https://doi.org/10.3390/coatings16040442 - 7 Apr 2026
Viewed by 75
Abstract
High-speed laser cladding (HLC) technology can provide high cooling rates and low dilution rates for the preparation of metastable Fe-based amorphous phases. In this work, the effects of Ta content on the microstructure, mechanical properties, and soft magnetic performance of Fe-based amorphous alloys [...] Read more.
High-speed laser cladding (HLC) technology can provide high cooling rates and low dilution rates for the preparation of metastable Fe-based amorphous phases. In this work, the effects of Ta content on the microstructure, mechanical properties, and soft magnetic performance of Fe-based amorphous alloys were systematically investigated. The results indicated that Ta remained uniformly dispersed within the FeSiB amorphous powder, and no new phases were formed after mechanical ball milling. The higher mixing enthalpy of Ta and its atomic radius difference from other elements (such as Fe, Si, B) were beneficial in improving glass-forming ability (GFA), and with an increase in Ta element content from 0% to 2%, 4% and 6%, the amorphous phase content was 48.6%, 51.5%, 60.4% and 54.8%, respectively. The average microhardness of the coating with a Ta content of 4% was 1310 HV0.2, which was 50HV0.2 higher than before; in addition, the wear rate reduced from 2.21 × 10−4 mg·N−1·m−1 to 2.06 × 10−4 mg·N−1·m−1. Also, corrosion tests showed that the coating with a Ta content of 4% displayed superior corrosion resistance compared to that before the Ta addition. However, because the element Ta could alter the local electronic environment and enhance the local magnetic anisotropy of FeSiB, the saturation magnetic flux density (Ms) decreased from 1.64 T to 1.56 T, and the coercivity (Hc) increased from 0.9 A/m to 1.3 A/m, which caused degradation of the soft magnetic properties. Full article
(This article belongs to the Special Issue Laser Coatings and Surface Engineering)
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13 pages, 3902 KB  
Article
Acceptor-Enriched Charge-Transfer Engineering for Long-Life and High-Rate Organic Cathodes in Aqueous Proton Batteries
by Xirui Song, Xinglin Yang, Jinlong Yang, Weichao Zhang and Peixiang Shi
Coatings 2026, 16(4), 441; https://doi.org/10.3390/coatings16040441 - 6 Apr 2026
Viewed by 168
Abstract
Aqueous proton batteries (APBs) are promising for safe energy storage, yet their cathode development is hindered by the lack of organic materials with reversible redox activity and long cycling stability in acidic media. Herein, an acceptor-enriched PNZ–TCNQ organic charge-transfer complex was constructed by [...] Read more.
Aqueous proton batteries (APBs) are promising for safe energy storage, yet their cathode development is hindered by the lack of organic materials with reversible redox activity and long cycling stability in acidic media. Herein, an acceptor-enriched PNZ–TCNQ organic charge-transfer complex was constructed by increasing the TCNQ ratio. Spectroscopic results are consistent with strengthened donor–acceptor interactions and altered local electronic environments. The PNZ–TCNQ cathode delivered ~190 mAh g−1 at 0.6 A g−1 and retained ~85% capacity after 10,000 cycles at 5 A g−1 in acidic three-electrode tests. Kinetic analyses revealed mixed charge storage contributions from pseudocapacitive and diffusion-influenced processes. In situ/ex situ characterizations confirmed reversible redox evolution of the donor–acceptor complex with preserved molecular backbones. This work shows that tuning intermolecular charge-transfer interactions is an effective strategy for improving the cycling stability of organic cathodes in acidic aqueous electrolytes. Full article
(This article belongs to the Section Surface Engineering for Energy Harvesting, Conversion, and Storage)
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13 pages, 1942 KB  
Article
High-Resolution Investigation of the Interfaces in Cathodic Arc Evaporated TiN/CrAlN Multilayer Coatings
by Saeideh Naghdali, Helene Waldl, Maximilian Schiester, Markus Pohler, Christoph Czettl, Michael Tkadletz and Nina Schalk
Coatings 2026, 16(4), 438; https://doi.org/10.3390/coatings16040438 - 6 Apr 2026
Viewed by 186
Abstract
TiN/CrAlN multilayer coatings were synthesized by cathodic arc deposition using 2-fold substrate rotation and alternating targets. The effect of substrate rotation on the layer sequence, elemental fluctuations and interface quality was examined using high-resolution transmission electron microscopy and atom probe tomography. The layers [...] Read more.
TiN/CrAlN multilayer coatings were synthesized by cathodic arc deposition using 2-fold substrate rotation and alternating targets. The effect of substrate rotation on the layer sequence, elemental fluctuations and interface quality was examined using high-resolution transmission electron microscopy and atom probe tomography. The layers exhibited semi-coherent growth across the interfaces. Minor interface roughness and elemental intermixing limited to below 2 nm at the interface could be observed. Further, the formation of a Ti-enriched sublayer in the Cr1−xAlxN as a result of the 2-fold rotation was identified. Full article
(This article belongs to the Special Issue Recent Developments in Tribological and Mechanical Performance of Metallic Materials and Coatings)
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18 pages, 6112 KB  
Article
Study on Permeability Performance of OGFC Steel Slag Skid-Resistant Wearing Course Based on Interconnected Void Characteristics
by Yanjun Liu, Dengyun Hou, Shuxin Zheng and Cheng Wan
Coatings 2026, 16(4), 440; https://doi.org/10.3390/coatings16040440 - 5 Apr 2026
Viewed by 202
Abstract
To investigate the effects of distribution characteristics of microscopic voids (including the connectivity degree, pore-throat morphology, and size) on the permeability performance of open-graded friction course (OGFC) asphalt mixtures with steel slag as the anti-skid wearing course, two-dimensional computed tomography (CT) images of [...] Read more.
To investigate the effects of distribution characteristics of microscopic voids (including the connectivity degree, pore-throat morphology, and size) on the permeability performance of open-graded friction course (OGFC) asphalt mixtures with steel slag as the anti-skid wearing course, two-dimensional computed tomography (CT) images of OGFC steel slag asphalt mixture specimens were first obtained via X-ray technology. The MATLAB R2022b-based image subtraction algorithm was then adopted to identify the interconnected voids inside the specimens to quantitatively characterize the morphological differences in interconnected voids in OGFC steel slag asphalt mixtures with different gradations. Furthermore, Finite Element simulation by ANSYS 2021 R1 was conducted to explore the influences of the diversion angle of interconnected voids on the water flow characteristics of OGFC steel slag asphalt mixtures, involving the variation laws of water flow velocity, water pressure and flow path in the diversion structure, thereby analyzing the resultant effects on the permeability performance of the mixtures. The results show that the combination of X-ray CT scanning and image processing technology enables more convenient, accurate and intuitive characterization of the internal void distribution characteristics of the mixtures. It was found that the pore-throat properties, including size, length, quantity and equivalent diameter, are the dominant factors restricting the permeability capacity of OGFC steel slag asphalt mixtures. As the diversion angle increases from 20° to 60°, the pressure gradient increases by up to 103.92%. After passing through the diversion section, the flow velocity increases by approximately four times. The streamline density at the channel axis is 4.2–4.5 times that near the channel wall. This study realizes the rapid extraction of void characteristics and the identification of key influencing factors on the permeability performance of OGFC steel slag asphalt mixtures, an achievement that cannot be attained by the previous macroscopic research on the permeability performance of such mixtures. Full article
(This article belongs to the Special Issue Asphalt Interface Engineering and Advanced Functional Coatings for Sustainable Pavements)
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16 pages, 5615 KB  
Article
Sequential Aging Tests of Cyclic Bending for the Reliability Assessment of Laminated Oxide/Silver/Oxide Flexible Transparent Conductors
by Jung-Yen Chang, Yu-Han Kao, Hung-Shuo Chang and Chiao-Chi Lin
Coatings 2026, 16(4), 439; https://doi.org/10.3390/coatings16040439 - 5 Apr 2026
Viewed by 190
Abstract
Flexible transparent conductors (FTCs) are key materials that determine the scalability and performance of flexible optoelectronic devices. This study explores the reliability of FTCs with laminated multilayer structures, specifically oxide/metal/oxide (OMO) films, through sequential testing composed of accelerated weathering and cyclic bending. Commercially [...] Read more.
Flexible transparent conductors (FTCs) are key materials that determine the scalability and performance of flexible optoelectronic devices. This study explores the reliability of FTCs with laminated multilayer structures, specifically oxide/metal/oxide (OMO) films, through sequential testing composed of accelerated weathering and cyclic bending. Commercially available ZTO/Ag/ZTO-based FTCs were selected as a model system to study, and Weibull analysis was employed to assess their failure behaviors. Results illustrate that weathered aged samples exhibit significantly impaired bending lifespan compared to unaged samples due to substrate embrittlement. Hence, the surface cracking mechanism alters as the weathering time is prolonged. Not only the weathering time, but also the thickness of the conductive metal layer plays an important role in influencing the bending reliability behaviors of the OMO FTCs. A sequential aging test that combines two-step UV weathering and an interim manual bending demonstrates that surface cracks can induce the degradation of both optical and electrical properties. Intricately complex bending modes would accelerate the deterioration. This study highlights the critical and synergistic roles of weathering aging and cyclic bending on the reliability of OMO FTCs, offering insights for future design and durability assessments of flexible optoelectronic devices. Research results also provide fundamental information for establishing application-specific reliability testing protocols for FTCs. Full article
(This article belongs to the Section Surface Engineering for Energy Harvesting, Conversion, and Storage)
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25 pages, 6094 KB  
Article
Crack Extension Characteristics of Continuously Reinforced Concrete and Asphalt Composite Pavements Under Thermo-Mechanical Coupling and Non-Uniform Tire Loading
by Xizhong Xu, Xiaomeng Zhang, Xiangpeng Yan, Jincheng Wei, Jiabo Hu and Wenjuan Wu
Coatings 2026, 16(4), 437; https://doi.org/10.3390/coatings16040437 - 4 Apr 2026
Viewed by 190
Abstract
This study investigates the fracture initiation and propagation mechanisms of continuously reinforced concrete–asphalt (CRC+AC) composite pavements under the synergistic effects of diurnal temperature fluctuations and non-uniform tire loading. A three-dimensional (3D) thermo-mechanical coupled finite element (FE) model was developed, with its underlying mechanical [...] Read more.
This study investigates the fracture initiation and propagation mechanisms of continuously reinforced concrete–asphalt (CRC+AC) composite pavements under the synergistic effects of diurnal temperature fluctuations and non-uniform tire loading. A three-dimensional (3D) thermo-mechanical coupled finite element (FE) model was developed, with its underlying mechanical framework validated through laboratory-scale model tests conducted at 20 °C. The experimental results, involving strain monitoring at varying depths, demonstrated a high degree of consistency with numerical predictions in terms of spatial strain distribution, thereby ensuring the model’s reliability in capturing interlayer load-transfer efficiency. Building upon this validated mechanical foundation, numerical simulations were extended to analyze the low-temperature fracture response. The numerical results indicate that the maximum longitudinal and transverse tensile stresses in the asphalt layer are concentrated at the pavement surface, whereas the maximum shear stress occurs at a depth of 2–3 cm near the leading and trailing edges of the wheel load. Under low-temperature gradients, the Mode I stress intensity factor (KI) at the crack tip exhibits a distinct diurnal opening–closing–reopening pattern, peaking at approximately 220 kPa·m1/2 during the early morning hours (05:00–06:00). Furthermore, numerical simulations reveal the significant sensitivity of shear-sliding to axle loads; specifically, the peak Mode II stress intensity factor (KII) increases monotonically from 190 to 230 kPa·m1/2 as the axle load rises from 10 t to 16 t. Under non-uniform contact pressure, longitudinal cracking is primarily characterized by a mixed Mode I and Mode II mechanism driven by coupled tensile and shear stresses, whereas transverse cracking is dominated by Mode II shear failure. These findings suggest that implementing targeted traffic restrictions for overloaded vehicles during identified high-risk time windows can significantly enhance the structural durability and service life of composite pavements in cold regions. Full article
(This article belongs to the Special Issue Advanced Coating Barriers for the Protection of Reinforced Concrete and Pavement, 3rd Edition)
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24 pages, 6050 KB  
Article
Hysteresis Heat Generation in Polyurethane O-Rings: Thermo-Mechanical Coupling Mechanism and Its Quantified Effect on Reciprocating Sealing Performance
by Chang Yang, Wenbo Luo, Jing Liu, Jiawei Liu, Yu Tang and Zhichao Wang
Coatings 2026, 16(4), 436; https://doi.org/10.3390/coatings16040436 - 4 Apr 2026
Viewed by 193
Abstract
Polyurethane O-ring seals are vital for the service life and sealing reliability of hydraulic systems, yet internal hysteresis heat generation under reciprocating motion causes localized temperature rise, altering contact pressure distribution and impairing sealing performance. This study aimed to clarify the coupled effects [...] Read more.
Polyurethane O-ring seals are vital for the service life and sealing reliability of hydraulic systems, yet internal hysteresis heat generation under reciprocating motion causes localized temperature rise, altering contact pressure distribution and impairing sealing performance. This study aimed to clarify the coupled effects of reciprocating motion parameters on O-ring hysteresis heat generation and sealing performance. A unified hysteresis heat generation rate expression was derived by combining the time–temperature superposition principle with the Maier–Göritz model, and the heat source model was integrated into a thermo-mechanically coupled finite element analysis (FEA) framework, validated by matching simulated and experimental temperature rise histories. Under baseline conditions, hysteresis heating causes the O-ring’s peak contact pressure to decrease by approximately 0.4 MPa during the outward stroke. Parametric analysis revealed that elevated operating parameters increase contact pressure to maintain effective sealing, but simultaneously intensify hysteresis heating. Quantitatively, the maximum O-ring temperature was highly sensitive to operating conditions, reaching 63.6 °C at 8 MPa hydraulic pressure, 60.0 °C at a 90 Hz reciprocating frequency, and up to 81.5 °C for a friction coefficient of 0.2. Although the current framework is limited by the exclusion of interfacial frictional heating, it enables the reliable quantitative prediction of thermal loads. Ultimately, this study provides a robust method for assessing sealing safety margins and offers theoretical guidance for the structural optimization of hydraulic sealing systems. Full article
(This article belongs to the Special Issue Polymer Coatings and Polymer Composites: Testing and Modeling)
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18 pages, 1516 KB  
Article
Fire Behavior and Thermal Performance of Nano-Clay-Modified EVA Encapsulation for Building-Integrated Photovoltaic Systems
by Haoming Yuan, Weishan Yang and Yixin Su
Coatings 2026, 16(4), 435; https://doi.org/10.3390/coatings16040435 - 3 Apr 2026
Viewed by 225
Abstract
The building-integrated photovoltaic (BIPV) system has advantages in construction and energy, but due to the use of flammable polymer packaging materials, it introduces complex fire safety-related challenges. Although polymer backboards are traditionally considered to be the main combustible components in photovoltaic modules, recent [...] Read more.
The building-integrated photovoltaic (BIPV) system has advantages in construction and energy, but due to the use of flammable polymer packaging materials, it introduces complex fire safety-related challenges. Although polymer backboards are traditionally considered to be the main combustible components in photovoltaic modules, recent studies have shown that ethylene–vinyl acetate (EVA) packaging materials play a key role in the development of fires. This study investigated the fire behavior, optical properties and system-level fire effects of montmorillonite (MMT) nano-clay-modified EVA packaging materials. Through the 50 kW/m2 conical calorimeter test, optical transmittance measurement and the accelerated aging test, pure EVA and EVA containing 3% MMT were evaluated, and the measured fire parameters were further incorporated into the simplified BIPV cavity fire model. The results show that MMT modification reduces the peak heat release rate of EVA by about 30%, delays the ignition time, and increases the formation of carbides, while maintaining the optical transmittance of more than 88%. At the system level, the reduction in heat release leads to a decrease in the cavity temperature and delays the ignition of adjacent insulation materials. These findings establish a direct link between material-level fire behavior and the fire performance of BIPV systems, indicating that nano-clay-modified EVA is a feasible strategy that can improve the fire safety of BIPV systems integrated into the facade without compromising optical or durability requirements. Full article
(This article belongs to the Section Functional Polymer Coatings and Films)
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18 pages, 9791 KB  
Article
The Influence of Zn on the Surface Tension and Wettability of the Al-10Si Alloy on IF Steel at 1023 K
by Xinyan Chen, Ya Liu, Changjun Wu and Xuping Su
Coatings 2026, 16(4), 434; https://doi.org/10.3390/coatings16040434 - 3 Apr 2026
Viewed by 166
Abstract
Objective: This work aims to reduce the surface tension of an aluminum–silicon alloy melt by adding different amounts of the Zn element, thus improving the coatability and coating quality of hot-dip aluminum plating on steel plates. Method: Wetting experiments were conducted at 1023 [...] Read more.
Objective: This work aims to reduce the surface tension of an aluminum–silicon alloy melt by adding different amounts of the Zn element, thus improving the coatability and coating quality of hot-dip aluminum plating on steel plates. Method: Wetting experiments were conducted at 1023 K using a modified sessile drop method. Conclusions: The addition of the Zn element can reduce the surface tension of the Al-Si alloy, thus decreasing the wettability of the Al-Si alloy. Zn vapor can break down the surface oxide film to expose the fresh melt. The wettability of the Al-10Si alloy on interstitial-free (IF) steel and surface tension were investigated using the modified sessile drop method at 1023 K. Axisymmetric Drop Shape Analysis software was utilized to calculate the contact angles of the Al-10Si-xZn/Al2O3 and Al-10Si-xZn/IF steel systems (x ranges from 0 wt.% to 5 wt.%). Moreover, the microtopography and microstructure of surfaces and cross-sections were analyzed by means of an energy-dispersive spectrometer and scanning electron microscope. The results indicated that the surface tension of the alloy melt gradually decreases with an increase in Zn content, ranging from 874 to 760 mN/m. The contact angle of the Al-10Si-xZn alloy melt on IF steel also progressively decreases with increasing Zn content, which is attributed to the lower surface tension of Zn. This study also discovered that the Zn element can disrupt the oxide film of the Al-10Si alloy, exposing the fresh melt and thereby reducing the surface tension of the alloy liquid, thus enhancing wettability. The addition of Zn might be capable of improving the hot-dip aluminizing coatability of steel plates and the quality of the coating. Full article
(This article belongs to the Special Issue Advances in Metal Composite Coatings and Films: Microstructure, Physicochemical and Mechanical Properties)
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26 pages, 14212 KB  
Article
Experimental Investigation on Mechanical Characteristics of U-Rib Stiffened Plates and Diaphragms for Steel Box Girder Segments Under Axial Compression
by Wenpei Dong, Haoqi Shi, Kai Zhang, Chengtao Yan and Fei Wang
Coatings 2026, 16(4), 433; https://doi.org/10.3390/coatings16040433 - 3 Apr 2026
Viewed by 185
Abstract
In order to study the stability of orthotropic steel box girders and the characteristics of the synergistic stress mechanism of key components, the test method of axial compression using the scale model of steel box girder segments was carried out, and the collaborative [...] Read more.
In order to study the stability of orthotropic steel box girders and the characteristics of the synergistic stress mechanism of key components, the test method of axial compression using the scale model of steel box girder segments was carried out, and the collaborative working performance of the plate ribs of the U-shaped stiffener plate and the influence mechanism of the diaphragm on the structural stability were systematically studied. The results show that the strain difference between the deckplate and the U rib increases significantly with the increase in load, and the distribution law of the end chamber is larger than the middle, and the bottom plate is larger than the top plate and the web plate. The diaphragm mainly bears the tensile force under axial load, which provides out-of-plane restraint for the stiffener, and its restraint effect is the strongest at the web plate and the weakest at the bottom plate. This paper clarifies the synergistic stress mechanism of U-rib stiffeners under high axial pressure conditions, quantifies the contribution of diaphragms to local stability, and provides a theoretical basis for the structural design of similar bridges. Full article
(This article belongs to the Section Environmental Aspects in Colloid and Interface Science)
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19 pages, 4528 KB  
Article
A Comparative Study on the Compressive Mechanical Properties of Modified Raw Bamboo Squares and Carbonized Bamboo Squares as Coarse Aggregate in Concrete
by Yuqi Zhou, Jiasu Ji, Mingmin Ding, Nuowen Geng, Mo Zong and Yang Wei
Coatings 2026, 16(4), 432; https://doi.org/10.3390/coatings16040432 - 3 Apr 2026
Viewed by 202
Abstract
Bamboo is widely available and renewable. Using bamboo blocks to partially replace coarse aggregates in the production of concrete solid bricks shows promising application prospects in areas such as nonload-bearing wall materials. However, as a natural biomass material, bamboo squares have disadvantages such [...] Read more.
Bamboo is widely available and renewable. Using bamboo blocks to partially replace coarse aggregates in the production of concrete solid bricks shows promising application prospects in areas such as nonload-bearing wall materials. However, as a natural biomass material, bamboo squares have disadvantages such as susceptibility to decay, water absorption, swelling, and drying shrinkage, necessitating modification when used as concrete coarse aggregate. This study subjected raw bamboo squares to high-temperature carbonization. The compressive performance of concrete made with these carbonized bamboo squares was first tested and compared with concrete containing raw bamboo squares. Subsequently, both raw and carbonized bamboo squares were modified using conventional methods: polyvinyl alcohol (PVA) treatment, epoxy mortar (EM) treatment, epoxy resin (EPR) treatment, water glass (WG) treatment, and glutinous rice glue treatment. Modified bamboo block concrete specimens were prepared, and their compressive strengths were tested and compared. The results indicated that the compressive mechanical performance of carbonized bamboo block concrete consistently outperformed that of raw bamboo block concrete across all substitution rates. Specifically, the optimal modification method—using epoxy mortar (EM) encapsulation—significantly enhanced the mechanical properties. At a high volumetric replacement rate of 30%, the EM-modified carbonized bamboo concrete achieved a compressive strength of 27.79 MPa, which is 15.1% higher than that of identically treated raw bamboo concrete and far exceeds the standard MU7.5 grade requirements. These quantitative findings provide a solid experimental and theoretical basis for the high-value application of bamboo squares in sustainable concrete solid bricks. Full article
(This article belongs to the Special Issue Corrosion Characteristics and Surface Protection of Coastal Infrastructure)
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17 pages, 4774 KB  
Article
Comparative Analysis of Cold-Mercury Gilding and Traditional Mercury Gilding: Technical Characteristics, Divergence, and Interrelation
by Yanbing Shao, Junchang Yang, Yao Jia and Na Wei
Coatings 2026, 16(4), 431; https://doi.org/10.3390/coatings16040431 - 3 Apr 2026
Viewed by 196
Abstract
Cold-mercury gilding uses mercury as an adhesive to bond gold foil onto the surface of copper and silver artifacts. This technique and mercury gilding (fire gilding) both belong to the Au-Hg system and are closely related in technology. Clarifying the technical differences between [...] Read more.
Cold-mercury gilding uses mercury as an adhesive to bond gold foil onto the surface of copper and silver artifacts. This technique and mercury gilding (fire gilding) both belong to the Au-Hg system and are closely related in technology. Clarifying the technical differences between them is of great significance for revealing the developmental sequence of ancient gilding technologies. On the basis of reconstructing traditional fire gilding, simulated cold-mercury-gilded samples were successfully prepared using experimental archeological methods, and multi-scale characterization was performed using SEM-EDS, XRD, and XPS. The results show that the surface of cold-mercury-gilded samples displays a micromorphology of folded and overlapped gold foil accompanied by locally dense particle aggregation. The cross-section of the gold layer exhibits a multilayer stacked structure, in which mercury is enriched at the gold layer/substrate interface and forms an AuHgCu/Ag diffusion layer. Room-temperature-stable Au-Hg and Ag-Hg phases such as Au2Hg and AgHg are present in the gold layer, reflecting complex phase transformation behavior of the Au-Hg/Ag-Hg system at room temperature. During cold-mercury gilding, liquid mercury first adheres to the gold foil, and then interdiffusion and phase reactions occur between mercury, gold, and copper/silver atoms at room temperature. Intermetallic compounds and diffusion layers formed at the interface achieve firm bonding between the gold layer and the substrate. Both cold-mercury gilding and mercury gilding achieve metallurgical bonding through atomic interdiffusion. However, affected by differences in the initial state of mercury and operating temperature, the phase transformation and atomic diffusion behaviors of the system differ significantly, which are ultimately reflected in the cross-sectional structure of the gold layer, the composition of the interfacial diffusion layer, and the types of phases. Therefore, mercury-gilded artifacts show superior gold layer durability and bonding strength with the substrate compared with cold-mercury-gilded artifacts. Both techniques pioneered the application of mercury in metallic gilding and represent important innovations in ancient surface decoration technology. Full article
(This article belongs to the Topic Microstructure and Properties in Metals and Alloys, 4th Edition)
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5 pages, 246 KB  
Editorial
Special Issue: “Laser-Assisted Coating Techniques and Surface Modifications”
by Haiying Song and Fujiang Tao
Coatings 2026, 16(4), 430; https://doi.org/10.3390/coatings16040430 - 3 Apr 2026
Viewed by 204
Abstract
With its outstanding directionality, high energy density, and flexible controllability, laser technology has become a key and multifunctional core tool in advanced manufacturing systems [...] Full article
(This article belongs to the Special Issue Laser-Assisted Coating Techniques and Surface Modifications)
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14 pages, 6712 KB  
Article
Smart Superhydrophobic Surfaces with Reversible Thermochromism for On-Demand Photothermal Anti-Icing
by Shengqi Lu, Junjie Huang, Liming Liu and Yanli Wang
Coatings 2026, 16(4), 429; https://doi.org/10.3390/coatings16040429 - 3 Apr 2026
Viewed by 225
Abstract
Photothermal superhydrophobic surfaces represent a promising solution for passive anti-icing; however, the persistent high solar absorption of static black coatings often leads to undesirable overheating under non-icing conditions. To address this limitation, we developed a smart superhydrophobic polydimethylsiloxane (PDMS) surface embedded with thermochromic [...] Read more.
Photothermal superhydrophobic surfaces represent a promising solution for passive anti-icing; however, the persistent high solar absorption of static black coatings often leads to undesirable overheating under non-icing conditions. To address this limitation, we developed a smart superhydrophobic polydimethylsiloxane (PDMS) surface embedded with thermochromic capsules (TC) (S-PDMS/TC) featuring reversible thermochromic capability via a facile combination of spin-coating and femtosecond laser ablation. The resulting hierarchical micro-grid structure acts as a sacrificial layer, shielding fragile nanostructures against mechanical abrasion, while endowing the surface with robust superhydrophobicity (contact angle > 155°). Uniquely, S-PDMS/TC exhibits an adaptive color transition from pale yellow to deep black when the temperature drops below 5 °C. This response enables on-demand photothermal enhancement, significantly boosting solar absorption in freezing environments while minimizing heat absorption at room temperature. Consequently, S-PDMS/TC demonstrates superior anti-icing performance, extending the freezing time to 310 s and reducing ice adhesion strength to 40.4 kPa. Notably, during photothermal de-icing, the meltwater exhibits spontaneous dewetting behavior driven by the replenishment of the air cushion, effectively preventing secondary icing. This work presents a mechanically durable and intelligent strategy for ice protection, successfully balancing efficient de-icing with thermal management. Full article
(This article belongs to the Special Issue Developments in Anti-Icing Coatings for Cold Environments)
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20 pages, 25127 KB  
Article
Investigation of Tool Wear and Surface Integrity in Turning γ-TiAl Alloy Under High-Pressure Cooling
by Erliang Liu, Yifan Xu, Baiwei Zhu, Limin Shi and Hailang Zhou
Coatings 2026, 16(4), 428; https://doi.org/10.3390/coatings16040428 - 3 Apr 2026
Viewed by 237
Abstract
To address the issues of high cutting temperature and insufficient heat dissipation during the machining of γ-TiAl alloys, this study systematically investigates the effects of three cooling strategies—dry cutting, flood cooling, and high-pressure cooling—on tool wear and surface integrity. The variations in tool [...] Read more.
To address the issues of high cutting temperature and insufficient heat dissipation during the machining of γ-TiAl alloys, this study systematically investigates the effects of three cooling strategies—dry cutting, flood cooling, and high-pressure cooling—on tool wear and surface integrity. The variations in tool wear, surface morphology, surface roughness, surface defects, microstructure, and microhardness were analyzed in detail. The experimental results indicate that adhesive wear is the dominant wear mechanism under all three cooling conditions. Owing to its superior penetration capability, high-pressure cooling significantly suppresses tool wear, although it may induce groove wear. In terms of surface integrity, high-pressure cooling significantly improves the machined surface quality while reducing surface defects, plastic deformation, and work hardening. Compared with dry cutting, the surface roughness decreases by approximately 9.1%–39.0%, the thickness of the plastically deformed layer is reduced by up to 50.74%, and the degree of work hardening decreases by approximately 11.5%–14.5%. With increasing cutting speed, the surface roughness, plastically deformed layer thickness, and degree of work hardening increase under all three cooling conditions; however, high-pressure cooling still maintains the best overall performance at high cutting speeds. These results indicate that high-pressure cooling effectively suppresses thermo-mechanical coupling in the cutting zone by enhancing coolant penetration and lubrication, thereby providing an efficient approach to reducing tool wear and improving the surface quality of machined γ-TiAl alloys. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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16 pages, 4729 KB  
Article
Analysis of Cutting Equation for Micro-Groove Tool and Its Impact on Shear Angle and Cutting Force in Tuning AISI201
by Wenfeng Yang, Lingyun Yang, Jian Liu and Jinxing Wu
Coatings 2026, 16(4), 427; https://doi.org/10.3390/coatings16040427 - 3 Apr 2026
Viewed by 197
Abstract
The face of cutting tools serves as the critical interface for chip–tool interaction and wear initiation, significantly influencing tool performance and service life. By implementing micro-groove structures on the face to reduce the chip–tool contact area, the cutting mechanics of the tool are [...] Read more.
The face of cutting tools serves as the critical interface for chip–tool interaction and wear initiation, significantly influencing tool performance and service life. By implementing micro-groove structures on the face to reduce the chip–tool contact area, the cutting mechanics of the tool are altered. Theoretical analysis indicates that the cutting equations of the grooved tool have changed, with the modified tool exhibiting a larger shear angle compared to the original design. Finite element simulations and experiments demonstrate that grooved tool exhibit optimized cutting mechanics, characterized by a larger shear angle and improved edge sharpness. The shear angle of grooved tool is increased by about 3 degrees and the chip thickness is reduced by about 0.05 mm. Cutting tests confirm that the grooved tool reduces the main cutting force by more than 18%, with a smaller wear area on the face and improved wear conditions near the cutting edge. Due to materials such as stainless steel and titanium alloy, which have similar difficult-to-machine properties. The present results are based on AISI 201 and the specific groove geometry used in this study, and further work is required before generalizing to other difficult-to-cut materials and groove designs. In summary, based on the experimental data, the micro-groove cutting tool outperforms the original tool in terms of shear angle, cutting force, and durability. Specifically, the shear angle of the micro-groove cutting tool is larger, the cutting force is reduced, and the wear on the face is decreased. Full article
(This article belongs to the Special Issue Surface Engineering of Alloys and Metals: Material Properties and Coating Performance)
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15 pages, 8294 KB  
Article
Corrosion Protection of a Novel Inhibitor@LDH Conversion Film on Steel: Insights from Long-Term Marine Atmospheric Field Experiments
by Zhenxi Wen, Qibo Li, Yuwan Tian, Yue Yu and Danmei Wu
Coatings 2026, 16(4), 426; https://doi.org/10.3390/coatings16040426 - 2 Apr 2026
Viewed by 262
Abstract
The marine atmospheric environment, characterized by a high chloride content, high humidity, and a high corrosion rate of structural steel, urgently demands anticorrosion methods that are compatible with other technologies such as alloy steel and organic coatings. In this study, an inhibitor-loaded conversion [...] Read more.
The marine atmospheric environment, characterized by a high chloride content, high humidity, and a high corrosion rate of structural steel, urgently demands anticorrosion methods that are compatible with other technologies such as alloy steel and organic coatings. In this study, an inhibitor-loaded conversion film was grown in situ on a steel surface to prevent chloride-induced corrosion. Specifically, a Mg-Fe layered double hydroxide (LDH) conversion film was grown on the steel surface, and p-aminobenzoate (pAB−) inhibitor ions were intercalated into the LDH. After half a year of natural corrosion in the actual marine atmospheric environment, the average corrosion rate of steel with the inhibitor@LDH film was 36.20 µm/a, which was 21% lower than that of the steel substrate (45.91 µm/a). The inhibitor@LDH film also effectively suppressed local pitting corrosion, with the density of corrosion pits significantly reduced by 64%. Furthermore, the inhibitor@LDH film promoted the formation of a denser and thinner rust layer on the steel surface, with a smaller crack width, fewer cracks, and an increased α-FeOOH/γ-FeOOH ratio. In summary, the inhibitor@LDH conversion film inhibits general and local corrosion on steel in a marine atmospheric environment. Full article
(This article belongs to the Special Issue Advanced Corrosion- and Wear-Resistant Coatings)
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19 pages, 8328 KB  
Article
Effect of Ni Interlayer on Microstructure and Properties of C276 Hastelloy/Q235 Steel Cladding Plates
by Lin Lv, Mingfang Wu, Fei Long, Mingkuan Zhou and Juan Pu
Coatings 2026, 16(4), 425; https://doi.org/10.3390/coatings16040425 - 2 Apr 2026
Viewed by 209
Abstract
C276 Hastelloy/Q235 Steel cladding plates were prepared by vacuum-sealed hot rolling (VSHR) with a small hole. The effects of different Ni interlayers on the macro-morphology, microstructure, mechanical properties and corrosion resistance of the cladding plates were systematically investigated. The results indicated that without [...] Read more.
C276 Hastelloy/Q235 Steel cladding plates were prepared by vacuum-sealed hot rolling (VSHR) with a small hole. The effects of different Ni interlayers on the macro-morphology, microstructure, mechanical properties and corrosion resistance of the cladding plates were systematically investigated. The results indicated that without an interlayer, a large number of Mo-rich white M6C particles formed near the C276 Hastelloy side, along with the formation of black Cr-Mn oxides at the interface. The addition of the Ni interlayer suppressed the diffusion of the C element from the Q235 Steel toward the C276 Hastelloy, consequently reducing the precipitation of M6C carbides and Cr-Mn oxides. When the Ni interlayer thickness was 0.5 mm, the M6C carbides on the Hastelloy side disappeared completely. The incorporation of a Ni interlayer increased the hardness of the C276 Hastelloy side and the interface layer, as well as the shear strength of the cladding plate. This was mainly because the Ni interlayer acted as a barrier to suppress the development of a Mo/Cr-depleted zone adjacent to the C276 Hastelloy and decrease interfacial Cr-Mn oxides, thus enhancing interfacial bonding. Under all three conditions, the cladding plates were bent without cracking. Moreover, the addition of a Ni interlayer also improved the corrosion resistance of the cross-section of the C276 Hastelloy. XPS analysis of the passive film revealed that the corrosion resistance was primarily attributed to the formation of Mo- and Cr-containing oxides on the surface. The corrosion resistance reached the optimal with the Ni interlayer thickness of 0.5 mm, in which Mo and Cr played a crucial role. Full article
(This article belongs to the Section High-Energy Beam Surface Engineering and Coatings)
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21 pages, 4221 KB  
Article
Linear and Nonlinear Optical Properties of SiO2/TiO2 Heterostructures Grown by Plasma-Enhanced Atomic Layer Deposition
by Jinsong Liu, Martin Mičulka, Raihan Rafi, Sebastian Beer, Denys Sevriukov, Stefan Nolte, Sven Schröder, Andreas Tünnermann, Isabelle Staude and Adriana Szeghalmi
Coatings 2026, 16(4), 424; https://doi.org/10.3390/coatings16040424 - 2 Apr 2026
Viewed by 230
Abstract
Second harmonic (SH) radiation can only be generated in non-centrosymmetric bulk crystals under electric dipole approximation. Nonlinear thin films made from bulk crystals are technologically challenging because of complex and high-temperature fabrication processes. In this work, heterostructures made of two distinct amorphous materials, [...] Read more.
Second harmonic (SH) radiation can only be generated in non-centrosymmetric bulk crystals under electric dipole approximation. Nonlinear thin films made from bulk crystals are technologically challenging because of complex and high-temperature fabrication processes. In this work, heterostructures made of two distinct amorphous materials, namely SiO2 and TiO2, were prepared through plasma-enhanced atomic layer deposition (PEALD) with deposition temperature of 100 °C. By using the uniaxial dispersion model, we characterized the form birefringence of the deposited films, which can play a crucial role for the phase-matching condition in nonlinear waveguides or other nonlinear optical applications. By applying a fringe-based technique, we determined the largest diagonal component of the effective bulk second-order susceptibility, χzzz(2) = 1.30 ± 0.13 pm/V, at a wavelength of 1032 nm. Noteworthy, we observed strong SHG signals from two-component nanolaminates, which are several orders of magnitude larger than those from single layers. The SHG signals from our samples only require the broken inversion symmetry at the interface. Here, optical properties of nanocomposites can be precisely engineered using the promising PEALD technology. Full article
(This article belongs to the Collection Advanced Optical Films and Coatings)
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