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Effects of Surface Layer Modification on Fatigue, Corrosion and Wear...
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Effects of Surface Layer Modification on Fatigue, Corrosion and Wear Behavior of Metallic Materials

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Corrosion, Wear and Erosion".

Deadline for manuscript submissions: 25 May 2025 | Viewed by 7651

Special Issue Editors

Prof. Dr. Jordan Todorov Maximov

E-Mail Website
Guest Editor
Material Science and Mechanics of Materials, Technical University of Gabrovo, 5300 Gabrovo, Bulgaria
Interests: mechanics of materials; surface engineering; surface integrity; fatigue strength improvement; wear resistance improvement; surface coldworking
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Galya Velikova Duncheva

E-Mail Website
Guest Editor
Material Science and Mechanics of Materials, Technical University of Gabrovo, 5300 Gabrovo, Bulgaria
Interests: mechanics of materials; surface engineering; surface integrity; fatigue strength improvement; wear resistance improvement; surface coldworking; process optimization; finite element simulation
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The surface layers (SL) of structural and machine elements are their outermost layers, and therefore, are the physical boundary interacting with other elements and/or the environment. In the process of operation, SLs are the most loaded. Working stresses are maximized; as a result, fatigue micro-cracks appear and develop and are, often aggressively, subjected to intense wear and the direct impact of the environment. Because of the defining role of SL in the operation process and their different physical–mechanical state compared to that of the bulk material, the idea of modifying only the surface layers and not the entire component is many times more effective. This special issue focuses on the effects of surface layer modification on the fatigue, corrosion and wear behavior of metallic materials.

Potential topics include the following:

  • Synthesis of new and development and research of existing techniques for modifying the surface layers of metal components by:
    • Creating a barrier or other protection (coatings such as PVD, CVD, thermal spraying, etc.; thin film deposition);
    • Surface treatments (cold working such as burnishing, shot peening, etc.; thermo-chemical diffusion; electron beam/laser hardening);
    • Combined (sequential application of known techniques) and hybrid (simultaneous application of known techniques) processes aimed at achieving a synergistic effect.
  • Correlations between surface modification techniques and surface integrity of the components.
  • Correlations between surface modification techniques and operating behaviour (fatigue, corrosion and wear) of the components.
  • Correlations between surface integrity and operating behaviour.

Prof. Dr. Jordan Todorov Maximov
Prof. Dr. Galya Velikova Duncheva
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Coatings is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • surface modification
  • fatigue behaviour
  • corrosion resistance
  • wear resistance
  • surface integrity
  • surface cold working
  • burnishing
  • coatings
  • thermo-chemical diffusion
  • electron-beam/laser surface hardening

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Published Papers (7 papers)

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Research

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11 pages, 7117 KiB  
Article
Analysis of Influence of Ultrasonic Shot Peening on Surface Plastic Behavior of Superalloy
by Xihui Shi, Jin Cai, Liwen Zhang, Yuliang Pan and Hao Wu
Coatings 2024, 14(11), 1382; https://doi.org/10.3390/coatings14111382 - 30 Oct 2024
Viewed by 496
Abstract
This work focuses on the effects of ultrasonic shot peening (USP) on grain refinement and orientation behavior in the surface region of GH4151 superalloy. The microstructure evolution of the alloy under USP durations were studied. The effects of USP-induced grain refinement, orientation, and [...] Read more.
This work focuses on the effects of ultrasonic shot peening (USP) on grain refinement and orientation behavior in the surface region of GH4151 superalloy. The microstructure evolution of the alloy under USP durations were studied. The effects of USP-induced grain refinement, orientation, and dislocation motion behavior were analyzed. The results indicated that during the USP process, the plastic deformation of the surface layer of superalloys is accompanied by changes in grain size and orientation. The random impact of the spheres on the surface area promotes grain refinement and grain rotation, enhancing the randomness of grain orientations and reducing the texture strength and the proportion of “soft” orientation distribution. Over a long period of treatment, a large number of spheres cause the slip planes and slip directions of each grain to rotate due to the additional shear stress from the impact, resulting in relatively consistent plastic deformation on the surface and the enhanced randomness of grain orientations, thus reducing the high texture strength introduced by previous machining processes. The understanding of dislocation pile-up behavior and the relationship between externally applied shear stress, pile-up characteristics, and grain refinement is essential for optimizing the USP process and achieving the desired material properties. Full article
(This article belongs to the Special Issue Effects of Surface Layer Modification on Fatigue, Corrosion and Wear Behavior of Metallic Materials)
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15 pages, 4192 KiB  
Article
Optimizing Powder-to-Liquid Ratios in Lost Foam Casting Coatings: Impacts on Viscosity, Shear Thinning Behavior, Coating Weight, and Surface Morphology
by Guojin Sun, Cairang Qian, Zhenggui Li and Qi Wang
Coatings 2024, 14(9), 1089; https://doi.org/10.3390/coatings14091089 - 24 Aug 2024
Viewed by 775
Abstract
This study explores the effects of the powder-to-liquid ratio on the performance characteristics of lost foam casting coatings. The investigation focuses on how variations in this ratio affect key properties, including apparent viscosity, shear thinning behavior, coating weight, and surface morphology. Through a [...] Read more.
This study explores the effects of the powder-to-liquid ratio on the performance characteristics of lost foam casting coatings. The investigation focuses on how variations in this ratio affect key properties, including apparent viscosity, shear thinning behavior, coating weight, and surface morphology. Through a series of controlled experiments, coatings were prepared with different powder-to-liquid ratios and assessed for their physical and application properties. The results indicate that increasing the powder-to-liquid ratio raises the apparent viscosity and modifies shear thinning behavior. Notably, ratios exceeding 2.0 result in a sharp increase in viscosity that impedes coating application. The optimal powder-to-liquid ratio was determined to be between 2.0 and 2.2, where coatings demonstrated enhanced uniformity, improved particle distribution, and superior surface morphology. Coating weight increased up to a ratio of 2.2 but decreased beyond this threshold due to excessive viscosity. Both microscopic and macroscopic analyses confirmed that a ratio of 2.0 to 2.2 strikes the best balance for coating performance. These findings underscore the importance of precise powder-to-liquid ratio control to optimize the quality of lost foam casting coatings, offering valuable insights for refining coating formulations and application techniques in industrial contexts. Full article
(This article belongs to the Special Issue Effects of Surface Layer Modification on Fatigue, Corrosion and Wear Behavior of Metallic Materials)
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18 pages, 8596 KiB  
Article
Corrosion Efficiency of Zn-Ni/ZrO2 and Zn-Co/ZrO2 Bi-Layer Systems: Impact of Zn-Alloy Sublayer Thickness
by Nelly Boshkova, Daniela Stoyanova, Irina Stambolova, Ognian Dimitrov, Sylviya Simeonova, Georgi Avdeev, Miglena Peshova, Vasil Bachvarov, Sonya Smrichkova and Nikolai Boshkov
Coatings 2024, 14(7), 792; https://doi.org/10.3390/coatings14070792 - 25 Jun 2024
Viewed by 1109
Abstract
The presented manuscript demonstrates the effect of the thickness of a zinc alloy sublayer on the corrosion resistance and stability of three types of bi-layer systems composed of Co- or Ni-modified zinc coatings (both as sublayers) and a top sol–gel ZrO2 film [...] Read more.
The presented manuscript demonstrates the effect of the thickness of a zinc alloy sublayer on the corrosion resistance and stability of three types of bi-layer systems composed of Co- or Ni-modified zinc coatings (both as sublayers) and a top sol–gel ZrO2 film in a 5% NaCl solution. In order to obtain more detailed information, the alloy sublayers were electrodeposited with three different thicknesses (1, 5 and 10 µm, respectively) on a low-carbon steel substrate. Three consecutive dip-coated ZrO2 sol–gel layers were deposited thereafter on the individual zinc alloy sublayers. For comparison, an ordinary electrodeposited zinc coating was obtained and investigated. The aim of this study was to evaluate the effect of the thickness of the zinc-based sublayer on the protective characteristics of the bi-layer systems. The surface morphology features and the phase composition of the latter systems were examined using scanning electron microscopy (SEM), atomic force microscopy (AFM), water contact angle (WCA) measurements and X-ray diffraction (XRD) analyses. The corrosion stability was evaluated by means of potentiodynamic polarization (PDP) curves and polarization resistance (Rp) measurements. The zirconia finish layers possessed an amorphous, dense and hydrophobic nature, while the sublayers were multicrystalline. The results confirmed the increased corrosion resistance of the protective system, which contains electrodeposited sublayer of Zn-Co alloy with a 10 µm thickness in a corrosive test medium. Full article
(This article belongs to the Special Issue Effects of Surface Layer Modification on Fatigue, Corrosion and Wear Behavior of Metallic Materials)
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16 pages, 19888 KiB  
Article
A Deep Learning Image Corrosion Classification Method for Marine Vessels Using an Eigen Tree Hierarchy Module
by Georgios Chliveros, Iason Tzanetatos and Stylianos V. Kontomaris
Coatings 2024, 14(6), 768; https://doi.org/10.3390/coatings14060768 - 18 Jun 2024
Viewed by 1132
Abstract
This paper involves the automation of a visual characterisation technique for corrosion in marine vessels, as it appears in the hull preventive coatings of marine vessels and their surfaces. We propose a module that maximizes the utilisation of features learned by a deep [...] Read more.
This paper involves the automation of a visual characterisation technique for corrosion in marine vessels, as it appears in the hull preventive coatings of marine vessels and their surfaces. We propose a module that maximizes the utilisation of features learned by a deep convolutional neural network to identify areas of corrosion and segment pixels in regions of inspection interest for corrosion detection. Our segmentation module is based on Eigen tree decomposition and information-based decision criteria in order to produce specific corroded spots—regions of interest. To assess performance and compare it with our method, we utilize several state-of-the-art deep learning architectures.The results indicate that our method achieves higher accuracy and precision while maintaining the significance score across the entire dataset. To the best of our knowledge, this is the first Eigen tree-based module in the literature in the context of trained neural network predictors for classifying corrosion in marine vessel images. Full article
(This article belongs to the Special Issue Effects of Surface Layer Modification on Fatigue, Corrosion and Wear Behavior of Metallic Materials)
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13 pages, 4748 KiB  
Article
Influence of Thickness on the Structure and Biological Response of Cu-O Coatings Deposited on cpTi
by Ivana Ilievska, Veronika Ivanova, Dimitar Dechev, Nikolay Ivanov, Maria Ormanova, Maria P. Nikolova, Yordan Handzhiyski, Andreana Andreeva, Stefan Valkov and Margarita D. Apostolova
Coatings 2024, 14(4), 455; https://doi.org/10.3390/coatings14040455 - 10 Apr 2024
Viewed by 980
Abstract
This work presents results on the influence of thickness on the structure and biological response of Cu-O coatings deposited on commercially pure titanium (cpTi) substrates using direct current (DC) magnetron sputtering. The deposition times were 5, 10, and 15 min to obtain coatings [...] Read more.
This work presents results on the influence of thickness on the structure and biological response of Cu-O coatings deposited on commercially pure titanium (cpTi) substrates using direct current (DC) magnetron sputtering. The deposition times were 5, 10, and 15 min to obtain coatings with different thicknesses. The results show that the films deposited for 5, 10, and 15 min correspond to thicknesses of 41, 74, and 125 nm, respectively. The phase composition of the coatings is in the form of a double-phase structure of CuO and Cu2O in all considered cases. The roughness is on the nanometric scale and no obvious trend as a function of the thickness can be observed for the deposited films. Also, it was found that, with an increase in the thickness of the films, the distribution of the heights becomes closer to symmetrical. The antimicrobial efficacy of different Cu-O-coated cpTi substrates was examined using a direct contact experiment. A possible bactericidal effect was investigated by inoculating a 200 μL bacterial suspension on CuO-coated cpTi and cpTi (control) for 24 h at 37 °C. The results showed that Cu-O-coated cpTi substrates have a 50%–60% higher antimicrobial activity than the substrate. At the same time, human osteosarcoma (MG-63) cells growing on Cu-O-coated cpTi substrates showed 80% viability following 24 h incubation. Depending on magnetron sputtering process parameters, a different coating thickness, various crystallite phase compositions, and diverse biocompatibility were obtained. Full article
(This article belongs to the Special Issue Effects of Surface Layer Modification on Fatigue, Corrosion and Wear Behavior of Metallic Materials)
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13 pages, 4344 KiB  
Article
Effect of Process Parameters on the Microstructure and Wear Resistance of Fe3Al/Cr3C2 Composites
by Yaohui Wang, Yingkai Feng, Xiaohu Sun, Shaoquan Liu and Guoqiang Chen
Coatings 2024, 14(4), 384; https://doi.org/10.3390/coatings14040384 - 25 Mar 2024
Cited by 1 | Viewed by 1024
Abstract
In this paper, a brake cylinder coating comprising a composite material of an Fe3Al and Cr3C2 mixed powder was prepared by adding laser cladding onto carbon structural steel. We studied the influence of process parameters on the microstructure [...] Read more.
In this paper, a brake cylinder coating comprising a composite material of an Fe3Al and Cr3C2 mixed powder was prepared by adding laser cladding onto carbon structural steel. We studied the influence of process parameters on the microstructure and tribological properties of the cladding materials using scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and 3D white light interferometer and wear tests. The influence of different processes on the morphology of the carbide strengthening phase was found to be relatively small with a Cr3C2 content of 15 wt.%. The carbides mainly exhibited a network structure in each group of cladding layers. The area of the network strengthening phase varied under different processes. Of the cladding layers formed with different processes, the scanning speed of the 0.003 m/s cladding layer had the lowest wear rate. When the laser power was too low or the powder feed rate was too high, unmelted Cr3C2 particles could be found in the cladding layer. During the wear process, the particles peeled off, causing severe abrasive wear. When the powder feeding rate was too low, more materials in the base material entered the cladding layer. This made the composition of the cladding layer similar to that of the grinding material, resulting in severe adhesive wear. Full article
(This article belongs to the Special Issue Effects of Surface Layer Modification on Fatigue, Corrosion and Wear Behavior of Metallic Materials)
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Review

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18 pages, 6467 KiB  
Review
Multifunctional Inhibitors: Additives to Control Corrosive Degradation and Microbial Adhesion
by Judit Telegdi
Coatings 2024, 14(5), 617; https://doi.org/10.3390/coatings14050617 - 14 May 2024
Cited by 1 | Viewed by 1476
Abstract
The chemical, electrochemical and microbiological corrosive degradation of metals is a versatile harmful problem that causes significant economic loss all over the world. The mitigation of these undesired processes needs basic knowledge on the mechanisms of processes in order to control these reactions [...] Read more.
The chemical, electrochemical and microbiological corrosive degradation of metals is a versatile harmful problem that causes significant economic loss all over the world. The mitigation of these undesired processes needs basic knowledge on the mechanisms of processes in order to control these reactions with environmentally acceptable chemicals and techniques. This paper focuses on the up-to-date possibilities that help in the mitigation of chemical/electrochemical corrosion and, at the same time, in decrease the deposition of corrosion relevant microorganisms, as the microbes in biofilms are more dangerous than the planktonic cells. Some chemicals or coatings due to their specific properties can fulfill multiple functions; they are able to control the corrosion caused by aggressive materials (that could be the metabolites of a corrosion relevant microorganism) and, at the same time, reduce the microbial adhesion. These additives that have important application possibilities in the chemical industry, marine environment, medical field, nanoelectronics, etc., can save energy, materials consumption and cost, and, at the same time, the efficiency is improved. All resolutions will be brought into prominence when the same chemicals (either in dissolved form or in coatings/nanolayers) can effectively control the different appearance of corrosion and, additionally, the microbial adhesion and microbiologically influenced corrosion. Full article
(This article belongs to the Special Issue Effects of Surface Layer Modification on Fatigue, Corrosion and Wear Behavior of Metallic Materials)
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