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Novel Coatings for Corrosion Protection

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

Deadline for manuscript submissions: closed (28 February 2023) | Viewed by 20148

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Prof. Dr. Qiang Wei

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Guest Editor

School of Mechanical Engineering, Hebei University of Technology, Tianjin 300401, China
Interests: man-machine and environmental engineering research including space environment simulation and effects; cross-scale and interdisciplinary research from materials science; mechanical engineering to intelligence manufacture; traditional Chinese medicine; dental material; heat treatment; surface engineering
Special Issues, Collections and Topics in MDPI journals

Dr. Chaoqun Xia

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Guest Editor

School of Materials Science and Engineering, Hebei University of Technology, Tianjin 300401, China
Interests: corrosion and protection of metal materials; new high-performance titanium/zirconium-based alloys; bulk amorphous/nanocrystalline alloys

Special Issue Information

Dear Colleagues,

Corrosion causes many economic losses and wastes resources every year. Common protection methods include cathodic protection, coating protection and adding corrosion inhibitors. Among them, the coating protection method has the characteristics of simple construction, long service life and high cost performance and has been widely studied and applied. The emerging anti-corrosion coating has the advantages of excellent mechanical properties, corrosion resistance and design plasticity. A variety of new anti-corrosion coatings have been applied more and more in all areas of life and play an extremely important role. This Special Issue of Coatings focuses on the Novel Coating for Corrosion Protection. The topics of interest for this this Special Issue include (but are not restricted to) the following:

Novel coatings to control and minimize corrosion;
Coatings for corrosion control in general;
Anti-corrosion coatings in extreme environment and conditions, e.g., for space environment, radiation, etc.;
Service behavior of coatings in corrosion conditions;
Characterization of nano-, micro- and macro-corrosion characterization of coatings under various environment conditions;
Any other aspects of anti-corrosion coatings.

Prof. Dr. Qiang Wei
Dr. Chaoqun Xia
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

anti-corrosion coatings
corrosion protection
service behavior
extreme environment
characterization analysis

Published Papers (9 papers)

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Research

13 pages, 4399 KiB

Open AccessArticle

Coating Condition Detection and Assessment on the Steel Girder of a Bridge through Hyperspectral Imaging

by Pengfei Ma, Jiaoli Li, Ying Zhuo, Pu Jiao and Genda Chen

Coatings 2023, 13(6), 1008; https://doi.org/10.3390/coatings13061008 - 29 May 2023

Cited by 6 | Viewed by 1916

Abstract

The organic coating of bridge steel girders is subjected to physical scratches, corrosion, and aging in natural weathering. The breakdown of the coating may cause serviceability and safety problems if left unnoticed. Conventional coating inspection is time-consuming and lacks information about the coating’s chemical integrity. A hyperspectral imaging method is proposed to detect the condition of steel coatings based on coating-responsive features in reflectance spectra. A field test was conducted on the real-world bridge, which shows obvious signs of degradation. The hyperspectral signature enables an assessment of the coating’s health and defect severity. The results indicated that the coating scratch can be effectively located in the domain of a hyperspectral image and the scratch depth can be determined by mapping a scratch depth indicator (SDI = R532 nm/R641 nm). Rust sources and products in steel girders can be identified by the unique spectral signatures in the VNIR range, and the rust stains (and thus stain areas) scattered on the coating can be pinpointed at pixel level by the chloride rust (CR) indicators >1.11 (CR = R733 nm/R841 nm). The chemical integrity of a topcoat is demonstrated by the short-wave infrared spectroscopy and the topcoat degradation can be evaluated by the decreased absorption at 8000 cm⁻¹ and 5850 cm⁻¹. Hyperspectral imaging enables faster and more reliable coating condition detection by the spectral features and provides an alternative for multi-object coating detection. Full article

(This article belongs to the Special Issue Novel Coatings for Corrosion Protection)

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12 pages, 5882 KiB

Open AccessArticle

Microstructure and Mechanical Properties of Co-Deposited Ti-Ni Films Prepared by Magnetron Sputtering

by Xiaolin Zhang, Yi Ding, Honglu Ma, Ruibin Zhao, Liangquan Wang and Fanyong Zhang

Coatings 2023, 13(3), 524; https://doi.org/10.3390/coatings13030524 - 27 Feb 2023

Cited by 3 | Viewed by 1643

Abstract

Ti-Ni films with various Ni contents (16.5, 22.0, 33.5 at. %) were deposited on Al alloy substrates using DC magnetron co-sputtering. The effects of Ni target power and substrate bias (−10, −70, −110 V) on morphologies, crystallography, nanomechanical properties and scratch behavior of films were studied. All the deposited Ti-Ni films exhibited a BCC structure of β-Ti (Ni). The Ti-Ni films grew with a normal columnar structure with good bonding to substrates. When increasing the Ni target power and substrate bias, the grain size grew larger and the surface became denser. The as-deposited Ti-Ni films significantly improved the hardness (>4 GPa) of the Al alloy substrate. With the increase of bias voltage, the hardness and modulus of the film increased. The hardness and modulus of the Ti-22.0Ni film prepared at −70 V bias were 5.17 GPa and 97.6 GPa, respectively, and it had good adhesion to the substrate. Full article

(This article belongs to the Special Issue Novel Coatings for Corrosion Protection)

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23 pages, 7406 KiB

Open AccessArticle

Combination of Electron Beam Surface Structuring and Plasma Electrolytic Oxidation for Advanced Surface Modification of Ti6Al4V Alloy

by Hugo Mora-Sanchez, Florian Pixner, Ricardo Buzolin, Marta Mohedano, Raúl Arrabal, Fernando Warchomicka and Endzhe Matykina

Coatings 2022, 12(10), 1573; https://doi.org/10.3390/coatings12101573 - 18 Oct 2022

Cited by 4 | Viewed by 1534

Abstract

The objective of this work is to study for the first time the combination of electron beam (EB) surface structuring and plasma electrolytic oxidation (PEO) with the aim of providing a multiscale topography and bioactive surface to the Ti6Al4V alloy for biomedical applications. Ca and P-containing coatings were produced via 45 s PEO treatments over multi-scale EB surface topographies. The coatings morphology and composition were characterized by a means of scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS). The effect on the previous EB topography was evaluated by means of a 3D optical profilometry and electrochemical response via potentiodynamic polarization tests. In general, the PEO process, morphology, composition and growth rate of the coatings were almost identical, irrespective of the topography treated. Minimal local differences were found in terms of morphology, and the growth rate were related to specific topographical features. Nevertheless, all the PEO-coated substrates presented essentially the same corrosion resistance. Electrochemical tests revealed a localized crevice corrosion susceptibility of all the bare EB topographies, which was successfully prevented after the PEO treatment. Full article

(This article belongs to the Special Issue Novel Coatings for Corrosion Protection)

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20 pages, 4484 KiB

Open AccessFeature PaperArticle

Characterization of Prepared Superhydrophobic Surfaces on AZ31 and AZ91 Alloys Etched with ZnCl₂ and SnCl₂

by Leoš Doskočil, Pavlína Šomanová, Jiří Másilko, Martin Buchtík, Michaela Hasoňová, Lukáš Kalina and Jaromír Wasserbauer

Coatings 2022, 12(10), 1414; https://doi.org/10.3390/coatings12101414 - 27 Sep 2022

Cited by 11 | Viewed by 1727

Abstract

Superhydrophobic surfaces were prepared using a two-step method that involved the etching of AZ31 and AZ91 magnesium alloys and then modifying the etched alloys with stearic acid. Magnesium alloys etched with ZnCl₂ and SnCl₂ exhibited surfaces roughened with micro- and nanoscale hierarchical structures consisting of two chemically distinct regions (Zn/Zn(OH)₂ or Sn/SnO₂ and Mg(OH)₂). An optimum etching time of ten minutes was chosen for both etchants. Superhydrophobic surfaces with the highest contact angle were prepared when stearic acid reacted with the etched alloys at 50 °C for 4 h. Stearic acid was bound as zinc stearate and magnesium stearate on Mg alloys etched with ZnCl₂ and SnCl₂ solutions, respectively. The superhydrophobic process on AZ31 alloys etched with ZnCl₂ and SnCl₂ improved the corrosion resistance in phosphate buffered saline (PBS) solution compared to bare AZ31 alloy, with the use of ZnCl₂ etchant leading to better results. An improvement in the corrosion resistance of AZ91 alloy was observed when the stearic-acid-modified AZ91 alloy was etched with SnCl₂. In contrast, the use of ZnCl₂ etchant to pretreat AZ91 alloy resulted in a significant deterioration in corrosion properties compared to bare AZ91 alloy. The microstructure of the Mg alloy had an impact on the etching and modification process. On the basis of the findings, a characterization of the chemistry of etching magnesium alloys and the formation of superhydrophobic surfaces was proposed. Magnesium alloys were prepared with superhydrophobic surfaces, incorporating antibacterial metals, features which may increase their potential for use in medical applications. Full article

(This article belongs to the Special Issue Novel Coatings for Corrosion Protection)

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12 pages, 2517 KiB

Open AccessFeature PaperArticle

Mechanical Properties Evolution and Damage Mechanism of Kevlar Fiber under Ozone Exposure in Near-Space Simulation

by Jie Ma, Qiang Wei, Hongbo Fan, Zhengpan Qi and Ning Hu

Coatings 2022, 12(5), 584; https://doi.org/10.3390/coatings12050584 - 24 Apr 2022

Cited by 2 | Viewed by 2506

Abstract

The stratospheric airship, a long-term floating vehicle in near-space, has become a new hotspot in aerospace exploration. The airship’s envelope material is vulnerable to ozone exposure in near-space and degrades. This paper used typical Kevlar fiber as the research material for an ozone exposure experiment in a near-space simulated environment. The results showed that the elongation of the Kevlar fiber decreased and the elastic modulus increased after ozone exposure. The tensile strength of fiber decreased gradually with an increase in ozone concentration and exposure time. When ozone concentration increased from 0 pphm to 1000 pphm, the tensile strength of fiber decreased from 2397 MPa to 2059 MPa. With increasing ozone exposure time from 0 h to 1000 h under ozone concentration 1000 pphm, the tensile strength of fiber decreased from 2332 MPa to 1954 MPa. The hydrogen bonds and partial amide groups in the fiber structure were damaged, and the surface chemical functional groups of the Kevlar fiber were reassembled under ozone exposure. Low molecular weight oxidation products, including -COO- structures, formed on the surface of the Kevlar fiber. This work explores the ground simulation method in a near-space environment and enriches the service data of airship envelope materials. Full article

(This article belongs to the Special Issue Novel Coatings for Corrosion Protection)

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14 pages, 5611 KiB

Open AccessArticle

Asynchronous Synergistic Damage Effect of Atomic Oxygen and Space Micro Debris on Kapton Film

by Peiyi Tong, Qiang Wei, Ning Hu and Xueguang Chen

Coatings 2022, 12(2), 179; https://doi.org/10.3390/coatings12020179 - 30 Jan 2022

Cited by 7 | Viewed by 2462

Abstract

In the low earth orbit environment, many environmental factors lead to the degradation of material properties. The synergistic effect of long-term atomic oxygen (AO) irradiation and instantaneous impact of micro debris (MD) on long-term and transient space environmental factors has attracted more and more attention. In this paper, the performance evolution of Kapton films under the conditions of MD, AO single factor load spectrum and MD + AO, AO + MD asynchronous synergistic load spectrum were studied by laser driven flyer and microwave atomic oxygen technology. The macro morphology, optical properties and quality changes of Kapton films before and after each load spectrum were compared, and the mechanism of micro morphology and structure changes was explored. The results show that compared with MD + AO loading spectrum, the surface holes of Kapton films are larger under AO + MD load spectrum condition, the residual aluminum particles formed by reverse sputtering of Al particles during impact are less, the average transmittance of the film decreases slightly, and the weight loss of Kapton film is slightly more under the same atomic oxygen exposure time. Under the condition of MD + AO load spectrum, plastic tearing cracks, craters and holes are formed on the surface of Kapton film; the edge of the hole formed under the condition of AO + MD load spectrum is straight, without obvious depression and tear characteristics. Under the condition of MD + AO load spectrum, due to the adhesion of Al after the impact of micro debris, the subsequent atomic oxygen erosion of the film is reduced, so the C-C bond is not seriously damaged, and a considerable part of the residual aluminum flyer is oxidized to alumina by atomic oxygen; The AO + MD loading spectrum test makes the film first eroded by atomic oxygen, resulting in the reduction in C–O bond and C–C bond. The fracture of C–N bond is caused by the hypervelocity impact of micro debris. Hypervelocity impact leads to the thermal decomposition of the material, destroys the C–N bond in the imide ring and generates an N–H bond. This study will provide a method reference and a reference for the multi-factor ground collaborative simulation of space environment of spacecraft materials. Full article

(This article belongs to the Special Issue Novel Coatings for Corrosion Protection)

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15 pages, 9347 KiB

Open AccessArticle

Impact of Engineering Surface Treatment on Surface Properties of Biomedical TC4 Alloys under a Simulated Human Environment

by Hongyun Deng, Kuixue Xu, Shuguang Liu, Chaofeng Zhang, Xiongwei Zhu, Haoran Zhou, Chaoqun Xia and Chunbao Shi

Coatings 2022, 12(2), 157; https://doi.org/10.3390/coatings12020157 - 27 Jan 2022

Cited by 3 | Viewed by 2045

Abstract

The impact of sandblasting, anodic oxidation, and anodic oxidation after sandblasting on the surface structure and properties of titanium alloys was investigated. It was found that the surface treatments had a significant influence on the surface roughness values, contact angle values, Vickers hardness, wear resistance, and corrosion resistance of titanium alloys. The surface roughness of titanium alloys with sandblasting treatment was increased by 67% compared to untreated specimen. The Vickers hardness of titanium alloys treated with anodic oxidation after sandblasting was found to increase from 380.8 HV to 408.5 HV, which was increased by 7.3%. The surface treatments in this work improved the wear resistance of the titanium alloys to some extent, and it can be found that the wear scar width is reduced by up to 18.6%. The corrosion resistance of the titanium alloys was found to improve on anodic oxidation. Sandblasting was found to increase surface roughness and promote the formation of a porous layer during the anodization process, resulting in a slight decrease in corrosion resistance. The corrosion current density was increased by 21% compared to the untreated specimen. The corrosion current density of the titanium alloy treated with anodic oxidation decreased to 7.01 × 10⁻⁸ A/cm². The corrosion current density was decreased by 24% compared to the untreated specimen. The corrosion current density of the titanium alloys treated with anodic oxidation after sandblasting decreased to 7.63 × 10⁻⁸ A/cm². The corrosion current density was decreased by 8.8% compared to the specimen with anodic oxidation. The anodic oxidation provided a hydrophilic property for the surface of Ti alloys, which could show a better osseointegration characteristic than that of sandblasting. The impact of the surface treatments on surface structure and properties of titanium alloys was studied. Full article

(This article belongs to the Special Issue Novel Coatings for Corrosion Protection)

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17 pages, 46030 KiB

Open AccessArticle

Numerical Analysis of High-Velocity Oxygen Fuel Thermal-Spray Process for Fe-Based Amorphous Coatings

by Jianxing Yu, Xin Liu, Yang Yu, Haoda Li, Pengfei Liu, Ruoke Sun, Limin Wang and Pengfei Li

Coatings 2021, 11(12), 1533; https://doi.org/10.3390/coatings11121533 - 13 Dec 2021

Cited by 4 | Viewed by 2367

Abstract

High-velocity oxygen fuel (HVOF)-sprayed amorphous alloy coatings usually have advantages of a dense structure that improve their resistance to corrosion, wear, and fatigue in the substrate. The flame flow characteristics and particle behaviors during the spray process have a significant influence on the amorphous coating structure and properties. In this study, a computational fluid dynamics model is enforced to analyze the flame flow and Fe-based amorphous alloy particle behavior in an HVOF spray process. The flame flow temperature, velocity characteristics, and the Fe₄₈Cr₁₅Mo₁₄C₁₅B₆Y₂ Fe-based amorphous alloy particles’ velocities, temperatures, flight trajectories, and mass concentration distribution characteristics are simulated. Moreover, the effects of the oxygen/fuel ratio, particle morphology parameter, particle-injection rate, and angle on the particle behavior are also investigated. Judging from the simulation results, the optimum amorphous alloy particle size varies between 20 and 30 μm, the shape factor is within the range of 0.9–1, the optimum O/F ratio is 3.4, the optimum injection angle is 45°, and the optimum injection rate is 10 m/s. With these conditions, most of the particles settled toward the centerline of the spray gun and are in a semisolid or solid state before affecting the substrate, giving the materials optimal coating structure and performance. Full article

(This article belongs to the Special Issue Novel Coatings for Corrosion Protection)

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14 pages, 6077 KiB

Open AccessArticle

In Situ Polymerization to Boron Nitride-Fluorinated Poly Methacrylate Composites as Thin but Robust Anti-Corrosion Coatings

by Qingqing Hu, Aijuan Lv, Yukang Ma, Yan Wang, Haoyi Zhang, Xin Mi and Qiang Xiao

Coatings 2021, 11(12), 1518; https://doi.org/10.3390/coatings11121518 - 10 Dec 2021

Cited by 2 | Viewed by 2491

Abstract

High-performance anti-corrosion coatings featuring easy processability and thin thickness are highly desired in industry. Yet, solution process coating often faces a sedimentation problem with particles which are used as reinforcement in coatings. In this contribution, boron nitride (BN) was modified by an acrylate silane coupling agent (KH-570) to obtain acrylated BN flakes. Afterwards, the acrylated BN flakes were in situ copolymerized with 2-(perfluorohexyl)ethyl methacrylate to synthesize BN-fluorinated poly methacrylate (PFBP) composites. The as-obtained PFBP composites can form stable coating solutions, in which sedimentation of BN flakes seldom happens. The coating solution can easily form uniform coatings on various substrates with nanoscale thickness, confirmed by scanning electron microscope (SEM). The corrosion resistance of the samples coated PFBP coatings in 3.5 wt.% sodium chloride solution was evaluated by electrochemical impedance spectroscopy (EIS). It is indicated that the incorporation of BN flakes greatly reduce the corrosion rate. Adhesion measurements and abrasion resistance test indicate the PFBP coating performs good adhesion to substrate and robustness. Through the in situ polymerization, acrylated BN flakes are connected with the polymer chain, which inhibits the sedimentation of BN in the coating solution. Additionally, the BN flakes dispersed in the fluorinated polymer act as barriers, improving the corrosion resistance of the coated samples. Full article

(This article belongs to the Special Issue Novel Coatings for Corrosion Protection)

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