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Advances in Metal Coatings for Wear and Corrosion Applications

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: 20 December 2024 | Viewed by 7471

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Special Issue Editors

Prof. Dr. Georgi Kostadinov

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Guest Editor

Institute of Soil Science, Agrotechnology and Plant Protection "Nikola Pushkarov", Sofia, Bulgaria
Interests: mechanisation of agriculture; agricultural engineering; mechanical properties; materials engineering; coating surface engineering; electrospark deposition; mathematical modelling; optimisation

Dr. Todor Penyashki

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Guest Editor

Institute of Soil Sciences, Agrotechnologies and Plant Protection “N. Pushkarov”, Sofia, Bulgaria
Interests: mechanical properties; materials engineering; coating surface engineering; electrospark deposition; technologies; tribology; powder technologies; intermetallic; mechanisation of agriculture; agricultural engineering

Dr. Mara Kandeva

E-Mail Website
Guest Editor

Faculty of Industrial Technology, Technical University of Sofia, Sofia, Bulgaria
Interests: tribology; friction; coating; lubrication; wear testing; surface engineering; materials

Special Issue Information

Dear Colleagues,

Wear- and corrosion-resistant coatings are among the most effective technological means for increasing the durability of equipment and machines and reducing labour, energy, and material costs; they are being increasingly used in all technical fields. In many cases, using coatings is the only possible or most economical decision to solve several technical problems. However, for the various products' numerous and different operating conditions, it is necessary to create coatings that differ in composition, structure, and morphology.

On the other hand, the modern intensification of production and operational processes also gives rise to the need to develop and create new coatings with improved composition, structure, construction, and properties. That is why the creation and development of new functional coatings with improved characteristics and increased service properties and the development of new coating materials and technologies for their deposition is one of the current research directions in advanced materials science.

This Special Issue, titled “Advances in Metal Coatings for Wear and Corrosion Applications”, aims to collate the latest advances in the field of wear- and corrosion-resistant coatings and provide a platform for their dissemination among scientists, researchers, and industrial experts.

We cordially invite you to contribute a research or review article to this Special Issue and make your scientific work more discoverable and popular.

We encourage the submission of work focused on, but not limited to, the following topics:

Development and improvement of processes and methods for surface modification;
Development of new coating materials and improvement of the technologies for their application, with possibilities to control the processes and characteristics of the resulting coatings;
Patterns of formation, quality characteristics, and properties of the resulting coatings;
Creation of and research into new wear- and corrosion-resistant coatings from new roofing materials, meeting different requirements depending on the specific operating conditions, such as improved microhardness, connection to the substrate, strength and toughness, heat resistance, biocompatibility, wear resistance, corrosion resistance, and economic efficiency;
Composite and multilayer coatings with a structure of layers with different phase compositions, and also with an amorphous and nanocrystalline structure;
Studies on the influence of the type and processing modes of surface treatment and the type of covering materials on the composition, structure, morphology, mechanism, and regularities of friction wear and corrosion wear of the modified surfaces;
Methods for research and modelling of the surface properties.

Prof. Dr. Georgi Kostadinov
Dr. Todor Penyashki
Dr. Mara Kandeva
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. Materials is an international peer-reviewed open access semimonthly 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

coatings
processes and methods
surface modification
new coating materials
structure
wear and corrosion resistance
characteristics
properties
biocompatibility

Published Papers (10 papers)

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Research

Jump to: Review

15 pages, 12716 KiB

Open AccessArticle

Microstructure and Erosion Wear of In Situ TiC-Reinforced Co-Cr-W-C (Stellite 6) Laser-Cladded Coatings

by Jacek Górka, Tomasz Poloczek, Damian Janicki, Aleksandra Lont, Sławomir Topór, Marcin Żuk and Agnieszka Rzeźnikiewicz

Materials 2024, 17(13), 3101; https://doi.org/10.3390/ma17133101 - 25 Jun 2024

Viewed by 219

Abstract

The article presents research results on the possibility of shaping the structure and properties of Co-Cr-W-C-Ti alloys (type Stellite 6) using laser cladding technology. Cobalt-based alloys are used in several industries because they are characterized by high erosion, abrasion, and corrosion resistance, retaining these properties at high temperatures. To further increase erosion resistance, it seems appropriate to reinforce material by in situ synthesis of hard phases. Among the transition metal carbides (TMCs), titanium carbide is one of the hardest and can have a positive effect on the extension of the lifetime of components made from cobalt-based alloys. In this article, concentration of C, W, and Ti due to the possibility of in situ synthesis of titanium carbides was subjected to detailed analysis. The provided research includes macrostructure and microstructure analysis, X-ray diffraction (XRD), microhardness, and penetrant tests. It was found that the optimal concentrations of Ti and C in the Co-Cr-W-C alloy allow the formation of titanium carbides, which significantly improves erosion resistance for low impact angles. Depending on the concentrations of titanium, carbon, and tungsten in the molten metal pool, it is possible to shape the alloy structure by influencing to morphology and size of the reinforcing phase in the form of the complex carbide (Ti,W)C. Full article

(This article belongs to the Special Issue Advances in Metal Coatings for Wear and Corrosion Applications)

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16 pages, 10059 KiB

Open AccessArticle

Increasing the Working Time of Forging Tools Used in the Industrial Process of Producing a Disk-Type Forging Assigned for a Gearbox through the Application of Hybrid Layers

by Marek Hawryluk, Łukasz Dudkiewicz, Jacek Borowski, Jan Marzec and Roger Tkocz

Materials 2024, 17(12), 3005; https://doi.org/10.3390/ma17123005 - 19 Jun 2024

Viewed by 332

Abstract

The article discusses the phenomena and destructive mechanisms occurring on the surface of 1.2344 steel dies used during the hot forging of disc-type forgings. Preliminary research has shown that gas nitriding alone, used so far, is insufficient due to the occurrence of destructive mechanisms other than abrasive wear, such as thermal and thermomechanical fatigue, which cause the average durability of such tools to be approximately 5000 forgings. Analyses were also carried out to assess the load on forging tools using numerical modeling (Forge 3.0NxT), which confirmed the occurrence of large and cyclically changing thermal and mechanical loads during the forging process. Therefore, in order to increase operational durability, it was decided to use two types of hybrid layers, differing in the PVD coating used: TiCrAlN and CrN, and then subjected to gas nitriding (GN). The obtained results showed that, depending on the area of the tool and the current working conditions, the applied PVD coatings protect the surface layer of the tool against the dominant destructive mechanisms. In both cases, the strength increased to the level of 7000 forgings, the tools could continue to work, and globally, slightly better results were obtained for the GN+TiCrAlN layer. The CrN-type layer protects the tool more against thermal fatigue, while the TiCrAlN layer is more resistant to abrasive wear. In areas where the hybrid layer was worn, a decrease in hardness was observed from 1300 HV to 600–700 HV, and in places of intense material flow (front—point 2 and tool bridge—point 9) the hardness dropped to below 400 HV, which may indicate local tempering of the material. Moreover, the research has shown that each process and tool should be analyzed individually, and the areas in the tool where particular destructive mechanisms dominate should be identified, so as to further protect the forging tool by using appropriate protective coatings in these areas. Full article

(This article belongs to the Special Issue Advances in Metal Coatings for Wear and Corrosion Applications)

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20 pages, 4939 KiB

Open AccessArticle

Wear Rate, Tribo-Corrosion, and Plastic Deformation Values of Co-Cr-Mo Alloy in Ringer Lactate Solution

by Raimundo Nonato Alves Silva, Rui Neto, Angela Vieira, Priscila Leite, Polyana Radi, Carolina Hahn da Silveira, M. D. Santos, Filomena Viana and Lúcia Vieira

Materials 2024, 17(10), 2327; https://doi.org/10.3390/ma17102327 - 14 May 2024

Viewed by 551

Abstract

This study investigates the tribocorrosion performance of a cast Co-Cr-Mo alloy prepared using casting and electromagnetic stirring (EMS) at specific frequencies. The tribocorrosion behaviour of the alloy was evaluated when exposed to Ringer’s lactate solution to optimize the EMS parameters and improve its properties. The research focuses on biomedical implant applications and explores how EMS affects alloy wear and corrosion resistance. As did the friction coefficient and wear volume, the wear rate of samples produced with EMS frequencies of 75 Hz and 150 Hz decreased. These improvements are attributed to the ability of EMS to refine grain size and homogenize the microstructure, thereby increasing the resistance to tribocorrosion. Techniques such as scanning electron microscopy (SEM) and profilometry were used for surface and wear analysis, while mechanical properties were evaluated through instrumented indentation tests. The findings confirm that EMS improves the alloy’s durability and tribocorrosion resistance, making it highly suitable for demanding biomedical applications such as joint replacements. This highlights the importance of advanced manufacturing techniques in optimizing biomedical alloys for simulated body conditions. Full article

(This article belongs to the Special Issue Advances in Metal Coatings for Wear and Corrosion Applications)

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21 pages, 8416 KiB

Open AccessArticle

Wear Mechanisms, Composition and Thickness of Antiwear Tribofilms Formed from Multi-Component Lubricants

by Anna E. Tsai and Kyriakos Komvopoulos

Materials 2024, 17(10), 2324; https://doi.org/10.3390/ma17102324 - 14 May 2024

Viewed by 603

Abstract

The antiwear properties of tribofilms formed on steel surfaces lubricated with various multi-component lubricants were investigated at an elevated temperature and under load-speed conditions conducive to sliding in the boundary lubrication regime. The lubricants contained base oil, reduced-level (secondary) zinc dialkyl dithiophosphate (ZDDP), and nitrogenous dispersant. The wear resistance of the tribofilms produced from different oil blends was evaluated in the context of the rate of change in the sliding track volume (wear rate for material loss) and the load-bearing capacity, chemical composition, and thickness of the tribofilms. Surface profilometry and scanning electron microscopy were used to quantify the wear performance and detect the prevailing wear mechanisms, whereas X-ray photoelectron spectroscopy elucidated the chemical composition and thickness of the tribofilms. The oil blends without ZDDP did not produce tribofilms with adequate antiwear properties, whereas the oil blends containing ZDDP and dispersant generated tribofilms with antiwear characteristics comparable to those of tribofilms produced from blends with a higher ZDDP content. Although dispersants can suspend oil contaminants and preserve the cleanness of the sliding surfaces, it was found that they can also reduce the antiwear efficacy of ZDDP. This was attributed to an additive-dispersant antagonistic behavior for surface adsorption sites affecting tribofilm chemistry and mechanical properties. Among the blends containing a mixture of ZDDP and dispersant, the best antiwear properties were demonstrated by the tribofilm produced from the blend consisting of base oil, 0.05 wt% ZDDP, and a bis-succinimide dispersant treated with ethylene carbonate. The findings of this investigation demonstrate the potential of multi-component lubricants with reduced-content ZDDP and nitrogen-based dispersant to form effective antiwear tribofilms. Full article

(This article belongs to the Special Issue Advances in Metal Coatings for Wear and Corrosion Applications)

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15 pages, 9466 KiB

Open AccessArticle

Study of Nanohydroxyapatite Coatings Prepared by the Electrophoretic Deposition Method at Various Voltage and Time Parameters

by Klaudia Malisz, Beata Świeczko-Żurek, Jean-Marc Olive, Grzegorz Gajowiec, Gilles Pecastaings, Aleksandra Laska and Alina Sionkowska

Materials 2024, 17(10), 2242; https://doi.org/10.3390/ma17102242 - 10 May 2024

Viewed by 539

Abstract

The aim of the work is to compare the properties of nanohydroxyapatite coatings obtained using the electrophoretic deposition method (EDP) at 10 V, 20 V, and 30 V, and with deposit times of 2 and 5 min. The primary sedimentation was used to minimize the risk of the formation of particle agglomerates on the sample surface. Evaluation of the coating was performed by using a Scanning Electron Microscope (SEM), Energy-Dispersive Spectroscopy (EDS), Atomic Force Microscopy (AFM), optical profilometer, drop shape analyzer, and a nanoscratch tester. All of the coatings are homogeneous without any agglomerates. When low voltage (10 V) was used, the coatings were uniform and continuous regardless of the deposition time. The increase in voltage resulted in the formation of cracks in the coatings. The wettability test shows the hydrophilic behavior of the coatings and the mean contact angle values are in the range of 20–37

°

. The coatings showed excellent adhesion to the substrate. The application of a maximum force of 400 mN did not cause delamination in most coatings. It is concluded that the optimal coating for orthopedic implants (such as hip joint implants, knee joint implants or facial elements) is obtained at 10 V and 5 min because of its homogeneity, and a contact angle that promotes osseointegration and great adhesion to the substrate. Full article

(This article belongs to the Special Issue Advances in Metal Coatings for Wear and Corrosion Applications)

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16 pages, 12831 KiB

Open AccessArticle

Electrochemical Characterization of Electrodeposited Copper in Amine CO₂ Capture Media

by Corentin Penot, Kranthi Kumar Maniam and Shiladitya Paul

Materials 2024, 17(8), 1825; https://doi.org/10.3390/ma17081825 - 16 Apr 2024

Viewed by 597

Abstract

This study explores the stability of electrodeposited copper catalysts utilized in electrochemical CO₂ reduction (ECR) across various amine media. The focus is on understanding the influence of different amine types, corrosion ramifications, and the efficacy of pulse ECR methodologies. Employing a suite of electrochemical techniques including potentiodynamic polarization, linear resistance polarization, cyclic voltammetry, and chronopotentiometry, the investigation reveals useful insights. The findings show that among the tested amines, CO₂-rich monoethanolamine (MEA) exhibits the highest corrosion rate. However, in most cases, the rates remain within tolerable limits for ECR operations. Primary amines, notably monoethanolamine (MEA), show enhanced compatibility with ECR processes, attributable to their resistance against carbonate salt precipitation and sustained stability over extended durations. Conversely, tertiary amines such as methyldiethanolamine (MDEA) present challenges due to the formation of carbonate salts during ECR, impeding their effective utilization. This study highlights the effectiveness of pulse ECR strategies in stabilizing ECR. A noticeable shift in cathodic potential and reduced deposit formation on the catalyst surface through periodic oxidation underscores the efficacy of such strategies. These findings offer insights for optimizing ECR in amine media, thereby providing promising pathways for advancements in CO₂ emission reduction technologies. Full article

(This article belongs to the Special Issue Advances in Metal Coatings for Wear and Corrosion Applications)

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14 pages, 28820 KiB

Open AccessArticle

Research on Coated Tool Life and Wear in Ta-2.5W Alloy Turning

by Bo Hu, Zhengqing Liu, Yang Wu, Qiucheng Wang and Dayu Shu

Materials 2024, 17(7), 1481; https://doi.org/10.3390/ma17071481 - 24 Mar 2024

Viewed by 717

Abstract

Due to its inherent high hardness, strength, and plasticity, tantalum–tungsten (Ta-W) alloy poses a considerable challenge in machining, resulting in pronounced tool wear, diminished tool lifespan, and suboptimal surface quality. This study undertook experiments utilizing uncoated carbide tools, TiAlN-coated carbide tools, and AlTiN-coated carbide tools for machining Ta-2.5W alloy. The investigation delved into the intricacies of surface temperature, tool longevity, and the distinctive wear characteristics under varying coating materials and cutting parameters. Concurrently, a comprehensive exploration of the wear mechanisms affecting the tools was conducted. Among the observed wear modes, flank wear emerged as the predominant issue for turning tools. Across all three tool types, adhesive wear and diffusion wear were identified as the principal wear mechanisms, with the TiAlN-coated tools displaying a reduced level of wear compared to their AlTiN-coated counterparts. The experimental findings conclusively revealed that TiAlN-coated carbide tools exhibited an extended tool lifespan in comparison to uncoated carbide tools and AlTiN-coated carbide tools, signifying superior cutting performance. Full article

(This article belongs to the Special Issue Advances in Metal Coatings for Wear and Corrosion Applications)

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16 pages, 4961 KiB

Open AccessArticle

Improving the Surface Quality and Tribological Characteristics of 3D-Printed Titanium Parts through Reactive Electro-Spark Deposition

by Georgi Kostadinov, Todor Penyashki, Antonio Nikolov and Aleksandar Vencl

Materials 2024, 17(2), 382; https://doi.org/10.3390/ma17020382 - 12 Jan 2024

Cited by 1 | Viewed by 652

Abstract

This work presents the results of research conducted with an aim to improve the surface quality, hardness and wear resistance of titanium alloy Ti6Al4V, obtained via the laser powder bed fusion of metals (PBF-LB/M) process of additive manufacturing (AM) known as the 3D printing of metals. The 3D surfaces were coated via reactive electrospark deposition (RESD) with low-pulse energy and electrode materials of low-melting metals and multi-component hard alloys. The relationship between the electrical parameters of the RESD process and the quality, composition, structure, microhardness and wear resistance of the treated surfaces were investigated and analysed. It was found that the roughness and thickness of the resulting surface layers could be changed by changing the RESD modes within the limits of 2.5–5 µm and 8–20 µm, respectively. RESD processing allowed us to achieve two to five times lower roughness than that of titanium AM surfaces. The microhardness and wear resistance of the RESD surfaces are two to four times higher than those of the titanium substrate. Possibilities for the purposeful synthesis of new wear-resistant phases and compounds and for obtaining surface layers with predetermined thickness and roughness were established. It was shown that the subsequent reaction’s electrospark processing helped to simultaneously reduce the roughness and increase the hardness and wear resistance of the modified surfaces, and can be successfully used instead of the material-energy-labour and machine-intensive finishing treatments of the titanium surfaces obtained after 3D printing. Full article

(This article belongs to the Special Issue Advances in Metal Coatings for Wear and Corrosion Applications)

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12 pages, 3871 KiB

Open AccessArticle

Testing for Abrasion Resistance of WC-Co Composites for Blades Used in Wood-Based Material Processing

by Joanna Wachowicz, Joanna Fik, Zbigniew Bałaga and Grzegorz Stradomski

Materials 2023, 16(17), 5836; https://doi.org/10.3390/ma16175836 - 25 Aug 2023

Cited by 1 | Viewed by 683

Abstract

Commonly used tool materials for machining wood-based materials are WC-Co carbides. Although they have been known for a long time, there is still much development in the field of sintered tool materials, especially WC-Co carbides and superhard materials. The use of new manufacturing methods (such as FAST—field-assisted sintering technology), which use pulses of electric current for heating, can improve the properties of the materials used for cutting tools, thereby increasing the cost-effectiveness of machining. The ability to increase tool life without the downtime associated with tool wear allows significant cost savings, particularly in mass production. This paper presents the results of a study of the effect of grain size and cobalt content of carbide tool sinters on the tribological properties of the materials studied. The powders used for consolidation were characterised by irregular shape and formed agglomerates of different sizes. Tribological tests were carried out using the T-01 (ball-on-disc) method. In order to determine the wear kinetics, the entire friction path was divided into 15 cycles of 200 m and the weight loss was measured after each stage. In order to determine the mechanism and intensity of wear of the tested materials under technically dry friction conditions, the surface of the tested sinters was observed before the test and after 5, 10, and 15 cycles. The conclusions of the study indicate that the predominant effect of surface cooperation at the friction node is abrasion due to the material chipping that occurs during the process. The results confirm the influence of sintered grain size and cobalt content on durability. In the context of the application of the materials in question for cutting tools, it can be pointed out that sintered WC(0.4)_4 has the highest potential for use in the manufacture of cutting tools. Full article

(This article belongs to the Special Issue Advances in Metal Coatings for Wear and Corrosion Applications)

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Review

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20 pages, 8121 KiB

Open AccessReview

Research Progress on the Wear Resistance of Key Components in Agricultural Machinery

by Ying Wang, Dong Li, Cheng Nie, Pan Gong, Junsheng Yang, Zhigang Hu, Bin Li and Ming Ma

Materials 2023, 16(24), 7646; https://doi.org/10.3390/ma16247646 - 14 Dec 2023

Cited by 1 | Viewed by 1537

Abstract

Agricultural mechanization is crucial in enhancing production efficiency, alleviating labor demands, reducing costs, improving agricultural product quality, and promoting sustainable development. However, wear and tear are inevitable when using agricultural machinery. The failure of critical wear-resistant parts is responsible for over 50% of rural machinery breakdowns. For instance, a domestic combine harvester typically only operates trouble-free for 20 to 30 h, and the service life of a rotary plow knife is approximately 80 h. Investigating the wear performance of key farm machinery components reinforces machinery design and maintenance strategies, extends machinery lifespans, enhances agricultural production efficiency, and advances agrarian sustainability. This paper provides a comprehensive overview of the latest research on the wear resistance of crucial agricultural machinery components. It delves into the factors influencing the wear resistance of these components and explores current effective measures to address wear-related issues. Additionally, it also summarizes the challenges and opportunities in researching the wear performance of key components in agricultural machinery and future development directions. Full article

(This article belongs to the Special Issue Advances in Metal Coatings for Wear and Corrosion Applications)

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Planned Papers

The below list represents only planned manuscripts. Some of these manuscripts have not been received by the Editorial Office yet. Papers submitted to MDPI journals are subject to peer-review.

Title: Characterization of wear resistance and corrosion resistance of plasma paste borided layers produced on pure titanium
Authors: Piotr Dziarski; Natalia Makuch
Affiliation: Poznan University of Technology, Institute of Materials Science and Engineering, Pl. M.Sklodowskiej-Curie 5, 60-965 Poznan, Poland
Abstract: Commercially pure titanium was plasma paste borided using various temperatures of the process. An increase in boriding temperature resulted in an increase in the thickness of the borided layer. All produced layers consisted of an outer compact TiB2 zone and an inner TiB zone in the form of whiskers penetrating into the substrate. The presence of hard titanium borides resulted in a significant increase in wear resistance compared to the non-borided pure titanium. However, the thickness of the layer produced was of great importance for wear behavior in respect of the time required for completely destruction of the layer. Higher wear resistance was characteristic of the TiB2 layer due to its compact character. Whereas, the specific morphology of TiB whiskers resulted in their lower wear resistance compared to the outer TiB2 layer. Plasma paste boriding of pure titanium also had an advantageous effect on corrosion resistance compared to the non-borided pure titanium.

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Advances in Metal Coatings for Wear and Corrosion Applications

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