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Surface Engineering in Materials (2nd Edition)
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Surface Engineering in Materials (2nd Edition)

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Thin Films and Interfaces".

Deadline for manuscript submissions: 20 October 2025 | Viewed by 6169

Special Issue Editor

Prof. Dr. Maria Richert

E-Mail Website
Guest Editor
Faculty of Management, AGH University of Science and Technology, Krakow Gramatyka 10, 30-067 Krakow, Poland
Interests: metals; surface engineering; nanomaterials; heat treatment; aluminum alloys; management and risk in metal industry
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Surface engineering is present in almost all areas of the economy. Due to the constant demand for various types of protective, decorative, wear-resistant and other coatings, numerous studies are carried out on the improvement of coating deposition techniques, and the mechanisms of their production are investigated. The search for new solutions in surface engineering is the driving force behind the innovative development of coatings in the automotive and aerospace sectors. This Special Issue covers all aspects related to surface engineering. It focuses on innovative solutions for the improvement and protection of surfaces, anti-corrosion coatings, surfaces covered with various types of coatings, produced by both conventional and unconventional methods and techniques. The presented solutions may also relate to the techniques of coating deposition or surface treatment, or to the protection of surfaces against wear or corrosion. The presented research may concern topics such as decorative surfaces, mechanical treatment and surface strengthening. Issues explaining the mechanisms of the formation of layers, coatings and other surface phenomena will be gladly accepted. All works including not only surface tests of products but also tools will be accepted. In particular, we encourage you to present the results of application or potentially application importance. Circular economy and risk in surface technologies may be the subject of studies, in particular the recovery of rare metals and the risks associated with harvesting them.

Prof. Dr. Maria Richert
Guest Editor

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

  • structure and phase composition of surface layers
  • surface residual stresses
  • wear resistance, corrosion resistance, heat resistance
  • wettability, biocompatibility
  • forming the properties of metal surfaces
  • composite and ceramic details
  • durability and reliability of surfaces
  • surface heat treatment, nitriding
  • over manufacturing methods, PVD, CVD, thermal spraying
  • surface protection, painting, anodizing
  • mechanisms of coating
  • circular economy and risk in surface technologies

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Related Special Issue

Published Papers (5 papers)

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Research

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14 pages, 4256 KB  
Communication
Characterization of Hard Coatings Using Acoustic Emission
by Ivana Sára Škrobáková, Peter Gogola, Marián Palcut and Ľubomír Čaplovič
Materials 2025, 18(16), 3777; https://doi.org/10.3390/ma18163777 - 12 Aug 2025
Cited by 1 | Viewed by 354
Abstract
Acoustic emission (AE) testing is a non-destructive method used in various applications. In our work we demonstrate its capabilities and potential in studying the functional properties of physical vapor deposited (PVD) coatings. The goal was to classify the coating damage during indentation testing [...] Read more.
Acoustic emission (AE) testing is a non-destructive method used in various applications. In our work we demonstrate its capabilities and potential in studying the functional properties of physical vapor deposited (PVD) coatings. The goal was to classify the coating damage during indentation testing more objectively by quantifying specific imprint features. The AE response was systematically recorded in nine sample conditions and 27 individual imprints, allowing us to identify correlations between the numerical values derived from the SEM observations and the characteristics of the AE signal. An increase in the delaminated coating area was found to correspond to an exponential increase in the AE signal energy. These findings suggest that AE analysis could reduce the reliance on SEM-based evaluation and help accelerate systematic research in the field of PVD coatings. The advantages of AE testing are discussed and conclusions for practical applications are provided. Full article
(This article belongs to the Special Issue Surface Engineering in Materials (2nd Edition))
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18 pages, 4701 KB  
Article
Investigation of the Wear Resistance of Hard Anodic Al2O3/IF-WS2 Coatings Deposited on Aluminium Alloys
by Joanna Korzekwa, Adam Jarząbek, Marek Bara, Mateusz Niedźwiedź, Krzysztof Cwynar and Dariusz Oleszak
Materials 2025, 18(15), 3471; https://doi.org/10.3390/ma18153471 - 24 Jul 2025
Viewed by 419
Abstract
The anodic oxide layer’s porosity is considered a functional feature, acting as a reservoir of lubricants. This feature enables the design of self-lubricating systems that effectively reduce friction and wear. To improve the tribological performance of Al2O3 anodic coatings on [...] Read more.
The anodic oxide layer’s porosity is considered a functional feature, acting as a reservoir of lubricants. This feature enables the design of self-lubricating systems that effectively reduce friction and wear. To improve the tribological performance of Al2O3 anodic coatings on EN AW 5251 aluminium alloys, this paper presents a modification of the coating with tungsten disulfide (IF-WS2) nanopowder and its effect on coating resistance. The wear properties of Al2O3/IF-WS2 coatings in contact with a cast iron pin were investigated. The results include the analysis of the friction coefficient in the reciprocating motion without oil lubrication at two loads, the analysis of the wear intensity of the cast iron pin, the characterisation of wear scars, and the analysis of SGP parameters. Two-level factorial analysis showed that load and nanomodification significantly affected the load-bearing parameter Rk. Incorporation of the modifier, especially under higher loads, reduced the Rk value, thus improving the tribological durability of the contact pair. Both load and nanomodification had a notable impact on the coefficient of friction. The use of IF-WS2-modified coatings reduced the coefficient, and higher loads further enhanced this effect, by approximately 9% at a load of 0.3 MPa and 15% at a load of 0.6 MPa, indicating improved lubricating conditions under greater contact stress. Full article
(This article belongs to the Special Issue Surface Engineering in Materials (2nd Edition))
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18 pages, 5671 KB  
Article
Stability of the Soft Sparking State in the Plasma Electrolytic Oxidation Process
by Stanisław Pietrzyk and Wojciech Gębarowski
Materials 2025, 18(5), 989; https://doi.org/10.3390/ma18050989 - 24 Feb 2025
Cited by 3 | Viewed by 710
Abstract
Soft sparking is a phenomenon observed during plasma electrolytic oxidation (PEO) performed under alternating current (AC) conditions. It is directly associated with the presence of cathodic polarization during the oxidation process, contributing to enhanced functional coating properties. However, the role of cathodic current [...] Read more.
Soft sparking is a phenomenon observed during plasma electrolytic oxidation (PEO) performed under alternating current (AC) conditions. It is directly associated with the presence of cathodic polarization during the oxidation process, contributing to enhanced functional coating properties. However, the role of cathodic current in oxide-layer formation remains ambiguous. This study presents findings suggesting that soft sparking is a dynamic equilibrium state occurring within a certain stability window, primarily governed by the anodic to cathodic charge ratio in AC cycles. By analyzing soft-sparking behavior under varying cathodic-to-anodic charge ratios, frequency, cathodic pulse duty cycles, and alkalinity of electrolytes, the proposal of a mechanism underlying this process is presented. The authors suggest that the soft-sparking state may be linked to the formation of active sites during cathodic polarization and their subsequent suppression during anodic polarization. This occurs due to oxidation and deposition of Al(OH)3, facilitated by localized OH− ion accumulation in these regions. Additionally, the restricted diffusion of water molecules toward the substrate may play a crucial role in sustaining the soft-sparking state. Full article
(This article belongs to the Special Issue Surface Engineering in Materials (2nd Edition))
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17 pages, 13526 KB  
Article
Thermal Barrier Coating on Diamond Particles for the SPS Sintering of the Diamond–ZrO2 Composite
by Lucyna Jaworska, Michał Stępień, Małgorzata Witkowska, Tomasz Skrzekut, Piotr Noga, Marcin Podsiadło, Dorota Tyrała, Janusz Konstanty and Karolina Kapica
Materials 2025, 18(4), 869; https://doi.org/10.3390/ma18040869 - 17 Feb 2025
Cited by 2 | Viewed by 880
Abstract
The aim of this work was to obtain a protective ZrO2 coating on diamond particles, which was to protect diamond from oxidation and graphitization, enabling sintering of diamond at higher temperatures and lower pressures than its thermodynamic stability in atmospheric conditions. The [...] Read more.
The aim of this work was to obtain a protective ZrO2 coating on diamond particles, which was to protect diamond from oxidation and graphitization, enabling sintering of diamond at higher temperatures and lower pressures than its thermodynamic stability in atmospheric conditions. The coatings were obtained by mixing diamond with zirconium and oxidizing in air or oxygen. Mixtures of diamond and 80 wt% zirconium were sintered by SPS method at temperatures of 1250 °C and 1450 °C. To stabilize the tetragonal structure of ZrO2, 3 mol% Y2O3 was added to zirconium before the milling process. The composition of powder phases, morphology, and microstructures of sintered materials were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy-dispersive spectrometry (EDS). Diffraction studies show the presence of zirconium monoclinic and tetragonal oxides in coatings, after oxidation in air, and in oxygen. Oxidation in oxygen flow is possible for lower temperatures (75 °C), which results in the presence of unreacted zirconium. In ZrO2 doped with yttria after the oxidation process in oxygen, there is no monoclinic ZrO2. It is possible to sinter the ZrO2–diamond composite at 1250 °C using the spark plasma sintering method without graphitization of the diamond. The sintered material consists of monoclinic and tetragonal ZrO2 structures. Full article
(This article belongs to the Special Issue Surface Engineering in Materials (2nd Edition))
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Review

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28 pages, 14019 KB  
Review
Surface Quality as a Factor Affecting the Functionality of Products Manufactured with Metal and 3D Printing Technologies
by Maria Richert, Marek Dudek and Dariusz Sala
Materials 2024, 17(21), 5371; https://doi.org/10.3390/ma17215371 - 2 Nov 2024
Cited by 12 | Viewed by 3311
Abstract
Surface engineering is one of the most extensive industries. Virtually all areas of the economy benefit from the achievements of surface engineering. Surface quality affects the quality of finished products as well as the quality of manufactured parts. It affects both functional qualities [...] Read more.
Surface engineering is one of the most extensive industries. Virtually all areas of the economy benefit from the achievements of surface engineering. Surface quality affects the quality of finished products as well as the quality of manufactured parts. It affects both functional qualities and esthetics. Surface quality affects the image and reputation of a brand. This is particularly true for cars and household appliances. Surface modification of products is also aimed at improving their functional and protective properties. This applies to surfaces for producing hydrophobic surfaces, anti-wear protection of friction pairs, corrosion protection, and others. Metal technologies and 3D printing benefit from surface technologies that improve their functionality and facilitate the operation of products. Surface engineering offers a range of different coating and layering methods from varnishing and painting to sophisticated nanometric coatings. This paper presents an overview of selected surface engineering issues pertaining to metal products, with a particular focus on surface modification of products manufactured by 3D printing technology. It evaluates the impact of the surface quality of products on their functional and performance qualities. Full article
(This article belongs to the Special Issue Surface Engineering in Materials (2nd Edition))
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