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Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance

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

Deadline for manuscript submissions: closed (20 February 2023) | Viewed by 29729

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Prof. Dr. Yong Sun

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School of Engineering and Sustainable Development, De Montfort University, The Gateway, Leicester LE1 9BH, UK
Interests: composite; surface engineering and coating technologies for tribological, corrosion resistance, and biomedical applications; characterisation of surface-engineered systems; tribology, corrosion, and tribocorrosion of surface-engineered materials
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Dear Colleagues,

Corrosion is one of the most damaging and costly material degradation problems in industry. It leads to economic losses equivalent to 3–4% of the GDP of an industrialised country every year. Many materials derive their corrosion resistance from passivity, i.e., the formation of a passive film at the surface. Any damage to the passive film during service can lead to accelerated corrosion, which in turn can lead to accelerated wear. Thus, tribocorrosion is also a common degradation phenomenon in industry. Many efforts have been made for decades to tackle the corrosion and tribocorrosion problems. Among the many techniques developed, surface engineering and coating technologies are the most effective because material degradation due to corrosion is a surface- and subsurface-related problem.

A surface engineering and coating system is a composite system comprising the surface layer, the subsurface zone and the substrate. Through the proper design and implementation of the surface coating, subsurface and substrate as a system, the corrosion and tribocorrosion resistance of engineering materials can be considerably enhanced. Significant progress has been made in this respect. This Special Issue aims to bring together the latest developments in this technologically and economically important area, encompassing coating development, corrosion and tribocorrosion characterisation and industrial applications.

It is my pleasure to invite you to submit a manuscript for this Special Issue. Contributions from academic research, application-oriented research and industrial field studies are welcome.

Full papers, communications and reviews are all welcome.

Dr. Yong Sun
Guest Editor

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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.

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Keywords

Surface engineering
Coatings
Corrosion
Corrosion protection
Tribocorrosion
Corrosive wear
Electrochemistry
Subsurface

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Related Special Issue

Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance—3rd Edition in Materials

Published Papers (13 papers)

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Editorial

Jump to: Research, Review

3 pages, 196 KiB

Open AccessEditorial

Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance

by Yong Sun

Materials 2023, 16(13), 4863; https://doi.org/10.3390/ma16134863 - 6 Jul 2023

Cited by 2 | Viewed by 1251

Abstract

Corrosion of materials not only accounts for about 3 to 4% of economic losses in GDP in an industrial nation, but it also contributes significantly to greenhouse emissions and climate change because material production is one of the largest greenhouse emitters [...] Full article

(This article belongs to the Special Issue Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance)

3 pages, 178 KiB

Open AccessEditorial

Special Issue: “Surface Engineering and Coating Technologies for Corrosion and Tribocorrosion Resistance”

by Yong Sun

Materials 2022, 15(8), 2885; https://doi.org/10.3390/ma15082885 - 14 Apr 2022

Cited by 1 | Viewed by 1277

Abstract

The corrosion of a material results from its interaction with the surrounding environment, which can lead to physical and chemical changes in the material and the loss of its functional properties [...] Full article

(This article belongs to the Special Issue Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance)

Research

Jump to: Editorial, Review

18 pages, 7297 KiB

Open AccessEditor’s ChoiceArticle

Molecular Understanding of the Interfacial Interaction and Corrosion Resistance between Epoxy Adhesive and Metallic Oxides on Galvanized Steel

by Shuangshuang Li, Yanliang Zhao, Hailang Wan, Jianping Lin and Junying Min

Materials 2023, 16(8), 3061; https://doi.org/10.3390/ma16083061 - 13 Apr 2023

Cited by 3 | Viewed by 2130

Abstract

The epoxy adhesive-galvanized steel adhesive structure has been widely used in various industrial fields, but achieving high bonding strength and corrosion resistance is a challenge. This study examined the impact of surface oxides on the interfacial bonding performance of two types of galvanized steel with Zn–Al or Zn–Al–Mg coatings. Scanning electron microscopy and X-ray photoelectron spectroscopy analysis showed that the Zn–Al coating was covered by ZnO and Al₂O₃, while MgO was additionally found on the Zn–Al–Mg coating. Both coatings exhibited excellent adhesion in dry environments, but after 21 days of water soaking, the Zn–Al–Mg joint demonstrated better corrosion resistance than the Zn–Al joint. Numerical simulations revealed that metallic oxides of ZnO, Al₂O₃, and MgO had different adsorption preferences for the main components of the adhesive. The adhesion stress at the coating–adhesive interface was mainly due to hydrogen bonds and ionic interactions, and the theoretical adhesion stress of MgO adhesive system was higher than that of ZnO and Al₂O₃. The corrosion resistance of the Zn–Al–Mg adhesive interface was mainly due to the stronger corrosion resistance of the coating itself, and the lower water-related hydrogen bond content at the MgO adhesive interface. Understanding these bonding mechanisms can lead to the development of improved adhesive-galvanized steel structures with enhanced corrosion resistance. Full article

(This article belongs to the Special Issue Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance)

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20 pages, 9572 KiB

Open AccessEditor’s ChoiceArticle

Corrosion Behavior of Nitrided Layer of Ti6Al4V Titanium Alloy by Hollow Cathodic Plasma Source Nitriding

by Lei Zhang, Minghao Shao, Zhehao Zhang, Xuening Yi, Jiwen Yan, Zelong Zhou, Dazhen Fang, Yongyong He and Yang Li

Materials 2023, 16(8), 2961; https://doi.org/10.3390/ma16082961 - 7 Apr 2023

Cited by 9 | Viewed by 2278

Abstract

Ti6Al4V titanium alloys, with high specific strength and good biological compatibility with the human body, are ideal materials for medical surgical implants. However, Ti6Al4V titanium alloys are prone to corrosion in the human environment, which affects the service life of implants and harms human health. In this work, hollow cathode plasm source nitriding (HCPSN) was used to generate nitrided layers on the surfaces of Ti6Al4V titanium alloys to improve their corrosion resistance. Ti6Al4V titanium alloys were nitrided in NH₃ at 510 °C for 0, 1, 2, and 4 h. The microstructure and phase composition of the Ti-N nitriding layer was characterized by high-resolution transmission electron microscopy, atomic force microscopy, scanning electron microscopy, X-ray diffraction, and X-ray photoelectron spectroscopy. This modified layer was identified to be composed of TiN, Ti₂N, and α-Ti (N) phase. To study the corrosion properties of different phases, the nitriding 4 h samples were mechanically ground and polished to obtain the various surfaces of Ti₂N and α-Ti (N) phases. The potentiodynamic polarization and electrochemical impedance measurements were conducted in Hank’s solution to characterize the corrosion resistance of Ti-N nitriding layers in the human environment. The relationship between corrosion resistance and the microstructure of the Ti-N nitriding layer was discussed. The new Ti-N nitriding layer that can improve corrosion resistance provides a broader prospect for applying Ti6Al4V titanium alloy in the medical field. Full article

(This article belongs to the Special Issue Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance)

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11 pages, 3188 KiB

Open AccessEditor’s ChoiceArticle

N⁺-Implantation on Nb Coating as Protective Layer for Metal Bipolar Plate in PEMFCs and Their Electrochemical Characteristics

by Yu-Sung Kim, Jin-Young Choi, Cheong-Ha Kim, In-Sik Lee, Shinhee Jun, Daeil Kim, Byung-Chul Cha and Dae-Wook Kim

Materials 2022, 15(23), 8612; https://doi.org/10.3390/ma15238612 - 2 Dec 2022

Cited by 3 | Viewed by 1380

Abstract

Nitrogen ions were implanted into the coated Nb layer by plasma immersion ion implantation to improve resistance to corrosion of a metal bipolar plate. Due to nitrogen implantation, the corrosion behavior of the Nb layer was enhanced. The electron microscope observation reveals that the microstructure of the Nb layer became denser and had fewer defects with increasing implantation energy. As a result, the densified structure effectively prevented direct contact with the corrosive electrolyte. In addition, at a higher implantation rate (6.40 × 10¹⁷ N₂/cm²), a thin amorphous layer was formed on the surface, and the implanted nitrogen ions reacted at neighboring Nb sites, resulting in the localized formation of nitrides. Such phase and structural changes contributed to further improve corrosion resistance. In particular, the implanted Nb layer at bias voltage of 10 kV exhibited a current density more than one order of magnitude smaller with a two times faster stabilization than the as-deposited Nb layer under the PEMFC operating conditions. Full article

(This article belongs to the Special Issue Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance)

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14 pages, 3226 KiB

Open AccessArticle

The Influence of Heat Treatment on Corrosion Resistance and Microhardness of Hot-Dip Zinc Coating Deposited on Steel Bolts

by Dariusz Jędrzejczyk and Elżbieta Szatkowska

Materials 2022, 15(17), 5887; https://doi.org/10.3390/ma15175887 - 26 Aug 2022

Cited by 5 | Viewed by 1914

Abstract

The analyzed topic refers to the corrosion resistance and changes in microhardness of the heat-treated (HT) hot-dip zinc coating deposited on bolts. The research aimed to evaluate the influence of the HT on the increase of the coating hardness and changes in anticorrosion properties. Hot-dip zinc coating was deposited in industrial conditions (acc. EN ISO 10684) on chosen bolts (M12x60). The achieved results were assessed based on corrosion resistance tests in neutral salt spray (salt chamber) and microhardness measurements. Tests were conducted in accordance with the adopted fractional plan, generated in the DOE module of the Statistica software. Using the conjugate gradient method optimal parameters of HT were determined. The conducted tests proved that the controlled heat treatment may increase the hardness of the hot-dip zinc coating without a significant deterioration in its basic protective function (corrosion resistance). The observed changes in the hardness and corrosion resistance of the zinc coating are a consequence of changes in its structure. Full article

(This article belongs to the Special Issue Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance)

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20 pages, 6639 KiB

Open AccessArticle

Tribocorrosion and Abrasive Wear Test of 22MnCrB5 Hot-Formed Steel

by Dariusz Ulbrich, Arkadiusz Stachowiak, Jakub Kowalczyk, Daniel Wieczorek and Waldemar Matysiak

Materials 2022, 15(11), 3892; https://doi.org/10.3390/ma15113892 - 30 May 2022

Cited by 10 | Viewed by 1906

Abstract

The article presents the results of research on abrasive and tribocorrosion wear of boron steel. This type of steel is used in the automotive and agricultural industries for the production of tools working in soil. The main goal of the article is the evaluation of tribocorrosion and abrasive wear for hot-formed 22MnCrB5 steel and a comparison of the obtained results with test results for steel in a cold-formed state. The spinning bowl method to determine the wear of samples working in the abrasive mass was used. Furthermore, a stand developed based on the ball-on-plate system allows to determine the wear during the interaction of friction and corrosion. After the hot-forming process, 22MnCrB5 steel was three times more resistant for the abrasive wear than steel without this treatment. The average wear intensity for 22MnCrB5 untreated steel was 0.00046 g per km, while for 22MnCrB5 hot-formed steel it was 0.00014 g per km. The tribocorrosion tests show that the wear trace of hot-formed 22MnCrB5 steel was about 7.03 µm, and for cold-formed 22MnCrB5 steel a 12.11 µm trace was noticed. The hot-forming method allows to obtain the desired shape of the machine element and improves the anti-wear and anti-corrosion properties for boron steel. Full article

(This article belongs to the Special Issue Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance)

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18 pages, 10513 KiB

Open AccessArticle

Hydrothermal Corrosion of Double Layer Glass/Ceramic Coatings Obtained from Preceramic Polymers

by Ivana Parchovianská, Milan Parchovianský, Hana Kaňková, Aleksandra Nowicka and Dušan Galusek

Materials 2021, 14(24), 7777; https://doi.org/10.3390/ma14247777 - 16 Dec 2021

Cited by 5 | Viewed by 2239

Abstract

Polysilazane-based double layer composite coatings consisting of a polymer-derived ceramic (PDC) bond-coat and a PDC top-coat that contains ceramic passive and glass fillers were developed. To investigate the environmental protection ability of the prepared coatings, quasi-dynamic corrosion tests under hydrothermal conditions were conducted at 200 °C for 48–192 h. The tested PDC coatings exhibited significant mass loss of up to 2.25 mg/cm² after 192 h of corrosion tests, which was attributed to the leaching of elements from the PDC coatings to the corrosion medium. Analysis of corrosion solutions by inductively coupled plasma optical emission spectrometry (ICP-OES) confirmed the presence of Ba, Al, Si, Y, Zr, and Cr, the main component of the steel substrate, in the corrosion medium. Scanning electron microscopy (SEM) of the corroded surfaces revealed randomly distributed globular crystallites approximately 3.5 µm in diameter. Energy-dispersive X-ray spectroscopy (EDXS) of the precipitates showed the presence of Ba, Al, Si, and O. The predominant phases detected after corrosion tests by X-ray powder diffraction analysis (XRD) were monoclinic and cubic ZrO₂, originating from the used passive fillers. In addition, the crystalline phase of BaAl₂Si₂O₈ was also identified, which is in accordance with the results of EDXS analysis of the precipitates formed on the coating surface. Full article

(This article belongs to the Special Issue Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance)

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15 pages, 7875 KiB

Open AccessArticle

Preparation and Properties of Mo Coating on H13 Steel by Electro Spark Deposition Process

by Wenquan Wang, Ming Du, Xinge Zhang, Chengqun Luan and Yingtao Tian

Materials 2021, 14(13), 3700; https://doi.org/10.3390/ma14133700 - 1 Jul 2021

Cited by 16 | Viewed by 2232

Abstract

H13 steel is often damaged by wear, erosion, and thermal fatigue. It is one of the essential methods to improve the service life of H13 steel by preparing a coating on it. Due to the advantages of high melting point, good wear, and corrosion resistance of Mo, Mo coating was fabricated on H13 steel by electro spark deposition (ESD) process in this study. The influences of the depositing parameters (deposition power, discharge frequency, and specific deposition time) on the roughness of the coating, thickness, and properties were investigated in detail. The optimized depositing parameters were obtained by comparing roughness, thickness, and crack performance of the coating. The results show that the cross-section of the coating mainly consisted of strengthening zone and transition zone. Metallurgical bonding was formed between the coating and substrate. The Mo coating mainly consisted of Fe_9.7Mo_0.3, Fe-Cr, FeMo, and Fe₂Mo cemented carbide phases, and an amorphous phase. The Mo coating had better microhardness, wear, and corrosion resistance than substrate, which could significantly improve the service life of the H13 steel. Full article

(This article belongs to the Special Issue Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance)

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15 pages, 8881 KiB

Open AccessArticle

Optimization of Pickling Solution for Improving the Phosphatability of Advanced High-Strength Steels

by Sangwon Cho, Sang-Jin Ko, Jin-Seok Yoo, Joong-Chul Park, Yun-Ha Yoo and Jung-Gu Kim

Materials 2021, 14(1), 233; https://doi.org/10.3390/ma14010233 - 5 Jan 2021

Cited by 8 | Viewed by 3200

Abstract

This study investigated the optimum pickling conditions for improving the phosphatability of advanced high-strength steel (AHSS) using surface analysis and electrochemical measurements. To remove the SiO₂ that forms on the surface of AHSS, 30 wt.% NH₄HF₂ was added to the pickling solution, resulting in a significant reduction in the amount of SiO₂ remaining on the surface of the AHSS. The phosphatability was improved remarkably using HNO₃ concentrations higher than 13% in the pickling solution. Furthermore, phosphate crystals became finer after pickling with a HNO₃-based solution rather than a HCl-based solution. Electrochemical impedance spectroscopy (EIS) data indicated that the corrosion resistance of AHSS subjected to HNO₃-based pickling was higher than that of AHSS subjected to HCl-based pickling. Fluorine compounds, which were involved in the phosphate treatment process, were only formed on the surface of steel in HNO₃-based solutions. The F compounds reacted with the phosphate solution to increase the pH of the bulk solution, which greatly improved the phosphatability. The phosphatability was better under HNO₃-based conditions than a HCl-based condition due to the fineness of the phosphate structure and the increased surface roughness. Full article

(This article belongs to the Special Issue Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance)

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Review

Jump to: Editorial, Research

15 pages, 4633 KiB

Open AccessReview

Improving the Wear and Corrosion Resistance of Aeronautical Component Material by Laser Shock Processing: A Review

by Jiajun Wu, Zhihu Zhou, Xingze Lin, Hongchao Qiao, Jibin Zhao and Wangwang Ding

Materials 2023, 16(11), 4124; https://doi.org/10.3390/ma16114124 - 1 Jun 2023

Cited by 5 | Viewed by 1802

Abstract

Since the extreme service conditions, the serious failure problems caused by wear and corrosion are often encountered in the service process for aeronautical components. Laser shock processing (LSP) is a novel surface-strengthening technology to modify microstructures and induce beneficial compressive residual stress on the near-surface layer of metallic materials, thereby enhancing mechanical performances. In this work, the fundamental mechanism of LSP was summarized in detail. Several typical cases of applying LSP treatment to improve aeronautical components’ wear and corrosion resistance were introduced. Since the stress effect generated by laser-induced plasma shock waves will lead to the gradient distribution of compressive residual stress, microhardness, and microstruture evolution. Due to the enhancement of microhardness and the introduction of beneficial compressive residual stress by LSP treatment, the wear resistance of aeronautical component materials is evidently improved. In addition, LSP can lead to grain refinement and crystal defect formation, which can increase the hot corrosion resistance of aeronautical component materials. This work will provide significant reference value and guiding significance for researchers to further explore the fundamental mechanism of LSP and the aspects of the aeronautical components’ wear and corrosion resistance extension. Full article

(This article belongs to the Special Issue Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance)

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26 pages, 7444 KiB

Open AccessFeature PaperReview

Recent Progress of Polymeric Corrosion Inhibitor: Structure and Application

by Xuanyi Wang, Shuang Liu, Jing Yan, Junping Zhang, Qiuyu Zhang and Yi Yan

Materials 2023, 16(8), 2954; https://doi.org/10.3390/ma16082954 - 7 Apr 2023

Cited by 14 | Viewed by 3751

Abstract

An anti-corrosion inhibitor is one of the most useful methods to prevent metal corrosion toward different media. In comparison with small molecular inhibitors, a polymeric inhibitor can integrate more adsorption groups and generate a synergetic effect, which has been widely used in industry and become a hot topic in academic research. Generally, both natural polymer-based inhibitors and synthetic polymeric inhibitors have been developed. Herein, we summarize the recent progress of polymeric inhibitors during the last decade, especially the structure design and application of synthetic polymeric inhibitor and related hybrid/composite. Full article

(This article belongs to the Special Issue Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance)

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18 pages, 2253 KiB

Open AccessReview

Application of Electrophoretic Deposition as an Advanced Technique of Inhibited Polymer Films Formation on Metals from Environmentally Safe Aqueous Solutions of Inhibited Formulations

by Natalia A. Shapagina and Vladimir V. Dushik

Materials 2023, 16(1), 19; https://doi.org/10.3390/ma16010019 - 20 Dec 2022

Cited by 8 | Viewed by 2561

Abstract

The presented paper analyzes polymer films formed from aqueous solutions of organosilanes, corrosion inhibitors and their compositions. Methods of depositing inhibited films on metal samples, such as dipping and exposure of the sample in a modifying solution, as well as an alternative method, electrophoretic deposition (EPD), are discussed. Information is provided on the history of the EPD method, its essence, production process, areas of application of this technology, advantages over existing analogues, as well as its varieties. The article considers the promise of using the EPD method to form protective inhibited polymer films on metal surfaces from aqueous solutions of inhibitor formulations consisting of molecules of organosilanes and corrosion inhibitors. Full article

(This article belongs to the Special Issue Surface Engineering & Coating Technologies for Corrosion and Tribocorrosion Resistance)

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