Search Results (1,300)

Multi-principal element nitrides have great application potential in protective coatings. However, the investigation of the oxidation and corrosion resistance of multi-principal element nitride coatings is still insufficient. The synthesis and high-temperature performance of AlCrNbSiTiN multi-principal element nitride coatings fabricated through optimized arc ion plating (AIP) were explored. Leveraging the high ionization efficiency and ion kinetic energy characteristic of AIP, coatings with significantly fewer internal defects were obtained. These coatings demonstrate superior mechanical properties, including a maximum hardness of 36.5 GPa and critical crack propagation resistance (CPR) values approaching 2000 N². Optimal coatings exhibited exceptional water vapor corrosion resistance (5.15 at% O after 200 h). The coatings prepared at −150 V had the optimal corrosion resistance, with the coating resistance and corrosion current density being 1.68 × 10⁴ Ω·cm² and 0.79 μA·cm⁻², respectively. AlCrNbSiTiN coatings produced under these optimized AIP conditions exhibit remarkably high-temperature oxidation, highlighting their potential for use in demanding engineering applications. Full article

Wetting behavior of molten metals on solid substrates is a critical phenomenon influencing numerous industrial applications, including welding, anti-corrosion coatings, and metal additive manufacturing (AM). In particular, molten metal jetting (MMJ), an emerging AM technology, requires that the molten metal remain pinned at the nozzle exit. Thus, each new metal requires a specific nozzle material to ensure consistent droplet ejection and deposition, making it important to rapidly identify the appropriate wetting combinations. However, traditional measurements of wetting angles require expensive equipment and only allow one combination of materials to be investigated at a time which can be time consuming. This work introduces a rapid screening method based on sessile droplet experiments to evaluate wetting profiles across multiple metal–substrate combinations simultaneously. This study investigates the wetting interactions of molten Al alloy (Al4008), Cu, and Sn on various ceramic and metal substrates to identify optimal material combinations for MMJ nozzle designs. Results demonstrate that Al4008 achieves wetting on ceramic substrates such as AlN, TiO₂, and SiC, with varying mechanisms including chemical reactions and weak surface interactions. Additionally, theoretical predictions regarding miscibility gaps and melting point differences were verified for Cu and Sn on refractory metals like Mo and W. Findings from this study contribute to the establishment of a materials compatibility library, enabling the selection of wetting/non-wetting combinations for stable MMJ operation. This resource not only advances MMJ technologies but also provides valuable insights for broader applications such as welding, coating, and printed electronics. Full article

The use of molybdenum-based alloys as materials for components operating under high temperatures and significant mechanical loads is widely recognized due to their excellent mechanical properties. However, their low high-temperature resistance remains a critical limitation, which can be effectively mitigated by applying protective coatings. In this study, we investigate the influence of a two-step coating process on the properties and performance of the TZM molybdenum alloy. In the first step, pack cementation was performed. Simultaneous surface saturation with aluminum and silicon, a process known as aluminosiliconizing, was conducted at 1000 °C for 6 h. The saturating mixture comprised powders of aluminum, silicon, aluminum oxide, and ammonium chloride. The second step involved the application of a pre-ceramic coating based on polyhydrosiloxane modified with silicon and boron. This treatment effectively eliminated pores and cracks within the coating. Thermodynamic calculations were carried out to evaluate the likelihood of aluminizing and siliconizing reactions under the applied conditions. Aluminosiliconizing of the TZM alloy resulted in the formation of a protective layer 20–30 µm thick. The multiphase structure of this layer included intermetallics (Al₆₃Mo₃₇, MoAl₃), nitrides (Mo₂N, AlN, Si₃N₄), oxide (Al₂O₃), and a solid solution α-Mo(Al). Subsequent treatment with silicon- and boron-modified polyhydrosiloxane led to the development of a thicker surface layer, 130–160 µm in thickness, composed of crystalline Si, amorphous SiO₂, and likely amorphous boron. A transitional oxide layer ((Al,Si)₂O₃) 5–7 µm thick was also observed. The resulting coating demonstrated excellent structural integrity and chemical inertness in an argon atmosphere at temperatures up to 1100 °C. High-temperature stability at 800 °C was observed for both coating types: aluminosiliconizing, and aluminosiliconizing followed by the pre-ceramic coating. Moreover, additional oxide layers of SiO₂ and B₂O₃ formed on the two-step coated TZM alloy during heating at 800 °C for 24 h. These layers acted as an effective barrier, preventing the evaporation of the substrate material. Full article

Yttria-stabilized zirconia(YSZ) was introduced into the Al₂O₃-TiO₂-CeO₂ coating prepared by plasma spraying to improve the wear resistance of the coating and prolong the service life of the weathering steel. The nano-agglomerated powder was prepared by mechanical ball milling and spray-drying technology, powder was sprayed on the surface of Q355 steel substrate by atmospheric plasma sparing (APS), the Al₂O₃-TiO₂-CeO₂/YSZ composite coating was prepared, and the effects of YSZ on the phase, microstructure, and tribological properties of the composite coating were studied. The results show that nano-agglomerated powders with micron size (average size 55 μm) can be prepared by spray-drying technology, and after high-temperature sintering, the nano-agglomerated powders are denser and form the α-Al₂O₃ phase. The composite coating prepared by plasma spraying has a bimodal structure, and after adding YSZ, the phases in the coating are mainly α-Al₂O₃, γ-Al₂O₃, and t-ZrO₂, the grain size is fine, and the porosity is reduced. The specific wear rate is only 4.4 × 10⁻⁵ mm³ N⁻¹·m⁻¹, the relative wear resistance is 6.3 times higher than that of the substrate, and the wear mechanism of the coating is mainly slight adhesive wear and abrasive wear, which shows excellent friction and wear properties at room temperature. Full article

Thermal barrier coatings (TBCs) extend gas-turbine blade lifetime by improving high-temperature oxidation resistance and mechanical performance. We investigated the microstructural evolution, TGO growth, and Al depletion in air-plasma-sprayed (APS) single-layer YSZ top coat over a NiCrCoAlY bond coat on Ni-based superalloy circular plates, heat treated isothermally at 850 °C and 1000 °C for 50–5000 h. Cross-sectional SEM/EDS analysis showed TGO quadratic thickening kinetics at both temperatures, reaching ~10 µm at 1000 °C/5000 h, the growth rate of which was ~5.8 times higher than at 850 °C. On top of the single-layer TGO of Al₂O₃ observed from the onset, a NiCrCo oxide layer appeared and grew from ≥500 h at 850 °C, with increasing growth rate and cracking. The layer configuration of the YSZ top coat, the TGO of Al₂O₃, and the bond coat (comprising β-NiAl and γ-NiCr) on top of GTD111, showed an Al concentration gradient in the bond coat starting at 850 °C for 250 h, which intensified with increased duration and temperature. The decrease in Al concentration in the bond coat and the growth of TGO are due to the dissolution of β-NiAl and subsequent Al diffusion to the Al₂O₃ TGO. Full article

The 316L stainless steel, uncoated and coated with two types of EB-PVD thin-film deposits, was tested in liquid lead both under oxygen-saturated conditions (~10⁻³ wt.%) for exposure times of 1000 and 2000 h and under low-oxygen conditions (~10⁸ wt.%) for 1000 h. The first coating consisted of a ~1 µm NiCrAlY thin film. At the same time, the second was a NiCrAlY/Al₂O₃ multilayer with a total thickness of ~3 µm, on top of which an additional 100–200 nm metallic Cr layer was deposited. Uncoated specimens tested under oxygen-saturated conditions developed a duplex oxide layer on their surface. SEM-EDS analyses revealed that the inner layer was denser and contained Fe, Cr, and O, whereas the outer layer was more porous and composed mainly of Fe and O. Microscopic examinations indicated that the multilayer-coated specimens exposed to low-oxygen conditions exhibited no signs of material degradation. In contrast, both the uncoated samples and those coated only with a single NiCrAlY layer showed generalised corrosion over the entire surface after exposure to liquid lead at low oxygen concentrations. The austenitic microstructure was degraded to a depth of 100–200 µm. Vickers microhardness indentations performed on the structurally altered regions revealed two distinct corrosion zones with markedly different hardness values. Full article

The long-term corrosion behavior of Al₂O₃-3%TiO₂ (AT3) coatings doped with1%, 5% and 8% CeO₂ prepared by plasma spraying was studied in 5% NaCl solution. The results showed that the protective performance of CeO₂-doped coatings was significantly higher than that of undoped coatings, primarily due to the reduction in coating porosity caused by the addition of rare-earth elements. Among the doped coatings, the 5% CeO₂-doped coating exhibited the best protective performance. The addition of rare-earth oxides CeO₂ reduced the content of γ-Al₂O₃ in the coating, but when the concentration of CeO₂ increased to 8%, the Ce element was rich in the gap of the coating. Excessive CeO₂ enriched in the gaps and coexisted more with Ti, and prevented the formation of the AlTi phase, which affected the performance of the coating. Electrochemical and XPS results revealed that an appropriate amount of Ce atoms or CeO₂ particles could fill the pores of the coating. During long-term immersion, Ce (IV) was converted to Ce (III), which demonstrated that Ce atoms have high chemical activity in coatings. The thermodynamic calculation results show that more CeO₂ particles improved the adsorption of corrosive ions. It indicated that the content of doped rare-earth oxides exceeding 5% would be utilized as an active material in the corrosive process. Full article

Aluminum and its alloys are widely used in aerospace and industrial sectors due to their high specific strength, low density, and abundance. However, their low hardness, high corrosion susceptibility, and poor wear resistance limit broader applications. Surface treatments such as electroplating, PVD/CVD, and anodizing have been used to enhance surface properties. Plasma electrolytic oxidation (PEO), also known as micro-arc oxidation (MAO), has emerged as a promising technique for producing durable ceramic coatings on light metals like Al, Mg, and Ti alloys. In this study, PEO was applied to AA6061 aluminum alloy using an AC power source in potentiostatic mode at 350 V and 400 V, 1000 Hz, and 80% duty cycle for 30 min in a silicate-based electrolyte (5 g/L Na₂SiO₃ + 5 g/L KOH) maintained at 25–40 °C. The effect of voltage on the coating morphology, thickness, and corrosion resistance was investigated. The coatings exhibited porous structures with pancake-like, crater, and nodular features, and thicknesses ranged from 0.053 to 83.64 µm. XRD analysis confirmed the presence of Al, α-Al₂O₃, Ƴ-Al₂O₃, and mullite. The 400 V-coated sample showed superior corrosion resistance ( $E_{corr}= -0.77 \mathrm{V}$; $i_{corr}=0.28 \mu \mathrm{A}/{\mathrm{c}\mathrm{m}}^2$) and improved hardness (up to 233 HV), compared to 89 HV for the bare AA6061. Full article

Filtration of submicron particles and nanoparticles is an important problem in nano-industry and in air conditioning and ventilation systems. The presence of submicron particles comprising fungal spores, bacteria, viruses, microplastic, and tobacco-smoke tar in ambient air is a severe problem in air conditioning systems. Many nanotechnology material processes used for catalyst, solar cells, gas sensors, energy storage devices, anti-corrosion and hydrophobic surface coating, optical glasses, ceramics, nanocomposite membranes, textiles, and cosmetics production also generate various types of nanoparticles, which can retain in a conveying gas released into the atmosphere. Particles in this size range are particularly difficult to remove from the air by conventional methods, e.g., electrostatic precipitators, conventional filters, or cyclones. For these reasons, nanofibrous filters produced by electrospinning were developed to remove fine particles from the post-processing gases. The physical basis of electrospinning used for nanofilters production is an employment of electrical forces to create a tangential stress on the surface of a viscous liquid jet, usually a polymer solution, flowing out from a capillary nozzle. The paper presents results for investigation of the filtration process of metal oxide nanoparticles: TiO₂, MgO, and Al₂O₃ by electrospun nanofibrous filter. The filter was produced from polyvinylidene fluoride (PVDF). The concentration of polymer dissolved in dimethylacetamide (DMAC) and acetone mixture was 15 wt.%. The flow rate of polymer solution was 1 mL/h. The nanoparticle aerosol was produced by the atomization of a suspension of these nanoparticles in a solvent (methanol) using an aerosol generator. The experimental results presented in this paper show that nanofilters made of PVDF with surface density of 13 g/m² have a high filtration efficiency for nano- and microparticles, larger than 90%. The gas flow rate through the channel was set to 960 and 670 l/min. The novelty of this paper was the investigation of air filtration from various types of nanoparticles produced by different nanotechnology processes by nanofibrous filters and studies of the morphology of nanoparticle deposited onto the nanofibers. Full article

Titanium alloys are widely employed in structural and electrochemical applications owing to their excellent mechanical properties and inherent corrosion resistance. However, their stability in harsh acidic environments, such as those encountered in energy storage systems, remains a critical issue. In this study, composite ceramic coatings were synthesized on a Ti6Al4V alloy using plasma electrolytic oxidation (PEO) in silicate-, phosphate-, and sulfate-based electrolytes, with and without the addition of α-alumina nanoparticles. The resulting coatings were comprehensively characterized to assess their surface morphology, chemical and phase compositions, and corrosion performance. Thus, the corrosion current density decreased from 9.7 × 10⁴ for bare Ti6Al4V to 143 nA/cm² for the coating fabricated in phosphate electrolyte with alumina nanoparticles, while the corrosion potential shifted anodically from –0.68 to +0.49 V vs. silver chloride electrode in 5 M H₂SO₄. Among the tested electrolytes, coatings produced in the phosphate-based electrolyte with Al₂O₃ showed the highest polarization resistance (113 kΩ·cm²), outperforming those fabricated in silicate- (71.6 kΩ·cm²) and sulfate-based (89.0 kΩ·cm²) systems. The composite coatings exhibited a multiphase structure with reduced surface porosity and the incorporation of crystalline oxide phases. Notably, titania–alumina nanoparticle composites demonstrated significantly enhanced corrosion resistance. These findings confirm that PEO-derived composite coatings provide an effective surface engineering strategy for enhancing the stability of the Ti6Al4V alloy in aggressive acidic environments relevant to advanced electrochemical systems. Full article

Binary oxide ceramics have emerged as key materials in solar energy research due to their versatility, chemical stability, and tunable electronic properties. This study presents a comparative analysis of seven prominent oxides (TiO₂, ZnO, Al₂O₃, SiO₂, CeO₂, Fe₂O₃, and WO₃), focusing on their functional roles in silicon, perovskite, dye-sensitized, and thin-film solar cells. A bibliometric analysis covering over 50,000 publications highlights TiO₂ and ZnO as the most widely studied materials, serving as electron transport layers, antireflective coatings, and buffer layers. Al₂O₃ and SiO₂ demonstrate highly specialized applications in surface passivation and interface engineering, while CeO₂ offers UV-blocking capability and Fe₂O₃ shows potential as an absorber material in photoelectrochemical systems. WO₃ is noted for its multifunctionality and suitability for scalable, high-rate processing. Together, these findings suggest that binary oxide ceramics are poised to transition from supporting roles to essential components of stable, efficient, and environmentally safer next-generation solar cells. Full article

Photocatalytic hydrogen evolution from water is a sustainable approach to producing clean energy and promoting sustainable development. However, the low efficiency of photocatalysts under visible light and even near-infrared irradiation remains the current bottleneck in photocatalytic overall water splitting (POWS). Herein, we introduce an Al₂O₃/InP/Al photocatalyst with high efficiency and stability, which achieved an apparent quantum efficiency of 0.97% at 500 nm and operated for 10 h without significant performance decay. The high quantum efficiency and stability are attributed to the combination of the electron-rich Al reflective layer and Al₂O₃ protective layer coating, which synergistically facilitate charge separation. Additionally, the newly generated O₂ from water over the Al₂O₃/InP/Al photocatalyst was removed under reduced pressure, thus inhibiting InP photocorrosion and enabling POWS under visible light irradiation. This study offers valuable insights for the development of efficient solar photocatalysts for water splitting. Full article

The unique cutting–burnishing coupling effect in BTA deep hole drilling generates a high-hardness and -brittleness white layer (ultrafine martensitic layer), which will degrade component performance and accelerate tool wear. This work investigated the formation mechanism and the mechanical properties of the white layer generated in three distinct regions (the cutting edge radius zone, cutting–burnishing corner zone, and guide pad edge zone) through nanoindentation, SEM and BSE. The microstructure and thickness of the white layer under different feedrates are investigated. The correlations between the white layer, the structure of guide pads, and wear behaviors of the TiN- and TiCN/Al₂O₃-coated guide pads are revealed. Variations in hardness are observed across different zones. The white layer undergoes a soft-to-hard transition due to rapid quenching and the cutting–burnishing effect at the sharp corner. The highest hardness (9.758 GPa) was observed in the guide pad zone, accompanied by grain refinement. The chamfered TiN-coated guide pad exhibits superior wear resistance but suffers fatigue cracking and adhesive wear in the initial guiding zone. The TiCN/Al₂O₃-coated pad with rounded corners experiences brittle spalling in the mid-to-rear guiding zone. These findings enhance the understanding of the white layer formation in deep hole drilling and provide a foundation for tool optimization. Full article

In this study, we report, for the first time, the tribo-catalytic degradation of methyl orange (MO) using Cu/Al₂O₃ nanoparticles under mechanical stirring conditions. The hybrid catalyst was synthesized via a wet impregnation method and characterized through different techniques, confirming structural integrity and compositional uniformity. When subjected to friction generated by a PTFE-coated magnetic stir bar, Cu/Al₂O₃ nanoparticles exhibited high tribo-catalytic activity, achieving up to 95% MO degradation within 10 h under dark conditions. The observed activity surpasses that of alumina alone and is attributed to the synergistic effects between copper and alumina, facilitating charge separation and enhancing reactive oxygen species (ROS) formation. Tribo-catalytic efficiency was further influenced by stirring speed and contact area, confirming the key role of mechanical friction. Reusability tests demonstrated stable performance over five cycles, highlighting the material’s durability and potential for practical environmental remediation applications. Full article

This study investigates the microstructural evolution and damage mechanisms of the nickel-based single-crystal superalloy DD9-thermal barrier coating (TBC) system under 1050 °C high-temperature oxidation, while conducting a comparative analysis of oxidation behavior with the DD6-TBC system. Results show that both systems have similar oxidation mechanisms but face long-term oxidation drawbacks: as oxidation time increases, the thermally grown oxide (TGO) evolves into a mixed oxide layer and an Al₂O₃ layer, with initial rapid TGO growth consuming Al in the bond coat (BC) and subsequent Al depletion slowing growth, though long-term TGO accumulation raises cracking and spallation risks. DD9 and DD6 substrates significantly affect substrate-BC interfacial interdiffusion: the interdiffusion zone (IDZ) and secondary reaction zone (SRZ) grow continuously (SRZ growing faster), and linear topologically close-packed (TCP) phases precipitate in the SRZ, spreading throughout the substrate and impairing high-temperature mechanical properties. Specifically, DD9’s IDZ growth rate is faster than DD6’s in the first 800 h of oxidation but slows below DD6’s afterward, reflecting DD9’s superior long-term oxidation resistance due to better temperature resistance and high-temperature stability. This study clarifies key high-temperature service disadvantages of the two systems, providing experimental support for coated turbine blade life evaluation and a theoretical basis for optimizing third-generation single-crystal superalloy-TBC systems to enhance high-temperature service stability. Full article