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Oxidation, Wear, Corrosion Behaviors and Activated Bonding Properties of Coatings...
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Oxidation, Wear, Corrosion Behaviors and Activated Bonding Properties of Coatings Deposited on Metals

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

Deadline for manuscript submissions: 25 June 2024 | Viewed by 16208

Special Issue Editors

Dr. Diana-Petronela Burduhos-Nergis

E-Mail Website
Guest Editor
Materials Engineering and Industrial Safety, “Gheorghe Asachi” Technical University of Iasi, 700050 Iasi, Romania
Interests: materials characterization; corrosion protection; coatings; materials chemistry; thin layer; phosphate coatings; materials engineering
Dr. Ioan-Gabriel Sandu

E-Mail Website
Guest Editor
Materials Engineering and Industrial Safety, "Gheorghe Asachi" Technical University of Iasi, 700050 Iasi, Romania
Interests: thin layers; microstructural characterization; biomaterials; corrosion; XRD; DTA; mechanical characterization; coatings

Special Issue Information

Dear Colleagues,

The corrosion resistance of metals is a key issue in many industrial fields. Corrosion leads to high economic losses, so adequate protection is vital in many applications.

Coatings are the most important technology when countering corrosion of metal surfaces. In order to reduce the corrosion rate of metals, they must have a high wear resistance and good adherence to the surface. In recent years, the field of coatings used to improve the corrosion resistance of metal surface has become significant.

This Special Issue aims to collect the latest research and experimental papers on effective new coatings that inhibit corrosion. Moreover, it aims to contain papers with advanced concepts about the development and characterization (structural, tribological and chemical) of several types of coatings such as organic coatings, bio-based coatings, metallic coatings, sol–gel coatings, pretreatments, etc. The objectives of this Special Issue include the obtainment and characterization of new advanced coatings used to improve the corrosion resistance of metals in different corrosive media.

Areas of interest include, but are not limited to:

  • Anodizing;
  • Cold-spray coatings;
  • Electrodeposition;
  • Electroless deposition;
  • Plasma spraying;
  • Physical vapor deposition;
  • Thermal spray coatings;
  • Corrosion behaviour in simulated or real environments;
  • Conversion coatings;
  • Cathodic protection;
  • Activated bonding properties;
  • Chemical vapor deposition.

Dr. Diana-Petronela Burduhos-Nergis
Dr. Ioan-Gabriel Sandu
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

  • wear and corrosion resistance
  • protective corrosion coatings
  • activated bonding properties
  • microstructure

Published Papers (9 papers)

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Research

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20 pages, 18484 KiB  
Article
Effect of Low-Temperature Plasma Carburization on Fretting Wear Behavior of AISI 316L Stainless Steel
by Lu Sun, Yuandong Li, Chi Cao, Guangli Bi and Xiaomei Luo
Coatings 2024, 14(2), 158; https://doi.org/10.3390/coatings14020158 - 25 Jan 2024
Viewed by 739
Abstract
AISI 316L stainless steel has received considerable attention as a common material for key ball valve components; however, its properties cannot be improved through traditional phase transformation, and fretting wears the contact interface between valve parts. A carburized layer was prepared on the [...] Read more.
AISI 316L stainless steel has received considerable attention as a common material for key ball valve components; however, its properties cannot be improved through traditional phase transformation, and fretting wears the contact interface between valve parts. A carburized layer was prepared on the surface of AISI 316L stainless steel by using double-glow low-temperature plasma carburization technology. This study reveals the effect of double-glow low-temperature plasma carburization technology on the fretting wear mechanism of AISI 316L steel under different normal loads and displacements. The fretting wear behavior and energy dissipation of the AISI 316L steel and the carburized layer were studied on an SRV-V fretting friction and wear machine with ball–plane contact. The wear mark morphology was analyzed by using scanning electron microscopy (SEM), the phase structure of the carburized layer was characterized with X-ray diffractometry (XRD), and the wear profile and wear volume were evaluated with laser confocal microscopy. The carburized layer contains a single Sc phase, a uniform and dense structure, and a metallurgically combined matrix. After plasma carburizing, the sample exhibited a maximum surface hardness of 897 ± 18 HV0.2, which is approximately four times higher than that of the matrix (273 ± 33 HV0.2). Moreover, the surface roughness was approximately doubled. The wear depth, wear rate, and frictional dissipation energy coefficient of the carburized layer were significantly reduced by up to approximately an order of magnitude compared with the matrix, while the wear resistance and fretting wear stability of the carburized layer were significantly improved. Under different load conditions, the wear mechanism of the AISI 316L steel changed from adhesive wear and abrasive wear to adhesive wear, fatigue delamination, and abrasive wear. Meanwhile, the wear mechanism of the carburized layer changed from adhesive wear to adhesive wear and fatigue delamination, accompanied by a furrowing effect. Under variable displacement conditions, both the AISI 316L steel and carburized layer mainly exhibited adhesive wear and fatigue peeling. Oxygen elements accumulated in the wear marks of the AISI 316L steel and carburized layer, indicating oxidative wear. The fretting wear properties of the AISI 316L steel and carburized layer were determined using the coupled competition between mechanical factors and thermochemical factors. Low-temperature plasma carburization technology improved the stability of the fretting wear process and changed the fretting regime of the AISI 316L steel and could be considered as anti-wearing coatings of ball valves. Full article
(This article belongs to the Special Issue Oxidation, Wear, Corrosion Behaviors and Activated Bonding Properties of Coatings Deposited on Metals)
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24 pages, 21778 KiB  
Article
Uniform-Density Micro-Textured Ball-End Milling Cutter Model Based on Fractal and Uniform Distribution Theory
by Pei Han, Xin Tong, Shucai Yang and Xiyue Wang
Coatings 2023, 13(8), 1446; https://doi.org/10.3390/coatings13081446 - 16 Aug 2023
Viewed by 810
Abstract
At present, for micro-textured tools, the determination of the micro-texture placement area depends on the derivation of the cutting geometric model. The micro-texture distribution form applies geometric methods, and the research methods and accuracy are limited. Therefore, in this paper, the ball-end milling [...] Read more.
At present, for micro-textured tools, the determination of the micro-texture placement area depends on the derivation of the cutting geometric model. The micro-texture distribution form applies geometric methods, and the research methods and accuracy are limited. Therefore, in this paper, the ball-end milling cutter is taken as the research object. Based on fractal theory, the morphology of the tool before and after wear is compared to determine the tool–chip contact area. The uniform-density micro-texture distribution model is established using the uniform distribution point theorem, and the synergistic mechanism of the edge and the micro-texture is revealed. The strength of the micro-textured tool with uniform density under the action of the edge is studied by simulation. Finally, the determination of the tool–chip contact area and the establishment of a uniform-density micro-texture model is realized. It is proved that the synergistic effect of the cutting edge and the micro-texture has a positive effect on the milling behavior of the tool. When comparing the non-edge and non-texture tools with the cutting-edge tools, the maximum strain and stress of the cutting-edge micro-textured tools increased by 12% and 30%, and 30% and 20%, respectively, without affecting the normal use of the tool. This research provides a new method for the design of micro-textured tools. Full article
(This article belongs to the Special Issue Oxidation, Wear, Corrosion Behaviors and Activated Bonding Properties of Coatings Deposited on Metals)
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20 pages, 14588 KiB  
Article
Analysis of Physicochemical Properties of W1.8507 Steel Parts with Sharp Edges, Thermochemically Treated by Plasma Nitriding with and without Polarized Screens
by Mihai Axinte, Petrica Vizureanu, Nicanor Cimpoesu, Carmen Nejneru, Diana-Petronela Burduhos-Nergis and Elena-Luiza Epure
Coatings 2023, 13(1), 177; https://doi.org/10.3390/coatings13010177 - 13 Jan 2023
Cited by 1 | Viewed by 1896
Abstract
The plasma nitriding edge effect phenomenon is characteristic of parts with sharp edges. The intersection for the discharge of negative light of the two adjacent faces causes the apparition of this effect. In some cases, this effect causes disturbance to the general process. [...] Read more.
The plasma nitriding edge effect phenomenon is characteristic of parts with sharp edges. The intersection for the discharge of negative light of the two adjacent faces causes the apparition of this effect. In some cases, this effect causes disturbance to the general process. In this work, a sample with different angles of 30°, 60°, and 90° was analyzed. The sample was subjected to ion nitriding with and without the cathode grid to highlight the reduction of the edge effect on the non-uniformity appearing on the edges and corners of the parts. The effect of the active screen was also analyzed by hardness measurements in the area of the nitride edges and by SEM and EDX analyses in the mentioned areas. Additionally, the influence of active screens was studied by nanoindentation and scratch tests and by measuring the contact angle of coolants and liquid lubricants on the nitride surfaces with both methods. Full article
(This article belongs to the Special Issue Oxidation, Wear, Corrosion Behaviors and Activated Bonding Properties of Coatings Deposited on Metals)
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16 pages, 3930 KiB  
Article
Controlling the Layer Thickness of Zinc Oxide Photoanode and the Dye-Soaking Time for an Optimal-Efficiency Dye-Sensitized Solar Cell
by Kaiswariah Magiswaran, Mohd Natashah Norizan, Norsuria Mahmed, Ili Salwani Mohamad, Siti Norhafizah Idris, Mohd Faizul Mohd Sabri, Nowshad Amin, Andrei Victor Sandu, Petrica Vizureanu, Marcin Nabiałek and Mohd Arif Anuar Mohd Salleh
Coatings 2023, 13(1), 20; https://doi.org/10.3390/coatings13010020 - 22 Dec 2022
Cited by 1 | Viewed by 1920
Abstract
Dye-sensitized solar cells (DSSCs) were developed by exploiting the photovoltaic effect to convert solar energy into electrical energy. The photoanode layer thickness significantly affects the semiconductor film’s ability to carry electronic charges, adsorb sensitizing dye molecules, and lower the recombination of photo-excited electrons [...] Read more.
Dye-sensitized solar cells (DSSCs) were developed by exploiting the photovoltaic effect to convert solar energy into electrical energy. The photoanode layer thickness significantly affects the semiconductor film’s ability to carry electronic charges, adsorb sensitizing dye molecules, and lower the recombination of photo-excited electrons injected into the semiconductor. This study investigated the dependence of the zinc oxide (ZnO) photoanode thin-film thickness and the film soaking time in N719 dye on the photocurrent–voltage characteristics. The ZnO photoanode was applied to glass using the doctor blade method. The thickness was varied by changing the scotch tape layers. The ZnO-based DSSC attained an efficiency of 2.77% with three-layered photoanodes soaked in the dye for three hours, compared to a maximum efficiency of 0.68% that was achieved with three cycles using the dip-coating method in other research. The layer thickness of the ZnO photoanode and its optimal adsorption time for the dye are important parameters that determine the efficiency of the DSSC. Therefore, this work provides important insights to further improve the performance of DSSCs. Full article
(This article belongs to the Special Issue Oxidation, Wear, Corrosion Behaviors and Activated Bonding Properties of Coatings Deposited on Metals)
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25 pages, 11085 KiB  
Article
Influence of Fin Thickness on the Thermal Performance and Selection of Coating Method for a Bus Duct Conductor
by Mark Selvan, Mohd Sharizal Abdul Aziz, Mohd Arif Anuar Mohd Salleh, Nurulakmal Mohd Sharif, Chu Yee Khor, Heng Pin Ong, Mohd Remy Rozaini Mohd Arif Zainol, Petrica Vizureanu, Diana-Petronela Burduhos-Nergis and Andrei Victor Sandu
Coatings 2023, 13(1), 12; https://doi.org/10.3390/coatings13010012 - 22 Dec 2022
Cited by 1 | Viewed by 2281
Abstract
This paper studies the fin thickness variation effect on a bus duct conductor’s thermal performance and the nanocomposite coating method selection for the bus duct conductor’s heat sink. ANSYS FLUENT was used to create a numerical model resembling the experimental setup. The IEC [...] Read more.
This paper studies the fin thickness variation effect on a bus duct conductor’s thermal performance and the nanocomposite coating method selection for the bus duct conductor’s heat sink. ANSYS FLUENT was used to create a numerical model resembling the experimental setup. The IEC 60439-1 and IEC 60439-2 standards were used to benchmark the experimental data. The results revealed that the “chimney effect” induces an increment of the hot air adjacent to the heat sink. A conspicuous increase in the total heat transfer rate and fin effectiveness was observed as the fin thickness was reduced. This study revealed that s1 = 1 mm was the best fin thickness with 1.254 fin effectiveness, 1.862 W of total heat transfer rate, and 17.5 Nusselt number. Additionally, various coating methods were examined experimentally to select the best nanocomposite coating for the bus duct conductor’s heat sink. The ultrasonic agitation was the best coating method, which resulted in the lowest average resistance (8.8 μΩ) and a better percentage of Ag (0.6%–2.5%) on the substrate surface. Thus, the current outcomes are expected to better comprehend the impact of fin thickness on thermal performance, as well as the selection of coating method for the bus duct conductor. Full article
(This article belongs to the Special Issue Oxidation, Wear, Corrosion Behaviors and Activated Bonding Properties of Coatings Deposited on Metals)
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14 pages, 5458 KiB  
Article
Mathematical Modeling and Experimental Validation of Surface Roughness in Ball Burnishing Process
by Rahul O. Vaishya, Vivek Sharma, Vinod Mishra, Anurag Gupta, Mandeep Dhanda, R. S. Walia, Manoj Kumar, Ankit D. Oza, Dumitru Doru Burduhos-Nergis and Diana Petronela Burduhos-Nergis
Coatings 2022, 12(10), 1506; https://doi.org/10.3390/coatings12101506 - 09 Oct 2022
Cited by 5 | Viewed by 1673
Abstract
Burnishing is a cold working technique used as a surface enrichment to meet the desired surface properties of the workpiece. It improves the visual properties, dimensional tolerances, fatigue strength, surface roughness, and hardness of the work material by applying appropriate pressure through a [...] Read more.
Burnishing is a cold working technique used as a surface enrichment to meet the desired surface properties of the workpiece. It improves the visual properties, dimensional tolerances, fatigue strength, surface roughness, and hardness of the work material by applying appropriate pressure through a complex ball burnishing tool to cause plastic deformation. In the current work, the mathematical modeling of the burnishing process was carried out to predict surface roughness by considering the process parameters such as contact radius, penetration depth, and elastic rebound. Further, a customized tungsten carbide (W.C.) insert having a hardness of 80 HRC was developed for the burnishing operation. The micro-hardness of the resulting burnished surface improved from 44 to 48 HRC. The surface quality of the tungsten carbide insert improved by up to 17.1 nm through polishing. Several experiments were performed by selecting appropriate process parameters using developed model feedback. The surface quality of the workpiece improved by up to 45 nm, which resulted in automatic improvements in fatigue strength up to seven times that of the virgin material. The results predicted from the mathematical model were in good agreement (less than 5% deviation) with the experimental results. This study helps to understand the surface formation mechanism in the burnishing process in more detail. Additionally, the achieved results show a significant improvement in the surface finish (~95%), indicating the potential of the burnishing process and how fast and cost-effective it is. The novelty of this paper lies in the improvement in surface roughness and the validation of our mathematical model results with the experimental results. Full article
(This article belongs to the Special Issue Oxidation, Wear, Corrosion Behaviors and Activated Bonding Properties of Coatings Deposited on Metals)
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20 pages, 14561 KiB  
Article
Analysis of the Physical-Mechanical Properties of the Zinc Phosphate Layer Deposited on a Nodular Cast Iron Substrate
by Carmen Nejneru, Diana-Petronela Burduhos-Nergis, Mihai Axinte, Manuela Cristina Perju and Costica Bejinariu
Coatings 2022, 12(10), 1384; https://doi.org/10.3390/coatings12101384 - 22 Sep 2022
Cited by 1 | Viewed by 1382
Abstract
The rotors of submersible wastewater pumps, generally made of nodular graphite cast iron, are subjected to complex processes of corrosive erosion during operation. To improve the characteristics of erosion resistance by impact with solid particles in the corrosive environment of wastewater, cast iron [...] Read more.
The rotors of submersible wastewater pumps, generally made of nodular graphite cast iron, are subjected to complex processes of corrosive erosion during operation. To improve the characteristics of erosion resistance by impact with solid particles in the corrosive environment of wastewater, cast iron was subjected to a chemical phosphating treatment. In the paper, the scratch test behaviour of nodular cast iron and phosphate nodular cast iron is analysed comparatively, studying the behaviour of the deposited layer and its adhesion to the substrate. The nanoindentation characteristics of nodular cast iron and phosphate nodular cast iron were also studied. It was observed that the deposited layer is not compact, but when pressed, it does not crack and does not detach from the substrate; it is impregnated in the substrate in the metal matrix, but not on the area with carbon nodules. The SEM micrographs show that the deposited phosphate layer is relatively porous and can change the behaviour of the liquid flow moving on the surface of the rotor due to its hydrophilic behaviour; this also allows the formation of a boundary layer that adheres to the surface of the rotor and protects it from the impacts of microparticles driven by the liquid stream. Full article
(This article belongs to the Special Issue Oxidation, Wear, Corrosion Behaviors and Activated Bonding Properties of Coatings Deposited on Metals)
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25 pages, 14707 KiB  
Article
Corrosion Behaviour of Nodular Cast Iron Used for Rotor Manufacturing in Different Wastewaters
by Carmen Nejneru, Diana-Petronela Burduhos-Nergis, Mihai Axinte, Manuela Cristina Perju and Costica Bejinariu
Coatings 2022, 12(7), 911; https://doi.org/10.3390/coatings12070911 - 28 Jun 2022
Cited by 2 | Viewed by 1627
Abstract
Submersible drainage sump pumps work in a highly corrosive environment, forming films with corrosive reaction products on the surface. Pump rotors are high-demand parts, so they are made of quality materials with good wear and corrosion resistance properties such as nodular graphite cast [...] Read more.
Submersible drainage sump pumps work in a highly corrosive environment, forming films with corrosive reaction products on the surface. Pump rotors are high-demand parts, so they are made of quality materials with good wear and corrosion resistance properties such as nodular graphite cast iron. This paper analyses the corrosion behaviour of cast iron used in the manufacture of rotors in three types of wastewaters, with variable pH. Nodular graphite cast iron samples were immersed in wastewater for 30, 60, and 90 days and tested by linear polarisation and electrochemical impedance spectroscopy (EIS). Also, the layers of reaction products formed on the surface of the material were analysed by SEM and EDS. The results showed that nodular cast-iron immersed in wastewater with acidic pH showed intense corrosion, the oxide layer formed on its surface is unstable. Also, the final structure of the product layer is that of a tri-layer with cations and anions absorbed from the corrosion media: the double-electric layer directly connected to the metal surface, an internal layer consisting of ferrous compounds and ferric compounds that control the diffusion of oxygen, an outer layer, and a compact crust of ferric compounds. The change in the pH of the wastewater has a major influence on the corrosion rate of the cast iron, which increases from 356.4 µm/year in DWW-1 (6.5 pH) to 1440 µm/year in DWW-2 (3 pH) and 1743 µm/year DWWW-3 (11 pH) respectively. As can be seen, the experimental study covers the problem of the corrosion behaviour of the pump rotor in various types of wastewaters this aspect is particularly important for the good use of wastewater pumps and to predict possible deviations for the operation of the equipment within the treatment plants. Full article
(This article belongs to the Special Issue Oxidation, Wear, Corrosion Behaviors and Activated Bonding Properties of Coatings Deposited on Metals)
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Review

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11 pages, 4299 KiB  
Review
High-Entropy Alloy for Thin Film Application: A Review
by Nur Izzati Muhammad Nadzri, Dewi Suriyani Che Halin, Mohd Mustafa Al Bakri Abdullah, Sudha Joseph, Mohd Arif Anuar Mohd Salleh, Petrica Vizureanu, Diana-Petronela Burduhos-Nergis and Andrei Victor Sandu
Coatings 2022, 12(12), 1842; https://doi.org/10.3390/coatings12121842 - 28 Nov 2022
Cited by 7 | Viewed by 3103
Abstract
High entropy alloy (HEA) involves the addition of five or more elements into the materials system. This provides a multidimensional configuration space that is limitless in terms of its properties and functions. Some high-entropy alloys have already been shown to have superior properties [...] Read more.
High entropy alloy (HEA) involves the addition of five or more elements into the materials system. This provides a multidimensional configuration space that is limitless in terms of its properties and functions. Some high-entropy alloys have already been shown to have superior properties over conventional alloys, especially the CoCr-based HEA materials. Better high-entropy alloy applications may be discovered, especially in micro- and nano-level structures, hence the development of thin film/coating -based HEA materials. Therefore, in this review paper, we are aiming to provide recent studies on the thin film/coating-based high-entropy alloy on fundamental issues related to methods of preparation, phase formation and mechanical properties. We found that sputtering has been extensively used to grow thin-film-based HEAs as it allowed parameters to be controlled with homogeneous growth. The evolution from bulk to thin samples can also be observed with the mechanical properties has exceeded the bulk-based HEA expectations, which are high hardness, better interfacial bonding and tribological behaviour and higher corrosion resistant. Full article
(This article belongs to the Special Issue Oxidation, Wear, Corrosion Behaviors and Activated Bonding Properties of Coatings Deposited on Metals)
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