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Surface Modification and Coating of Metallic Materials: Microstructure, Tribology and...
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Surface Modification and Coating of Metallic Materials: Microstructure, Tribology and Corrosion

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Surface Characterization, Deposition and Modification".

Deadline for manuscript submissions: closed (31 March 2022) | Viewed by 18029

Special Issue Editors

Dr. Ahmed Omar Mosleh

E-Mail Website1 Website2 Website3 Website4
Guest Editor
1. Department of Physical Metallurgy of Non-Ferrous Metals, National University of Science and Technology (MISIS), Moscow, Russia
2. Department of Mechanical Engineering, Faculty of Engineering at Shoubra, Benha University, Benha, Egypt
Interests: metals; surface modification; microstructure; mechanical properties; materials characterization; metallurgy; additive manufacturing; metal matrix composites; superplastic forming and sheet metal work; wear; corrosion; heat resistant alloys; Titanium alloys; alloy design; heat treatment of metals; metallurgy & metallurgical engineering; materials science
Special Issues, Collections and Topics in MDPI journals
Dr. Alexey N. Solonin

E-Mail Website1 Website2 Website3
Guest Editor
Department of Physical Metallurgy of Non-Ferrous Metals, National University of Science & Technology (MISIS), Moscow, Russia
Interests: material characterization; materials mechanical properties; microstructure materials processing; advanced materials; heat treatment; metallurgical engineering; 3D printing; additive manufacturing; materials technology; powders alloys science education; recrystallisation powder technology; aluminum alloys; phase transformations; metal matrix composites; bulk metallic glasses; metal goams
Special Issues, Collections and Topics in MDPI journals
Dr. Essam B. Moustafa

E-Mail Website
Guest Editor
Mechanical Engineering Department, Faculty of Engineering, King Abdulaziz University (KAU), Jeddah P.O. Box 80204, Saudi Arabia
Interests: metals; surface composites; surface modification; friction stir welding/processing; microstructure; mechanical properties; materials characterization; wear; corrosion
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

In recent decades, the growing demand for high performance, long lifetime, reliability of metallic parts, high energy efficiency, and low environmental impact has fuelled the growth of surface modification technologies. It is a pleasure to invite you to submit your papers to the current Special Issue, entitled “Surface Modification and Coating of Metallic Materials: Microstructure, Tribology, and Corrosion.” Surface modification of metallic materials via friction stir processing, laser melting processing, and chemical treatments. Compositing the surface with nano-reinforcements aiming to improve its characterizations. Surface coating technologies are considered to be a part of advanced surface modification; thus, articles on coatings are also welcome. Papers including microstructure analysis, hardness, tribology, and corrosion investigation of the modified surface are welcome. The main focus of this issue is to highlight the visible approaches of surface modification for improving wear and corrosion resistance. Simultaneously, besides the wear and corrosion investigations, the microstructure of the modified surface or surface composite is important to be studied.

the topics of interest of this Special Issue include, but are not limited to, the following:

  • Surface modification (laser melting processes, friction stir processing, chemical methods;
  • Surface compositing;
  • Surface characterizations research (microstructure, hardness, tribological analysis, corrosion, surface roughness;
  • Tribological coatings, wear and corrosion protection;
  • Surface characterization and tribo-testing.

Dr. Ahmed Omar Mosleh
Dr. Alexey N. Solonin
Dr. Essam B. Moustafa
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

  • metallic materials
  • surface modifications
  • surface coatings
  • laser melting process
  • wear

Published Papers (7 papers)

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Research

16 pages, 7953 KiB  
Article
The Influence of Boron Carbide on the Mechanical Properties and Bonding Strength of B4C/Nickel 63 Coatings of Brake Disc
by Balasubramanian Ramesh, Ammar H. Elsheikh, Shanmugam Satishkumar, Abdul Munaf Shaik, Joy Djuansjah, Mahmoud Ahmadein, Essam B. Moustafa and Naser A. Alsaleh
Coatings 2022, 12(5), 663; https://doi.org/10.3390/coatings12050663 - 12 May 2022
Cited by 6 | Viewed by 2055
Abstract
Metal-based ceramic composite laser cladding offers substantial compensations in enhancing brake disc surface characteristics. Laser cladding was utilized to combine B4C powder (10–40%) with Ni 63 powder to make Boron Carbide (B4C)/Nickel 63 composite coatings. For the subsequent experiments, [...] Read more.
Metal-based ceramic composite laser cladding offers substantial compensations in enhancing brake disc surface characteristics. Laser cladding was utilized to combine B4C powder (10–40%) with Ni 63 powder to make Boron Carbide (B4C)/Nickel 63 composite coatings. For the subsequent experiments, the specimens were ground and polished. Bonding strength, fracture toughness, and residual stress were examined with the B4C content. The fracture morphologies were checked using a scanning electron microscope (SEM). It was observed that the bonding strength of various coatings might approach 175 MPa. Best bonding was observed when the B4C level was between 15% and 30%. The porousness of the coating continuously raised as B4C content increased. The coating’s maximum permeability was 5.6% after the B4C level reached 30%. As the B4C level in the coating grew, the coating’s compression resistance decreased. The bonding strength was within desirable limits, and compression resistance was consistently strong. The material bending strength increased when the B4C materials were reduced below 35%; at this level, the bending strength was highest. The bending strength was covered by the optimal range of bonding strength. Good bonding strength and mechanical characteristics were achieved when B4C content was 20% to 30%. The 20% B4C coating had the smoothest fracture morphologies and the strongest bonding strength, making it the most stable. For the estimation of total matrix deformation and corresponding coating stress on coated brake discs, Ansys software was utilized to create a static structural model. Full article
(This article belongs to the Special Issue Surface Modification and Coating of Metallic Materials: Microstructure, Tribology and Corrosion)
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13 pages, 3992 KiB  
Article
Electrochemical Behavior of Cu-MWCNT Nanocomposites Manufactured by Powder Technology
by Moustafa M. Mohammed, Elsayed M. Elsayed, Omyma A. El-Kady, Naser A. Alsaleh, Ammar H. Elsheikh, Fadl A. Essa, Mahmoud Ahmadein and Joy Djuansjah
Coatings 2022, 12(3), 409; https://doi.org/10.3390/coatings12030409 - 19 Mar 2022
Cited by 5 | Viewed by 1979
Abstract
This paper presents an experimental investigation of the fabrication of Cu–multi-walled carbon nanotube (MWCNT) nanocomposites prepared via the electroless chemical deposition technique followed by the powder metallurgy (PM) method. To enhance the dispersion and wettability of MWCNTs with a Cu matrix, MWCNTs were [...] Read more.
This paper presents an experimental investigation of the fabrication of Cu–multi-walled carbon nanotube (MWCNT) nanocomposites prepared via the electroless chemical deposition technique followed by the powder metallurgy (PM) method. To enhance the dispersion and wettability of MWCNTs with a Cu matrix, MWCNTs were given an electroless coating of Ag nanoparticles. MWCNTs with 0.4, 0.8, and 1.2 wt.% were first coated with 5 wt.% Ag nanoparticles, then mechanically milled with Cu nanoparticles using a 10:1 ball-to-powder ratio for 60 min at 300 rpm. The mixed samples (35 g) were subjected to a compression pressure of 700 MPa and sintered at 950 °C in a hydrogen-inert gas furnace. Mapping and microstructure analyses were conducted to analyze the constituents’ homogeneity. In addition, the electrochemical properties and corrosion resistance of specimens were investigated. The results revealed that the relative density decreased by raising the MWCNTs’ content. Electrical resistivity increased gradually with the addition of MWCNTs coated by Ag nanoparticles, and the thermal conductivity decreased. It was also revealed that the smallest corrosion rate could be obtained for the sample with 1.2 wt.% MWCNTs, which is the appropriate rate for the electrochemical deposition. Full article
(This article belongs to the Special Issue Surface Modification and Coating of Metallic Materials: Microstructure, Tribology and Corrosion)
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12 pages, 5491 KiB  
Article
The Effect of Incorporating Ceramic Particles with Different Morphologies on the Microstructure, Mechanical and Tribological Behavior of Hybrid TaC_ BN/AA2024 Nanocomposites
by Emad Ismat Ghandourah, Essam B. Moustafa, Hossameldin Hussein and Ahmed O. Mosleh
Coatings 2021, 11(12), 1560; https://doi.org/10.3390/coatings11121560 - 18 Dec 2021
Cited by 6 | Viewed by 2098
Abstract
Improving the mechanical durability and wear resistance of aluminum alloys is a research challenge that can be solved by their reinforcement with ceramics. This article is concerned with the improvement of the mechanical properties and wear resistance of the AA2024 aluminum alloy surface. [...] Read more.
Improving the mechanical durability and wear resistance of aluminum alloys is a research challenge that can be solved by their reinforcement with ceramics. This article is concerned with the improvement of the mechanical properties and wear resistance of the AA2024 aluminum alloy surface. Surface composites were prepared by incorporating a hybrid of heavy particles (tantalum carbide (TaC), light nanoparticles, and boron nitride (BN)) into the AA2024 alloy using the friction stir process (FSP) approach. Three pattern holes were milled in the base metal to produce the composites with different volume fractions of the reinforcements. The effects of the FSP and the reinforcements on the microstructure, mechanical properties, and wear resistance are investigated. In addition to the FSP, the reinforced particles contributed to greater grain refinement. The rolled elongated grains became equiaxed ultrafine grains reaching 6 ± 1 µm. The refinement and acceptable distribution in the reinforcements significantly improved the hardness and wear resistance of the produced composites. Overall, the hardness was increased by 60% and the wear resistance increased by 40 times compared to the base alloy. Full article
(This article belongs to the Special Issue Surface Modification and Coating of Metallic Materials: Microstructure, Tribology and Corrosion)
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13 pages, 5855 KiB  
Article
Nano-Surface Composite Coating Reinforced by Ta2C, Al2O3 and MWCNTs Nanoparticles for Aluminum Base via FSP
by Essam B. Moustafa, Waheed Sami Abushanab, Ammar Melaibari, Anastasia V. Mikhaylovskaya, Mohamed Shaaban Abdel-Wahab and Ahmed O. Mosleh
Coatings 2021, 11(12), 1496; https://doi.org/10.3390/coatings11121496 - 05 Dec 2021
Cited by 6 | Viewed by 2490
Abstract
In the present work, an advanced technique was applied to coat an Al 2024 alloy with a surface composite layer reinforced with various nanoparticles. The surface of Al 2024 aluminum alloy was modified with Ta2C, Al2O3 and multi [...] Read more.
In the present work, an advanced technique was applied to coat an Al 2024 alloy with a surface composite layer reinforced with various nanoparticles. The surface of Al 2024 aluminum alloy was modified with Ta2C, Al2O3 and multi wall carbon nanotubes MWCNTs nanoparticles by friction stir process (FSP). An improvement in the surface of the fabricated nanocomposite due to the refinement of the microstructure grains was achieved. In addition, a significant improvement in the hardness and wear behavior was observed. The reinforcement particles were incorporated into double and triple hybrid composite particles to determine the most effective combination for the controlled properties. The results showed that for the composite reinforced with a double hybrid of Al2O3 and MWCNTs, the microstructure grains of the fabricated nanocomposite surface were refined by 40 times. The hardness was significantly improved, i.e., it was increased by 48% by incorporating the triple reinforcement (Ta2C, Al2O3, and MWCNTs) into the surface of Al 2024 aluminum alloy. The results of wear properties were in agreement with the results of hardness; the maximum wear resistance was obtained for Al 2024-Ta2C + Al2O3 + MWCNTs, and the wear rate was reduced by 11 times. Full article
(This article belongs to the Special Issue Surface Modification and Coating of Metallic Materials: Microstructure, Tribology and Corrosion)
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17 pages, 5831 KiB  
Article
An Optimized Multilayer Perceptrons Model Using Grey Wolf Optimizer to Predict Mechanical and Microstructural Properties of Friction Stir Processed Aluminum Alloy Reinforced by Nanoparticles
by Ahmed B. Khoshaim, Essam B. Moustafa, Omar Talal Bafakeeh and Ammar H. Elsheikh
Coatings 2021, 11(12), 1476; https://doi.org/10.3390/coatings11121476 - 30 Nov 2021
Cited by 73 | Viewed by 2501
Abstract
In the current investigation, AA2024 aluminum alloy is reinforced by alumina nanoparticles using a friction stir process (FSP) with multiple passes. The mechanical properties and microstructure observation are conducted experimentally using tensile, microhardness, and microscopy analysis methods. The impacts of the process parameters [...] Read more.
In the current investigation, AA2024 aluminum alloy is reinforced by alumina nanoparticles using a friction stir process (FSP) with multiple passes. The mechanical properties and microstructure observation are conducted experimentally using tensile, microhardness, and microscopy analysis methods. The impacts of the process parameters on the output responses, such as mechanical properties and microstructure grain refinement, were investigated. The effect of multiple FSP passes on the grain refinement, and various mechanical properties are evaluated, then the results are conducted to train a hybrid artificial intelligence predictive model. The model consists of a multilayer perceptrons optimized by a grey wolf optimizer to predict mechanical and microstructural properties of friction stir processed aluminum alloy reinforced by alumina nanoparticles. The inputs of the model were rotational speed, linear processing speed, and number of passes; while the outputs were grain size, aspect ratio, microhardness, and ultimate tensile strength. The prediction accuracy of the developed hybrid model was compared with that of standalone multilayer perceptrons model using different error measures. The developed hybrid model shows a higher accuracy compared with the standalone model. Full article
(This article belongs to the Special Issue Surface Modification and Coating of Metallic Materials: Microstructure, Tribology and Corrosion)
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16 pages, 7717 KiB  
Article
Interfacial Microstructure and Corrosion Behaviour of Mild Steel Coated with Alumina Nanoparticles Doped Tin Composite via Direct Tinning Route
by Abdulaziz S. Alghamdi, K. S. Abdel Halim, Mohammed A. Amin, Abdullah S. Alshammari, Naglaa Fathy and Mohamed Ramadan
Coatings 2021, 11(11), 1318; https://doi.org/10.3390/coatings11111318 - 29 Oct 2021
Cited by 5 | Viewed by 2298
Abstract
The improvement of the surface properties of ferrous metallic materials has become a crucial criterion for advanced engineering applications. The interfacial microstructure and corrosion behaviour of mild steel coated with alumina nanoparticles doped in tin composite using the direct tinning technique were investigated. [...] Read more.
The improvement of the surface properties of ferrous metallic materials has become a crucial criterion for advanced engineering applications. The interfacial microstructure and corrosion behaviour of mild steel coated with alumina nanoparticles doped in tin composite using the direct tinning technique were investigated. A coating layer of tin composite containing different loads of Al2O3 nanoparticles (0.25 wt.%, 0.50 wt.%, 1.00 wt.% and 1.5 wt.%) was prepared and directly deposited on a mild steel substrate. This type of a direct tinning process is considered to be a simple and low-cost route for protecting metallic materials from corrosion. It was found that the thickness of both the composite layer and Fe-Sn intermetallic layer at the coated interfaces was highly affected by the presence of alumina nanoparticles that effectively inhibit the diffusion of Sn atoms into the Fe substrate. For the samples coated with lower content of alumina nanoparticles (0.25 wt.% and 0.50 wt.%), the thickness of the Fe-Sn intermetallic coating (IMC) layer is decreased due to Fe-Sn IMC suppression. Otherwise, for the addition of more alumina nanoparticles (1.00 wt.% and 1.50 wt.%), the thickness of the Fe-Sn IMC layer is slightly increased because of nanoparticle’s agglomeration and flotation. It can be reported that the presence of alumina nanoparticles in the coating layer improves, to a great extent, the corrosion resistance of Sn-composites surface on mild steel substrates. Although the tin composite coating layer with a high quantity of alumina nanoparticles (1.0 wt.%) exhibited better corrosion resistance than the other tested samples, such nanoparticle additions have become increasingly difficult to obtain. It was observed that the Al2O3 nanoparticles agglomeration and flotation that were detected in the coating surface may be related to high fraction nanoparticles loading and to the difference in the gravity for Sn and Al2O3 nanoparticles. However, based on our investigation, a coating layer that contains 0.50 wt.% alumina nanoparticles is highly recommended for achieving long lasting and high-performance corrosion resistance for coated mild steel with minimal coating layer defects. Full article
(This article belongs to the Special Issue Surface Modification and Coating of Metallic Materials: Microstructure, Tribology and Corrosion)
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18 pages, 102401 KiB  
Article
A Novel Comparative Study Based on the Economic Feasibility of the Ceramic Nanoparticles Role’s in Improving the Properties of the AA5250 Nanocomposites
by Waheed Sami Abushanab, Essam B. Moustafa, Ammar A. Melaibari, Anton D. Kotov and Ahmed O. Mosleh
Coatings 2021, 11(8), 977; https://doi.org/10.3390/coatings11080977 - 17 Aug 2021
Cited by 18 | Viewed by 2378
Abstract
In this paper, AA5250 aluminum sheets are reinforced with boron nitride (BN), silicon carbide (SiC), aluminum oxide (Al2O3), and vanadium carbide (VC). The nanocomposites metal matrix are manufactured using friction stir processing (FSP). A novel analytical comparison based on [...] Read more.
In this paper, AA5250 aluminum sheets are reinforced with boron nitride (BN), silicon carbide (SiC), aluminum oxide (Al2O3), and vanadium carbide (VC). The nanocomposites metal matrix are manufactured using friction stir processing (FSP). A novel analytical comparison based on an assessment of mechanical, physical properties and the cost of manufactured materials was conducted to help the engineers and designers choose the most economically feasible nanocomposite. The results revealed extra grain refining for all composites in the stirred zone (SZ) due to the Zener-pinning mechanism. The smallest grain size was obtained in AA5250/BN, and it decreased 20 times that of the base metal (BM). The highest wear resistance was achieved in AA5250/SiC, followed by AA5250/VC and AA5250/BN. The lowest coefficient of friction was obtained for AA5250/BN due to the self-lubrication property of BN; which was μ = 0.28. SiC AA5250 had the highest hardness, increasing three times more than the base metal in terms of its hardness. There was a detailed discussion of the probable explanations for the improvements. However, the outstanding characteristics of the BN nanoparticles, the AA5250/BN was reported to be lower than the AA5250/SiC. In comparison, the AA5250/SiC nanocomposite exhibits the optimum value due to its fitting for different properties relative to the cost. Full article
(This article belongs to the Special Issue Surface Modification and Coating of Metallic Materials: Microstructure, Tribology and Corrosion)
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