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Metal Coatings for Wear and Corrosion Applications

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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 October 2023) | Viewed by 11266

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Special Issue Editors

Dr. Gabriela Mǎrginean

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Guest Editor

Department of Materials Science and Testing, Westphalian University of Applied Sciences Gelsenkirchen Bocholt Recklinghausen, Neidenburger str. 43, 45897 Gelsenkirchen, Germany
Interests: thermal barrier coatings; self-fluxing alloys; marine corrosion; wear resistant cermets; additive manufacturing; PEM fuel cells
Special Issues, Collections and Topics in MDPI journals

Dr. Norbert Kazamer

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Guest Editor

Westphalian Energy Institute, Westphalian University of Applied Sciences Gelsenkirchen Bocholt Recklinghausen, Neidenburger str. 43, 45897 Gelsenkirchen, Germany
Interests: self-fluxing alloys; coatings post-processing; optimization; wear resistant coatings; oxygen evolution reaction; PEM water electrolysis
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue is dedicated to research activities concerning the wear and corrosion behaviour of metallic coating materials. Topics of interest may range from fundamental understanding of the wear of the corrosion mechanisms to special solutions for their practical application. Materials are exposed to different types of wear (friction, abrasion, erosion) and corrosion attack (chemical or electrochemical corrosion, molten salt corrosion, high-temperature corrosion), leading to severe material degradation. Therefore, the knowledge on surface engineering must be combined with fundamental information on materials science to understand the observed phenomena and prevent further failure.

In this context, submissions may tackle subjects as diverse as technologies for the deposition of metallic coatings, additive manufacturing methods, or the surface postprocessing of applied coatings using laser or electron beam sources. Functional gradient advanced materials as well as structured surfaces with special chemical, biological, optical, nuclear, aerospace, or other applications have been developed and applied in recent years, but some key problems still need to be elucidated and solved.

It is my pleasure to invite you to submit a manuscript for this Special Issue. Full papers, communications, and reviews are all welcome.

Dr. Gabriela Mǎrginean
Dr. Norbert Kazamer
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. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

coatings
aqueous corrosion
high temperature corrosion
sliding wear
abrasion
solid particle erosion
additive manufacturing
electron beam remelting
laser structuring

Published Papers (7 papers)

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Research

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21 pages, 13247 KiB

Open AccessArticle

The Effect of Mechanical Pretreatment on the Electrochemical Characteristics of PEO Coatings Prepared on Magnesium Alloy AZ80

by Ján Sovík, Daniel Kajánek, Filip Pastorek, Milan Štrbák, Zuzana Florková, Michal Jambor and Branislav Hadzima

Materials 2023, 16(16), 5650; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16165650 - 16 Aug 2023

Cited by 1 | Viewed by 822

Abstract

The main objective of this article is to provide new information on the effects of mechanical pretreatment of AZ80 magnesium alloy ground with SiC emery papers of different grain sizes on the plasma electrolytic oxidation (PEO) process and corrosion properties of AZ80 in 0.1 M NaCl solution. Then, the roughness of the coated samples was measured by confocal microscopy. The corrosion properties of the ground and coated surfaces were determined by potentiodynamic polarization (PDP) within 1 h of exposure, and electrochemical impedance spectroscopy (EIS) was performed during 168 h of exposure at laboratory temperature. Consequently, the obtained results of the PDP measurements were evaluated by the Tafel analysis and the EIS evaluation was performed by the equivalent circuit analysis through Nyquist diagrams. The morphology and structure of PEO coatings were observed by scanning electron microscopy (SEM) through the secondary imaging technology, and the presence of certain elements in PEO coatings was analyzed by EDS analysis. Full article

(This article belongs to the Special Issue Metal Coatings for Wear and Corrosion Applications)

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17 pages, 4555 KiB

Open AccessArticle

Role of 5 wt.% Mg Alloying in Al on Corrosion Characteristics of Al-Mg Coating Deposited by Plasma Arc Thermal Spray Process

by Hwa-Rang Jeong and Jitendra Kumar Singh

Materials 2023, 16(8), 3088; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16083088 - 13 Apr 2023

Cited by 2 | Viewed by 1179

Abstract

The corrosion of steel structures in coastal areas is a major issue. Therefore, in the present study, the protection against the corrosion of structural steel is carried out by depositing 100 μm thick Al and Al-5 Mg coatings using a plasma arc thermal spray process, immersing them in 3.5 wt.% NaCl solution for 41 days (d). To deposit such metals, one of the best known processes, arc thermal spray, is frequently used, but this process has severe defects and porosity. Thus, to minimize the porosity and defects of arc thermal spray, a plasma arc thermal spray process is developed. In this process, we used normal gas to create plasma instead of argon (Ar) and nitrogen (N₂) with hydrogen (H) and helium (He). Al-5 Mg alloy coating exhibited uniform and dense morphology, where it reduced more than four times the porosity compared to Al, where Mg fills the voids of the coating, resulting in greater bond adhesion and hydrophobicity. The open circuit potential (OCP) of both coatings exhibited electropositive values due to the formation of native oxide in Al, while in the case of Al-5 Mg, the coating is dense and uniform. However, after 1 d of immersion, both coatings showed activation in OCP, owing to the dissolution of splat particles from the corner where the sharp edges are present in the Al coating, while Mg preferentially dissolved in the Al-5 Mg coating and made galvanic cells. Mg is galvanically more active than Al in the Al-5 Mg coating. Due to the capacity of the corrosion products to cover the pores and defects, both coatings stabilized the OCP after 13 d of immersion. The total impedance of the Al-5 Mg coating is gradually increased and is higher than the Al, which can be attributed to the uniform and dense coating morphology where Mg dissolves and agglomerates to form globular corrosion products and deposit over the surface, thereby causing barrier protection. The defect bearing corrosion products on Al coating led to the cause having a higher corrosion rate than the Al-5 Mg coating. A total of 5 wt.% mg in the Al coating improved the corrosion rate by a rate of 1.6 times compared to the pure Al in the 3.5 wt.% NaCl solution after 41 d of immersion. Full article

(This article belongs to the Special Issue Metal Coatings for Wear and Corrosion Applications)

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10 pages, 8245 KiB

Open AccessArticle

Deformation-Induced Martensitic Transformation in Laser Cladded 304 Stainless Steel Coatings

by André T. Zeuner, Leonid Gerdt, Andrea Ostwald, Peter Grün, Maria Barbosa, Jörg Kaspar and Martina Zimmermann

Materials 2022, 15(18), 6392; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15186392 - 14 Sep 2022

Cited by 3 | Viewed by 1387

Abstract

There are only a few cost-effective solutions for coating applications in combined mechanical loading and corrosive environments. Stainless steel AISI 304 has the potential to fill this niche, showing excellent corrosion resistance while utilizing the deformation-induced phase transformation from γ-austenite to α’-martensite, which results in an increase in strength. However, it is not known whether this can occur in laser cladded material. Therefore, laser cladded AISI 304 coatings in as-cladded condition and after heat treatment at 1100 °C for 60 min were investigated before and after bending deformation, by means of light microscopy, energy-dispersive X-ray spectroscopy and electron backscatter diffraction. It was shown that due to the dendritic microstructure accompanied by an inhomogeneous distribution of the main alloying elements (Cr and Ni), no deformation-induced phase transformation occurred in the as-cladded coating. The applied approach with subsequent solution heat treatment at 1100 °C for 60 min resulted in a homogeneous γ-austenite microstructure, so that a deformation-induced martensitic transformation (DIMT) could occur in the coatings. However, the volume fraction of martensite that had been formed locally at individual shear bands was rather low, which can be possibly attributed to the high Ni content of the feedstock, stabilizing the γ-austenite microstructure. This study shows the possibility of exploiting the DIMT mechanism in heat-treated laser-cladded AISI 304 coatings. Full article

(This article belongs to the Special Issue Metal Coatings for Wear and Corrosion Applications)

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10 pages, 2463 KiB

Open AccessArticle

Investigations of Cavitation Erosion and Corrosion Behavior of Flame-Sprayed NiCrBSi/WC-12Co Composite Coatings

by Costel-Relu Ciubotariu, Doina Frunzaverde and Gabriela Marginean

Materials 2022, 15(8), 2943; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15082943 - 18 Apr 2022

Cited by 7 | Viewed by 1730

Abstract

Flame-sprayed NiCrBSi/WC-12Co composite coatings were deposited in different ratios on the surface of stainless steel. Oxyacetylene flame remelting treatment was applied to surfaces for refinement of the morphology of the layers and improvement of the coating/substrate adhesion. The performance of the coated specimens to cavitation erosion and electrochemical corrosion was evaluated by an ultrasonic vibratory method and, respectively, by polarization measurements. The microstructure was investigated by means of scanning electron microscopy (SEM) combined with energy dispersive X-ray analysis (EDX). The obtained results demonstrated that the addition of 15 wt.% WC-12Co to the self-fluxing alloy improves the resistance to cavitation erosion (the terminal erosion rate (Vs) decreased with 15% related to that of the NiCrBSi coating) without influencing the good corrosion resistance in NaCl solution. However, a further increase in WC-Co content led to a deterioration of these coating properties (the Vs has doubled related to that of the NiCrBSi coating). Moreover, the corrosion behavior of the latter composite coating was negatively influenced, a fact confirmed by increased values for the corrosion current density (i_corr). Based on the achieved experimental results, one may summarize that NiCrBSi/WC-Co composite coatings are able to increase the life cycle of expensive, high-performance components exposed to severe cavitation conditions. Full article

(This article belongs to the Special Issue Metal Coatings for Wear and Corrosion Applications)

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14 pages, 7906 KiB

Open AccessArticle

Comparative Study on the Thermal Performance of Cr-Cr_xO_y and YSZ-CoNiCrAlY Coatings Exposed at 900 °C

by Markus Kiryc, Norbert Kazamer, Deniz Kurumlu and Gabriela Marginean

Materials 2021, 14(20), 6040; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14206040 - 13 Oct 2021

Cited by 3 | Viewed by 1491

Abstract

Yttria stabilized zirconia (YSZ) thermal barrier coatings (TBCs) deposited on CoNiCrAlY oxidation protective bond coats are commonly required in temperature regimes up to 1200 °C (e.g., hot gas turbine regions) due to their superior thermal behavior and mechanical properties. For temperatures up to around 900 °C, oxidation protection can be alternatively provided by metallic-ceramic Cr-Cr_xO_y coatings. For the present research, Cr-Cr_xO_y atmospheric plasma sprayed (APS) and YSZ-CoNiCrAlY APS-high velocity oxy-fuel TBC coatings were deposited on a NiCr20Co18Ti substrate. The samples were isothermally heat treated at 900 °C for 10 h in an environmental atmosphere and subsequently isothermally oxidized at the same temperature for 1200 h. Investigations of the physical, chemical, and mechanical properties were performed on the as-sprayed, heat-treated, and oxidized samples. The oxidation behavior, microhardness, cohesion, and adhesion of the samples were correlated with the microstructural investigations and compared to the conventional TBC system. It could be shown that heat treating decreased the Cr-Cr_xO_y coatings crack susceptibility and led to the formation of a protective thermally grown Cr oxide layer. The experimental work on the YSZ-CoNiCrAlY system revealed that the phase composition of the bond coat has a direct influence on the oxidation protection of the coating system. Full article

(This article belongs to the Special Issue Metal Coatings for Wear and Corrosion Applications)

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13 pages, 3941 KiB

Open AccessArticle

Influence of the Laser Cladding Parameters on the Morphology, Wear and Corrosion Resistance of WC-Co/NiCrBSi Composite Coatings

by Iosif Hulka, Ion D. Uțu, Diana Avram, Mircea L. Dan, Alexandru Pascu, Elena M. Stanciu and Ionuț C. Roată

Materials 2021, 14(19), 5583; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14195583 - 26 Sep 2021

Cited by 19 | Viewed by 2428

Abstract

To enhance the sliding wear and corrosion behavior of steels with low carbon content, cermet composite coatings are usually deposited on their surface by various deposition processes. Laser cladding, compared to other deposition techniques such as electroplating, arc welding, and thermal spraying, has numerous advantages to produce such protective coatings. The paper presents the optimization of laser cladding deposition speed versus energy density in order to obtain WC-Co/NiCrBSi coatings with Ni-Al addition free of defects and reduced porosity deposited on low carbon steel substrate. The microstructure and chemical composition were investigated by SEM combined with EDX analysis while XRD was performed in order to examinate the phases within the coatings. In order to investigate the cladding speed influence on the coatings, hardness measurements, POD (pin on disk) wear tests and corrosion tests in 3.5% NaCl solution were carried out. The results showed that an optimal cladding speed has a crucial impact on the microstructure, composition, and hardness. It was found out that optimizing the cladding deposition speed proved to be effective in enhancing the sliding wear resistance and corrosion behavior by controlling the iron content within the coatings. Full article

(This article belongs to the Special Issue Metal Coatings for Wear and Corrosion Applications)

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Review

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15 pages, 5184 KiB

Open AccessReview

Human Body-Fluid-Assisted Fracture of Zinc Alloys as Biodegradable Temporary Implants: Challenges, Research Needs and Way Forward

by R. K. Singh Raman, Cuie Wen and Jörg F. Löffler

Materials 2023, 16(14), 4984; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16144984 - 13 Jul 2023

Viewed by 980

Abstract

Alloys of magnesium, zinc or iron that do not contain toxic elements are attractive as construction material for biodegradable implants, i.e., the type of implants that harmlessly dissolve away within the human body after they have completed their intended task. The synergistic influence of mechanical stress and corrosive human body fluid can cause sudden and catastrophic fracture of bioimplants due to phenomena such as stress corrosion cracking (SCC) and corrosion fatigue (CF). To date, SCC and CF of implants based on Zn have scarcely been investigated. This article is an overview of the challenges, research needs and way forward in understanding human body-fluid-assisted fractures (i.e., SCC and CF) of Zn alloys in human body fluid. Full article

(This article belongs to the Special Issue Metal Coatings for Wear and Corrosion Applications)

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