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Applied Mechanics
Volume 6
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10.3390/applmech6040076
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Article

Micro-Structured Multifunctional Greener Coatings Obtained by Plasma Spray

by
Spyridoula G. Farmaki
1,
Dimitrios A. Exarchos
1,*,
Panagiota T. Dalla
1,
Elias A. Ananiadis
1,
Vasileios Kechagias
2,
Alexandros E. Karantzalis
1 and
Theodore E. Matikas
1
1
Department of Material Science and Engineering, University of Ioannina, 45110 Ioannina, Greece
2
Superalloys Engineering S.A., Stadiou 10A, Kalochori, 57009 Thessaloniki, Greece
*
Author to whom correspondence should be addressed.
Appl. Mech. 2025, 6(4), 76; https://doi.org/10.3390/applmech6040076
Submission received: 23 July 2025 / Revised: 22 September 2025 / Accepted: 30 September 2025 / Published: 13 October 2025
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Abstract

The increasing reliance on conventional coatings such as WC-Co raises serious environmental and health concerns due to the toxicity of cobalt and the ecological footprint of these materials. To address this challenge, the present study explores the development of eco-friendly multifunctional coatings via the Plasma Spray (PS) process, using titanium (Ti), silicon carbide (SiC), and tungsten carbide-cobalt (WC-Co) mixtures as alternative feedstocks. Steel substrates were coated under different deposition strategies (powder mixing, layer-by-layer) and current settings (800-900 A). The coatings were characterized by scanning electron microscopy (SEM/EDX), 3D profilometry, sliding wear testing, and potentiodynamic corrosion measurements. Results showed that Ti-WC (mix, 900 A) and Ti-SiC (layer, 900 A) coatings achieved the most favorable performance, combining excellent adhesion, uniform coverage, reduced porosity, and improved resistance to wear and corrosion compared to conventional Cr2O3 coatings. Notably, Ti-WC coatings provided surface roughness values comparable to Cr2O3, while significantly lowering the environmental impact. These findings demonstrate that PS-based Ti-WC and Ti-SiC systems can serve as sustainable and high-performance alternatives for protective applications in harsh environments, particularly in marine industries, supporting the transition toward coatings with reduced ecological footprint.
Keywords: plasma spray; green multifunctional coatings; environmental sustainability plasma spray; green multifunctional coatings; environmental sustainability

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MDPI and ACS Style

Farmaki, S.G.; Exarchos, D.A.; Dalla, P.T.; Ananiadis, E.A.; Kechagias, V.; Karantzalis, A.E.; Matikas, T.E. Micro-Structured Multifunctional Greener Coatings Obtained by Plasma Spray. Appl. Mech. 2025, 6, 76. https://doi.org/10.3390/applmech6040076

AMA Style

Farmaki SG, Exarchos DA, Dalla PT, Ananiadis EA, Kechagias V, Karantzalis AE, Matikas TE. Micro-Structured Multifunctional Greener Coatings Obtained by Plasma Spray. Applied Mechanics. 2025; 6(4):76. https://doi.org/10.3390/applmech6040076

Chicago/Turabian Style

Farmaki, Spyridoula G., Dimitrios A. Exarchos, Panagiota T. Dalla, Elias A. Ananiadis, Vasileios Kechagias, Alexandros E. Karantzalis, and Theodore E. Matikas. 2025. "Micro-Structured Multifunctional Greener Coatings Obtained by Plasma Spray" Applied Mechanics 6, no. 4: 76. https://doi.org/10.3390/applmech6040076

APA Style

Farmaki, S. G., Exarchos, D. A., Dalla, P. T., Ananiadis, E. A., Kechagias, V., Karantzalis, A. E., & Matikas, T. E. (2025). Micro-Structured Multifunctional Greener Coatings Obtained by Plasma Spray. Applied Mechanics, 6(4), 76. https://doi.org/10.3390/applmech6040076

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