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Coatings
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Advanced Corrosion- and Wear-Resistant Coatings
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Advanced Corrosion- and Wear-Resistant Coatings

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

Deadline for manuscript submissions: 20 June 2026 | Viewed by 1362

Special Issue Editors

Dr. Wangping Wu

E-Mail Website
Guest Editor
School of Mechanical Engineering and Rail Transit, Changzhou University, Changzhou 213164, China
Interests: additive manufacturing; anti-corrosion/wear coatings; processing
Special Issues, Collections and Topics in MDPI journals
Dr. Mengqi Cong

E-Mail Website
Guest Editor
School of Materials Engineering, Jiangsu University of Technology, Changzhou 213001, China
Interests: lightweight materials; High-entropy alloys; metal additive manufacturing; anti-corrosion coatings; processing

Special Issue Information

Dear Colleagues,

The scope of this Special Issue will serve as a forum for papers in the following areas:

  1. Theoretical and experimental research, knowledge, and new ideas in corrosion/wear-protective and -preventive coating mechanisms of metal and ceramic, or polymer coatings.
  2. Recent developments in surface modification and strengthening techniques for advanced multi-functional coatings.
  3. A new initiative aiming to improve the wear and corrosion resistances of the coatings and its engineering application.
  4. Coatings produced by different processes, including, but not limited to, additive manufacturing processes, thermal spray, sol–gel, laser processes, laser and plasma processing, CVD, and electrodeposition.
  5. Experiments and processing of high-performance advanced coatings with exposure to high temperatures, high stress, and other extreme environmental conditions.
  6. Understanding the degradation mechanisms of coatings through friction, wear, or other dynamic loading conditions and corrosion.
  7. The latest developments of test methods considering the interplay between mechanical, chemical, and electrochemical interactions and the ability to predict performance and reliability.
  8. Computer modelling and simulation to predict coating properties, performance, durability, and reliability in service environments.

Dr. Wangping Wu
Dr. Mengqi Cong
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 250 words) can be sent to the Editorial Office for assessment.

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

  • coating
  • corrosion
  • wear
  • friction
  • surface
  • interface
  • engineering

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (5 papers)

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Research

13 pages, 2596 KB  
Article
Enhancement of Corrosion Resistance in 304 Stainless Steel Through Hybrid Parylene C–ALD Al2O3 Composite Coatings
by Xuewei Xie, Woon-Ming Lau, Po-Wan Shum, Yongqiang Fu and Tao Fu
Coatings 2026, 16(2), 240; https://doi.org/10.3390/coatings16020240 - 13 Feb 2026
Viewed by 52
Abstract
Parylene C films are subjected to inadequate corrosion resistance due to their relatively low adhesion and structural defects. To address this challenge, the CVD Parylene C film (10 μm thick) was composited with Al2O3 film (30 nm thick) prepared with [...] Read more.
Parylene C films are subjected to inadequate corrosion resistance due to their relatively low adhesion and structural defects. To address this challenge, the CVD Parylene C film (10 μm thick) was composited with Al2O3 film (30 nm thick) prepared with atomic layer deposition (ALD) technology in this work. Optical microscopic results indicate uniform thickness of the films and the reduced adhesion of Parylene C based thick films. SEM-EDX and AFM results show that the composite films have more blurred mounds morphology than the individual films, and Al2O3 film decreases the surface roughness of Parylene C film; compared with the single-layer film, the Ra value of the bilayer film decreased by approximately 6%. XPS, FTIR and XRD analyses confirm the structural components of Al2O3 and Parylene C films and the annealing effect of ALD process on Parylene C film. Tafel polarization and electrochemical impedance spectroscopy tests reveal that the 304-Parylene C–Al2O3 system exhibits the optimal corrosion resistance; its corrosion current density (icorr) is 8.099 × 10−5 μA/cm2 and the ALD Al2O3 thin film uniformly coats the Parylene C film, enhancing its physical barrier and chemical passivation under corrosive conditions. Full article
(This article belongs to the Special Issue Advanced Corrosion- and Wear-Resistant Coatings)
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25 pages, 4411 KB  
Article
Achieving High Hardness and Uniformity in Fe-Based Amorphous Coatings for Enhanced Wear Resistance via Explainable Machine Learning
by Enhao Zhang, Cong Ma, Jiachi Yuan, Shuang Yan, Zhibin Zhang, Zhiyuan Jing and Binbin Zhang
Coatings 2026, 16(2), 199; https://doi.org/10.3390/coatings16020199 - 5 Feb 2026
Viewed by 248
Abstract
High-Velocity Air-Fuel (HVAF) spraying of Fe-based amorphous coatings involves strong nonlinear coupling among multiple process parameters, while practical optimization is severely constrained by limited experimental data and poor model interpretability. To address these challenges, a systematic data-driven optimization framework integrating the Denoising Diffusion [...] Read more.
High-Velocity Air-Fuel (HVAF) spraying of Fe-based amorphous coatings involves strong nonlinear coupling among multiple process parameters, while practical optimization is severely constrained by limited experimental data and poor model interpretability. To address these challenges, a systematic data-driven optimization framework integrating the Denoising Diffusion Probabilistic Model (DDPM)-based data augmentation with explainable machine learning is proposed. Coating microhardness and hardness uniformity were jointly selected as target properties to capture both performance level and spatial reliability. Three generative models—Generative Adversarial Network (GAN), Variational Autoencoder (VAE), and DDPM—were comparatively evaluated using statistical matching and distribution-consistency metrics, revealing that DDPM most faithfully reproduces the intrinsic statistical characteristics of real HVAF process data. We benchmarked ten representative regression algorithms covering classical statistical learning, ensemble methods, and deep learning paradigms, with GBR demonstrating the highest predictive accuracy and stability. The inclusion of 10% DDPM-generated samples further improved the predictive precision of the GBR model. SHapley Additive exPlanations (SHAP) quantitatively identified spraying distance as the dominant parameter governing coating hardness, while elucidating the coupled effects of multiple parameters on hardness uniformity. By interpolatively expanding the process parameter space, a two-stage screening strategy identified 98 high-performance parameter combinations. Experimental validation confirmed that the optimal parameter set simultaneously achieved higher hardness and improved uniformity compared with the original best condition, resulting in a 13.6% reduction in wear rate. Full article
(This article belongs to the Special Issue Advanced Corrosion- and Wear-Resistant Coatings)
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18 pages, 3878 KB  
Article
A Comparative Study of Microstructure and Tribological Properties of Electroless Ni-P, Ni-W-P, and Ni-Ce-P Coatings on 6061 Aluminum Alloy: The Role of Heat Treatment
by Kailin Xue, Jiangping Nan and Tao Liu
Coatings 2026, 16(2), 197; https://doi.org/10.3390/coatings16020197 - 4 Feb 2026
Viewed by 217
Abstract
This study conducts a systematic comparison of binary Ni-P, ternary Ni-W-P, and ternary Ni-Ce-P electroless coatings on 6061-T6 aluminum alloy, focusing on the effects of post-plating heat treatment at 300, 350, and 400 °C. The originality of this work lies in its direct [...] Read more.
This study conducts a systematic comparison of binary Ni-P, ternary Ni-W-P, and ternary Ni-Ce-P electroless coatings on 6061-T6 aluminum alloy, focusing on the effects of post-plating heat treatment at 300, 350, and 400 °C. The originality of this work lies in its direct comparison of W and Ce doping under identical conditions and its identification of a critical brittle transition that decouples hardness from wear resistance. All coatings achieved peak hardness at 350 °C, with Ni-W-P reaching approximately 1691 ± 45 HV0.1 due to Ni3P precipitation and solid-solution strengthening. However, a key finding is the severe embrittlement of the Ni-P coating at 300 °C, where its wear rate increased by over 50 times despite a hardness increase. Treatment at 400 °C degraded wear performance across all systems, likely due to precipitate coarsening and substrate over-aging. The best overall performance within the tested window was achieved with the Ni-Ce-P coating heat-treated at 350 °C for 1 h, which exhibited a fine nodular structure and reduced the wear rate by 98.9% compared to the bare substrate. These results highlight the importance of balancing hardness and toughness, identifying an optimized processing window for enhancing the tribological performance of lightweight aluminum components. Full article
(This article belongs to the Special Issue Advanced Corrosion- and Wear-Resistant Coatings)
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11 pages, 4219 KB  
Communication
Oxygen Addition Influence on NiCrFe Mixed Layer
by Bianca-Georgiana Solomonea, Alexandru Anghel, Cristian P. Lungu, Cornel Staicu, Bogdan Butoi, Corneliu Porosnicu, Paul Dincă, Oana Pompilian, Arcadie Sobetkii, Anca Constantina Parau, Mihaela Dinu, Lidia Ruxandra Constantin, Alina Vladescu (Dragomir) and Catalin Vitelaru
Coatings 2026, 16(1), 96; https://doi.org/10.3390/coatings16010096 - 12 Jan 2026
Viewed by 170
Abstract
Carbon–metal composite NiCrFeC coatings, prepared with and without controlled oxygen addition, were investigated to evaluate the influence of oxygen on the structure, mechanical response, and tribological performance. X-ray diffraction revealed that oxygen-containing films (NiCrFeC + O2) exhibit a mixed metallic–oxide microstructure [...] Read more.
Carbon–metal composite NiCrFeC coatings, prepared with and without controlled oxygen addition, were investigated to evaluate the influence of oxygen on the structure, mechanical response, and tribological performance. X-ray diffraction revealed that oxygen-containing films (NiCrFeC + O2) exhibit a mixed metallic–oxide microstructure with CrNi, CrO, and NiO phases, whereas oxygen-free coatings show only CrNi crystalline peaks. The incorporation of oxygen led to a substantial increase in nano-hardness, from 0.84 GPa for NiCrFeC to 1.59 GPa for NiCrFeC + O2. Scratch testing up to 100 N indicated improved adhesion and higher critical loads for the oxygen-rich coatings. Tribological measurements performed under dry sliding conditions using a sapphire ball showed a significant reduction in friction: NiCrFeC + O2 stabilized at ~0.20, while NiCrFeC exhibited values between 0.25 and 0.35 at 0.5 N and 0.4–0.5 at 1 N, accompanied by non-uniform sliding due to coating failure. Wear-track analysis confirmed shallower penetration depths and narrower wear scars for NiCrFeC + O2, despite similar initial roughness (~35 nm). These findings demonstrate that oxygen incorporation enhances hardness, adhesion, and wear resistance while substantially lowering friction, making NiCrFeC + O2 coatings promising for low-friction dry-sliding applications. Full article
(This article belongs to the Special Issue Advanced Corrosion- and Wear-Resistant Coatings)
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16 pages, 4447 KB  
Article
Effects of Relaxation and Nanocrystallization on Wear and Corrosion Behaviors of Fe-Based Amorphous Coating
by Shenghai Weng, Zhibin Zhang, Yuxi Fu, Lin Xue, Peisong Song, Liliang Shao, Xiubing Liang, Jiangbo Cheng and Binbin Zhang
Coatings 2025, 15(12), 1497; https://doi.org/10.3390/coatings15121497 - 18 Dec 2025
Viewed by 429
Abstract
In this study, amorphous Fe60Nb3B17Si6Cr6Ni4Mo4 coatings were prepared using the high-velocity air fuel method. The microstructure, wear resistance, and corrosion resistance of the Fe60Nb3B17Si [...] Read more.
In this study, amorphous Fe60Nb3B17Si6Cr6Ni4Mo4 coatings were prepared using the high-velocity air fuel method. The microstructure, wear resistance, and corrosion resistance of the Fe60Nb3B17Si6Cr6Ni4Mo4 coatings were examined for various levels of nanocrystallization. In contrast to the as-sprayed coating, the samples that were heat-treated formed partial α-Fe and crystalline Cr2O3. The generated nanocrystals exerted a dispersion-strengthening effect on the coatings, leading to enhanced hardness and fracture toughness. When the annealing temperature was below the initial crystallization temperature, the wear resistance improved by approximately 1.65 times, the wear rate decreased to half of that in the as-sprayed state, and the depth of the wear scar reduced. However, the resistance of the coatings to corrosion deteriorated as the degree of crystallization increased. X-ray photoelectron spectroscopy analysis revealed that heat treatment modified the composition of the passive film, thereby influencing its corrosion resistance. These results provide crucial insights into the application of Fe-based amorphous coatings in wear- and corrosion-resistant environments. Full article
(This article belongs to the Special Issue Advanced Corrosion- and Wear-Resistant Coatings)
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