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Advances in Metal Composite Coatings and Films: Microstructure, Physicochemical and...
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Advances in Metal Composite Coatings and Films: Microstructure, Physicochemical and Mechanical Properties

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Thin Films".

Deadline for manuscript submissions: 31 August 2026 | Viewed by 2953

Editors

Prof. Dr. Ali Khalfallah

E-Mail Website
Guest Editor
CEMMPRE, Department of Mechanical Engineering, University of Coimbra, Rua Luís Reis Santos, 3030-788 Coimbra, Portugal
Interests: multidisciplinary modeling of the material behavior; characterization of mechanical properties of coatings; artificial intelligence; multi-scale simulations and materials characterization; additive manufacturing
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Zohra Benzarti

E-Mail Website
Guest Editor
CEMMPRE—Centre for Mechanical Engineering, Materials and Processes, ARISE—Advanced Production and Intelligent Systems, Department of Mechanical Engineering, University of Coimbra, Rua Luís Reis Santos, 3030-788 Coimbra, Portugal
Interests: MOCVD; MBE; electrodeposition; magnetron sputtering; thin films; optoelectronics; semiconductors; multifunctional materials; nanomaterials; green synthesis; antibacterial properties; photocatalysis; characterization of materials; corrosion; light sensors; photovoltaic cells; white LEDs; energy storage devices
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The continuous advancement of modern technologies has created an increasing demand for metal-based coatings and composite films with tailored multifunctional properties. These systems are essential for enhancing material performance in aggressive environments, improving wear, corrosion, and oxidation resistance, and enabling new functionalities such as self-healing, antibacterial, or catalytic behavior.

The proposed Special Issue, “Advances in Metal Composite Coatings and Films: Microstructure, Physicochemical and Mechanical Properties,” aims to bring together cutting-edge research focused on the design, synthesis, characterization, and performance evaluation of metal composite coatings and films.

This issue will highlight innovative processing routes, including electrodeposition, magnetron sputtering, physical and chemical vapor deposition, thermal spraying, sol–gel methods, laser cladding, and additive manufacturing for fabricating composite and hybrid coatings. Emphasis will be placed on understanding how processing parameters influence microstructure and, consequently, the physicochemical and mechanical properties that determine coating performance. Molecular-scale insights, in situ characterization, and computational modeling are also encouraged to strengthen the understanding of structure–property–performance relationships.

In addition, this Special Issue will address the integration of metal composite coatings in energy, biomedical, aerospace, and environmental applications, with particular attention to sustainability, durability, and performance optimization. Both experimental and theoretical studies, as well as comprehensive reviews, are welcome to provide a holistic perspective on this rapidly evolving field.

This Special Issue seeks to consolidate recent progress and emerging trends in the development of advanced metal composite coatings and films. It encompasses both fundamental and applied studies on the synthesis, processing, and characterization of metallic composites and hybrid coating systems, emphasizing the relationships between composition, microstructure, and functional properties.

We invite researchers and industry professionals from materials science, surface and interface engineering, chemistry, metallurgy, tribology, and applied physics to contribute original articles, short communications, reviews, and case studies addressing, but not limited to, the following topics:

  • Development and optimization of metal–matrix and hybrid composite coatings
  • Advanced deposition and surface modification techniques
  • Structure–property correlation studies at multiple length scales
  • Physicochemical characterization and in situ monitoring of coating formation
  • Mechanical, tribological, and corrosion performance under extreme conditions
  • Diffusion, adhesion, and interfacial phenomena in multilayer or gradient coatings
  • Functional and nanocomposite films for energy, biomedical, and catalytic applications
  • Modeling, simulation, and data-driven design of coatings
  • Durability, failure analysis, and surface protection mechanisms
  • Sustainable processing methods and recyclability considerations

We encourage the submission of original research articles, communications, and comprehensive reviews addressing advances in processing techniques, microstructural evolution, surface and interface phenomena, property optimization, and performance under real operating conditions. Studies exploring the integration of metal composite coatings in energy, biomedical, aerospace, and environmental systems, with a focus on sustainability, durability, and innovative functionalities, are particularly welcome.

Prof. Dr. Ali Khalfallah
Prof. Dr. Zohra Benzarti
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-anonymized 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

  • metal composite coatings
  • thin and thick films
  • microstructure–property relationships
  • physicochemical properties
  • mechanical performance
  • wear and corrosion resistance
  • electrodeposition and vapor deposition
  • thermal spray and surface engineering
  • nanocomposite and multifunctional coatings
  • advanced characterization and modeling
  • sustainable and high-performance materials

Benefits of Publishing in a Special Issue

  • Ease of navigation: Grouping papers by topic helps scholars navigate broad scope journals more efficiently.
  • Greater discoverability: Special Issues support the reach and impact of scientific research. Articles in Special Issues are more discoverable and cited more frequently.
  • Expansion of research network: Special Issues facilitate connections among authors, fostering scientific collaborations.
  • External promotion: Articles in Special Issues are often promoted through the journal's social media, increasing their visibility.
  • Reprint: MDPI Books provides the opportunity to republish successful Special Issues in book format, both online and in print.

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

Published Papers (5 papers)

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Research

22 pages, 13118 KB  
Article
Taguchi-Based Analysis of Microstructural and Tribological Effects of CrC, NbC, TiC, and VC Coatings on High-Speed Steels via the TRD Method
by Yılmaz Yurci, Musa Kiliç, Oktay Adiyaman and Yahya Hışman Çelik
Coatings 2026, 16(9), 1004; https://doi.org/10.3390/coatings16091004 (registering DOI) - 23 Aug 2026
Abstract
High-speed steel (HSS) substrates were coated with layers of CrC, NbC, TiC, and VC using thermo-reactive diffusion (TRD) at 900 and 1100 °C for 2 and 4 h. The experimental design was implemented according to the Taguchi L8 orthogonal array. Coating morphology was [...] Read more.
High-speed steel (HSS) substrates were coated with layers of CrC, NbC, TiC, and VC using thermo-reactive diffusion (TRD) at 900 and 1100 °C for 2 and 4 h. The experimental design was implemented according to the Taguchi L8 orthogonal array. Coating morphology was investigated using scanning electron microscopy (SEM) combined with energy-dispersive spectroscopy (EDS), while phase composition was determined by X-ray diffraction (XRD). The contributions of coating type, temperature, and time to coating thickness, microhardness, coefficient of friction, and specific wear rate were evaluated using analysis of variance (ANOVA). SEM and EDS analyses showed that coatings produced at lower temperatures and shorter times exhibited irregular layer thickness, localized porosity, and irregular carbide formation, while coatings applied at higher temperatures and longer times were associated with smoother layers, more homogeneous element distribution, and improved surface morphology. XRD analyses confirmed that the coatings consisted of dense carbide phases and that the chemical composition of the substrate affected the resulting coating phases. Phase composition analysis revealed the presence of phases such as Cr7C3 and Cr23C6 in the coatings. It was observed that coating thickness and hardness generally increased with increasing temperature and coating time. Variance analysis showed that the highest additive ratios in terms of coating thickness belonged to coating type (45.13%) and temperature (42.34%), while in terms of microhardness, temperature (39.92%) and coating type (37.77%) had higher additive ratios. The highest additive ratio in terms of friction coefficient was obtained with coating type (87.98%), while temperature (34.99%) and coating type (33.37%) were determined as the parameters with the highest additive ratios in terms of specific wear rate. NbC coatings generally showed lower performance values compared to other coating types under the examined experimental conditions. Full article
(This article belongs to the Special Issue Advances in Metal Composite Coatings and Films: Microstructure, Physicochemical and Mechanical Properties)
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16 pages, 11059 KB  
Article
Selective Corrosion of the α-Al Dendrite in a Hot-Dip Zn–14Al–0.5Mg Coating
by Yidong Huang, Ya Liu, Bin Dong, Xiangying Zhu and Changjun Wu
Coatings 2026, 16(6), 693; https://doi.org/10.3390/coatings16060693 - 10 Jun 2026
Viewed by 552
Abstract
Zn–Al–Mg coatings are widely used because of their excellent corrosion resistance, in which α-Al dendrites play a crucial role. This study investigated the selective corrosion behavior of α-Al dendrites in a hot-dip Zn–14Al–0.5Mg coating, including the as-received state, after 20 months of indoor [...] Read more.
Zn–Al–Mg coatings are widely used because of their excellent corrosion resistance, in which α-Al dendrites play a crucial role. This study investigated the selective corrosion behavior of α-Al dendrites in a hot-dip Zn–14Al–0.5Mg coating, including the as-received state, after 20 months of indoor exposure, and under salt spray corrosion. The coating consisted of α-Al dendrites, η-Zn phase, and a small amount of eutectic Zn–Al–Mg. Minor black spots were observed on the initial surface. After indoor storage, extensive corrosion occurred in α-Al dendritic regions, while the remaining η-Zn became protruding. Corrosion propagated preferentially along the Al-rich dendritic into the coating, reaching the substrate, rather than progressing layer by layer. Electrochemical testing results indicated spatial heterogeneity in the corrosion resistance of the coating surface after long-term indoor storage. Cl− could more readily penetrate into the corroded dendrites, accelerating corrosion and shifting the mode from lateral propagation to vertical penetration. The selective corrosion was attributed to dendrite segregation and surface oxide film breakdown. Controlling dendrite morphology is essential for improving coating performance. Full article
(This article belongs to the Special Issue Advances in Metal Composite Coatings and Films: Microstructure, Physicochemical and Mechanical Properties)
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22 pages, 8644 KB  
Article
Study on Yttrium-Enhanced Anti-Oxidation and Adhesion Properties of Al2O3 Oxide Scale on AFA Alloy Under Low Oxygen Partial Pressure
by Jin Ji, Xuxu Deng, Changjun Wu, Junxiu Chen, Xiangying Zhu and Ya Liu
Coatings 2026, 16(5), 620; https://doi.org/10.3390/coatings16050620 - 20 May 2026
Viewed by 657
Abstract
This work investigated the effect of yttrium addition on the pre-oxidation behavior of Fe–25Ni–20Cr–4Al–1Nb–1Mn–1.5Si-based alloys at 1000 °C in a 4% H2 + 0.2% CH4 + Ar + 0.25% H2O atmosphere. The oxidation resistance and oxide scale adhesion were [...] Read more.
This work investigated the effect of yttrium addition on the pre-oxidation behavior of Fe–25Ni–20Cr–4Al–1Nb–1Mn–1.5Si-based alloys at 1000 °C in a 4% H2 + 0.2% CH4 + Ar + 0.25% H2O atmosphere. The oxidation resistance and oxide scale adhesion were evaluated through cyclic oxidation tests and micro-scratch measurements. Results show that the Y-free alloy formed a discontinuous oxide layer, whereas all Y-containing alloys formed a continuous and dense Al2O3 scale. Incorporating 0.2 wt.% Y increased the work of adhesion by approximately 7 to 9 times relative to the Y-free sample, indicating a pronounced interfacial strengthening effect. The role of yttrium content and oxygen partial pressure in promoting alumina-scale formation was discussed based on thermodynamic considerations and microstructural evidence. Full article
(This article belongs to the Special Issue Advances in Metal Composite Coatings and Films: Microstructure, Physicochemical and Mechanical Properties)
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23 pages, 8219 KB  
Article
Tailoring the Multifunctional Properties of Electrospun PVA/PVP Nanofibers via TiO2 Nanoparticle Doping for Flexible Biomedical and Optoelectronic Applications
by Maher Hassan Rasheed, Asma Dahri, Qasim Shakir Kadhim, Ausama Abed Alkadhum Alajeely, Najmeddine Abdelmoula, Zohra Benzarti and Ali Khalfallah
Coatings 2026, 16(5), 564; https://doi.org/10.3390/coatings16050564 - 8 May 2026
Cited by 3 | Viewed by 597
Abstract
This study investigates the impact of TiO2 incorporation (0, 2, 4, 6, 8 wt.%) on the structural, optical, electrical, mechanical, and antibacterial properties of electrospun PVA/PVP nanofibers. FESEM observations revealed continuous, randomly oriented nanofibrous films with an average diameter in the 77–96 [...] Read more.
This study investigates the impact of TiO2 incorporation (0, 2, 4, 6, 8 wt.%) on the structural, optical, electrical, mechanical, and antibacterial properties of electrospun PVA/PVP nanofibers. FESEM observations revealed continuous, randomly oriented nanofibrous films with an average diameter in the 77–96 nm range, depending on TiO2 content. FTIR and XRD analyses confirmed successful nanoparticle integration, showing effective interfacial interactions and the presence of crystalline TiO2 phases within the semi-crystalline PVA/PVP matrix. Optical studies demonstrated a progressive decrease in the indirect band gap with increasing TiO2 loading, decreasing from 3.75 to 3.54 eV according to the Tauc method and from 3.70 to 3.43 eV according to the ASF method, accompanied by an increase in Urbach energy from 0.43 to 0.64 eV, indicating enhanced structural disorder and tail state formation. The optical dispersion parameters obtained from the Wemple−DiDomenico model were consistent with these trends. Electrical characterization showed enhanced DC conductivity with increasing TiO2 content and a marked reduction in thermal activation energy from 2.54 eV for the neat blend to 0.98 eV at higher TiO2 loading, confirming facilitated charge transport in nanocomposite system. Mechanical characterization indicated that TiO2 reinforcement improved both stiffness and strength, with the 6 wt.% sample achieving an optimal strength–ductility synergy (8.9 MPa and 121.5% elongation). Additionally, TiO2 loading significantly boosted antibacterial performance, particularly against Escherichia coli and Staphylococcus aureus at 8 wt.%. These multifunctional properties position PVA/PVP:TiO2 nanofibers as highly promising candidates for flexible biomedical coatings, optoelectronic devices, and advanced functional surfaces. Full article
(This article belongs to the Special Issue Advances in Metal Composite Coatings and Films: Microstructure, Physicochemical and Mechanical Properties)
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18 pages, 9791 KB  
Article
The Influence of Zn on the Surface Tension and Wettability of the Al-10Si Alloy on IF Steel at 1023 K
by Xinyan Chen, Ya Liu, Changjun Wu and Xuping Su
Coatings 2026, 16(4), 434; https://doi.org/10.3390/coatings16040434 - 3 Apr 2026
Cited by 1 | Viewed by 574
Abstract
Objective: This work aims to reduce the surface tension of an aluminum–silicon alloy melt by adding different amounts of the Zn element, thus improving the coatability and coating quality of hot-dip aluminum plating on steel plates. Method: Wetting experiments were conducted at 1023 [...] Read more.
Objective: This work aims to reduce the surface tension of an aluminum–silicon alloy melt by adding different amounts of the Zn element, thus improving the coatability and coating quality of hot-dip aluminum plating on steel plates. Method: Wetting experiments were conducted at 1023 K using a modified sessile drop method. Conclusions: The addition of the Zn element can reduce the surface tension of the Al-Si alloy, thus decreasing the wettability of the Al-Si alloy. Zn vapor can break down the surface oxide film to expose the fresh melt. The wettability of the Al-10Si alloy on interstitial-free (IF) steel and surface tension were investigated using the modified sessile drop method at 1023 K. Axisymmetric Drop Shape Analysis software was utilized to calculate the contact angles of the Al-10Si-xZn/Al2O3 and Al-10Si-xZn/IF steel systems (x ranges from 0 wt.% to 5 wt.%). Moreover, the microtopography and microstructure of surfaces and cross-sections were analyzed by means of an energy-dispersive spectrometer and scanning electron microscope. The results indicated that the surface tension of the alloy melt gradually decreases with an increase in Zn content, ranging from 874 to 760 mN/m. The contact angle of the Al-10Si-xZn alloy melt on IF steel also progressively decreases with increasing Zn content, which is attributed to the lower surface tension of Zn. This study also discovered that the Zn element can disrupt the oxide film of the Al-10Si alloy, exposing the fresh melt and thereby reducing the surface tension of the alloy liquid, thus enhancing wettability. The addition of Zn might be capable of improving the hot-dip aluminizing coatability of steel plates and the quality of the coating. Full article
(This article belongs to the Special Issue Advances in Metal Composite Coatings and Films: Microstructure, Physicochemical and Mechanical Properties)
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