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Additive Manufacturing of Metallic Components for Hard Coatings, 2nd Edition
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Additive Manufacturing of Metallic Components for Hard Coatings, 2nd Edition

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

Deadline for manuscript submissions: 30 November 2025 | Viewed by 1716

Special Issue Editor

Dr. Ainhoa Riquelme

E-Mail Website
Guest Editor
Department of Material Science and Metallurgical Engineering, Rey Juan Carlos University, 28933 Madrid, Spain
Interests: additive manufacturing; direct laser deposition; selective laser melting; laser cladding
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

We are thrilled to announce the second volume of our Special Issue, "Additive Manufacturing of Metallic Components for Hard Coatings" (https://www.mdpi.com/journal/coatings/special_issues/additive_manufacture_hard_coat). The first volume contained 12 published articles which were viewed more than 17000 times. Considering that this topic is receiving much attention, we would like to announce a second volume.   

Additive manufacturing is a method for the fabrication of 3D components, which are built layer-by-layer (i.e., 3D printing), and is expected to represent a revolution in the component fabrication sector. The technology provides the possibility of fabricating customized parts and the capability of producing complex geometries that are impossible to manufacture with other methods, and makes it possible to optimize the topology in order to obtain lightweight designs. Furthermore, the low material waste produced during additive manufacturing is a highlight from the point of view of the circular economy. For these reasons, the additive manufacturing of metals and metal matrix components could be a possible solution for obtaining components for hard coating applications; however, the additive manufacturing of metallic components is still limited, so the optimization of the fabrication parameters and the properties of these components must be developed and detailed, and thoroughly researched.

We are pleased to invite you to contribute to this Special Issue of Coatings with your original research articles and review papers. Contributions should focus on the fundamentals and applications of the additive manufacturing of metallic components for hard coatings, and we are particularly interested in those that emphasize the capability of the different additive manufacturing methods.

We look forward to receiving your contributions.

Dr. Ainhoa Riquelme
Guest Editor

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

  • additive manufacturing
  • selective laser melting
  • direct energy deposition
  • laser cladding
  • metals
  • metal matrix composites
  • cermets
  • hard coatings

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Published Papers (4 papers)

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Research

14 pages, 7044 KiB  
Article
Microstructure, Wear and Corrosion Properties of Inconel 718-CeO2 Composite Coatings
by Yu Liu, Guohui Li, Hui Liang, Zhanhui Zhang, Zeyu Li and Haiquan Jin
Coatings 2025, 15(7), 783; https://doi.org/10.3390/coatings15070783 - 2 Jul 2025
Viewed by 216
Abstract
Based on laser cladding technology, six composite coatings with different amounts of Inconel 718 and 0~5% CeO2 were successfully prepared on the 316L stainless steel substrate. The effect of different amounts of CeO2 particles was investigated and discussed, such as microstructure, [...] Read more.
Based on laser cladding technology, six composite coatings with different amounts of Inconel 718 and 0~5% CeO2 were successfully prepared on the 316L stainless steel substrate. The effect of different amounts of CeO2 particles was investigated and discussed, such as microstructure, phases, elemental distribution, microhardness, wear resistance and corrosion resistance. The results show that the phases are composed of γ~(Fe, Ni), Ni3Nb, (Nb0.03Ti0.97)Ni3, and MCX(M = Cr, Nb and Mo). When the amount of CeO2 particles is higher than 1%, some Ce2O3 compounds can be detected in coatings. The average microhardness values of N0~N5 are 604.6, 754.5, 771.6, 741.4, 694.5 and 677.3 HV0.2, respectively. There is a trend that the microhardness increases firstly and then decreases, because an appropriate amount of CeO2 can improve the solid solution strength. The average wear rate values of N0~N5 are 2.97 × 10−5, 1.22 × 10−5, 0.94 × 10−5, 1.53 × 10−5, 1.81 × 10−5 and 2.26 × 10−5 mm3∙N−1∙min−1, respectively. The N2 coating has the smallest corrosion current density of 2.05 × 10−4 A·cm−2, which is about 56% of the N0 coating. When the amount of CeO2 particles is 2%, the coating has the best wear resistance and corrosion resistance due to fine grains and Cr, Nb and Mo compounds. Full article
(This article belongs to the Special Issue Additive Manufacturing of Metallic Components for Hard Coatings, 2nd Edition)
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16 pages, 5657 KiB  
Article
Crack Propagation Mechanism in Thermal Barrier Coatings Containing Different Residual Grit Particles Under Thermal Cycling
by Xin Shen, Zhiyuan Wei, Zhenghao Jiang, Jianpu Zhang, Dingjun Li, Xiufang Gong, Qiyuan Li, Fei Zhao, Jianping Lai and Jiaxin Yu
Coatings 2025, 15(7), 747; https://doi.org/10.3390/coatings15070747 - 23 Jun 2025
Viewed by 305
Abstract
Residual particles embedded at the bond coat/substrate (BC/SUB) interface after grit blasting can affect the failure behavior of thermal barrier coatings (TBCs) under thermal cycling. This study employed a 2D finite element model combining the cohesive zone method (CZM) and extended finite element [...] Read more.
Residual particles embedded at the bond coat/substrate (BC/SUB) interface after grit blasting can affect the failure behavior of thermal barrier coatings (TBCs) under thermal cycling. This study employed a 2D finite element model combining the cohesive zone method (CZM) and extended finite element method (XFEM) to analyze the effect of interfacial grit particles. Specifically, the CZM was used to simulate crack propagation at the BC/thermally grown oxide (TGO) interface, while XFEM was applied to model the arbitrary crack propagation within the BC layer. Three models were analyzed: no grit inclusion, 20 μm grit particles, and 50 μm grit particles at the BC/SUB interface. This systematic variation allowed isolating the influence of particle size on the location of crack propagation onset, stress distribution, and crack growth behavior. The results showed that grit particles at the SUB/BC interface had negligible influence on the crack propagation location and rate at the BC/TGO interface, due to their spatial separation. However, their presence significantly altered the radial tensile stress distribution within the BC layer. Larger grit particles induced more intense stress concentrations and promoted earlier and more extensive vertical crack propagation within the BC. However, due to plastic deformation and stress redistribution in the BC, the crack propagation was progressively suppressed in the later stages of thermal cycling. Overall, grit particles primarily promoted vertical crack propagation within the BC layer. Optimizing grit blasting to control grit particle size is crucial for improving the durability of TBCs. Full article
(This article belongs to the Special Issue Additive Manufacturing of Metallic Components for Hard Coatings, 2nd Edition)
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15 pages, 16884 KiB  
Article
Assessing the Printability of Rene 65 Powder for Repairing Degraded GTD 111 Gas Turbine Blades Using L-DED and L-PBF
by Henry León-Henao, Edward D. Herderick, Alejandro Toro, Jorge E. Giraldo-Barrada and Antonio J. Ramirez
Coatings 2025, 15(4), 410; https://doi.org/10.3390/coatings15040410 - 30 Mar 2025
Viewed by 570
Abstract
Restoring components in the hot gas path of turbine engines after service-induced degradation is crucial for economic efficiency. This study investigates the printability of Rene 65 powder on a degraded first-stage turbine blade using two additive manufacturing techniques: Laser Powder Bed Fusion (L-PBF) [...] Read more.
Restoring components in the hot gas path of turbine engines after service-induced degradation is crucial for economic efficiency. This study investigates the printability of Rene 65 powder on a degraded first-stage turbine blade using two additive manufacturing techniques: Laser Powder Bed Fusion (L-PBF) and Laser Powder Directed Energy Deposition (L-DED). Deposited material was evaluated using optical microscopy (OM), scanning electron microscopy (SEM), and Electron Backscatter Diffraction (EBSD) to characterize its crystallographic texture, while microhardness testing provided insight into its mechanical properties. Our results show that L-PBF excels at replicating intricate features, such as small cooling holes, and produces a highly texturized microstructure oriented parallel to <001> under optimal parameters (80 W, 400 mm/s, unidirectional scanning), although at a slower pace. In contrast, L-DED offers a versatile, rapid, and cost-effective method for repairing medium to large parts, yielding an equiaxed microstructure and higher as-printed hardness—approaching GTD 111 values due to an aging effect from high heat input. Both processes effectively restored the dimensional integrity of degraded blade tips, paving the way for more sustainable and economical maintenance strategies in the aerospace industry. Full article
(This article belongs to the Special Issue Additive Manufacturing of Metallic Components for Hard Coatings, 2nd Edition)
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20 pages, 10586 KiB  
Article
Micromechanical Properties and Tribological Performance of Mo, Cr, and Ta Coatings Obtained by Cathodic Arc-Deposition
by Vadim Zakiev, Volodymyr Nadtoka, Islam Zakiev, Bohdan Mordyuk, Oleksandr Yakushenko, Igor Trofimov, Mykola Skoryk and Sviatoslav Yutskevych
Coatings 2025, 15(3), 358; https://doi.org/10.3390/coatings15030358 - 19 Mar 2025
Viewed by 411
Abstract
The aim of the study is a comparative analysis of micromechanical and microtribological properties of the cathodic arc-deposited Mo, Cr, and Ta coatings using nanoindentation and scratch test techniques as well as a microtribological dry sliding test with wear tracks post-examination and worn [...] Read more.
The aim of the study is a comparative analysis of micromechanical and microtribological properties of the cathodic arc-deposited Mo, Cr, and Ta coatings using nanoindentation and scratch test techniques as well as a microtribological dry sliding test with wear tracks post-examination and worn volume determination using interference profilometry. A new scratch test technique based on the statistical processing of registered sclerograms during a multi-pass scratch test well adopted for the scratch resistance assessment of rough surfaces is suggested. New approaches to microtribological testing based on the indentation tester equipped with an additional precision rotational stage are proposed, which could fill the gap between macro- and nano-scale. X-ray diffraction analysis reveals the structure of the studied coatings and phase compositions of the coating-substrate interface. Full article
(This article belongs to the Special Issue Additive Manufacturing of Metallic Components for Hard Coatings, 2nd Edition)
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