Corrosion Resistance, Mechanical Properties and Characterization of Metallic Materials and Coatings, 2nd Edition

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

Deadline for manuscript submissions: 10 December 2025 | Viewed by 10572

Special Issue Editors

School of Mechanical Engineering and Mechanics, Ningbo University, Ningbo 315211, China
Interests: corrosion electrochemistry; material characterization; electron microscopy (SEM, TEM); additive manufacture of metal
Special Issues, Collections and Topics in MDPI journals
Department of Mechanical and Energy Engineering, Southern University of Science and Technology, Shenzhen 518055, China
Interests: steels; high entropy alloys; TEM; In-situ TEM
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Corrosion resistance and mechanical properties have attracted great attention in the application and development of metallic material and coatings. The microstructure of metal is closely related to its performance, either for corrosion or mechanical performance. Investigation into the relationship between structure and properties is the most functional method and is used to uncover the mechanism for enhancing the performance of metals, offering the foundation for developing new-era materials.

Previously, we published the Special Issue “https://www.mdpi.com/journal/coatings/special_issues/Corrosion_Mechanical” online. This Special Issue is now closed and achieved great success. Building on this collaboration, we are keen to launch a second volume of the existing Special Issue. In this Special Issue, original research articles and reviews are welcome. Research areas may include (but are not limited to) the following:

(1) Fundamentals and application of metallic materials, coatings and microstructure characterization;

(2) Processes for coating deposition and modification, and the investigation of functional, protective and decorative coatings;

(3) Characterization techniques for metallic materials and coatings;

(4) Corrosion, wear, fatigue and fracture of metallic materials and coatings.

We look forward to receiving your contributions.

Dr. Siyuan Lu
Dr. Wenjun Lu
Guest Editors

Manuscript Submission Information

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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

  • corrosion resistance
  • mechanical properties
  • metallic materials
  • coatings
  • microstructure
  • material characterization
  • wear and errosion

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Published Papers (8 papers)

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Research

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21 pages, 4837 KiB  
Article
Research on Modified Thermal Barrier Coatings Against CMAS Corrosion Driven by Mechanism–Data Hybrid Model
by Dongdong Ye, Feixiang Wu, Zhou Xu, Yiwen Wu, Changdong Yin, Huanjie Fang and Houli Liu
Coatings 2024, 14(12), 1513; https://doi.org/10.3390/coatings14121513 - 30 Nov 2024
Viewed by 993
Abstract
With the development of high-efficiency gas turbine engines and increasing inlet temperatures, the performance of thermal barrier coatings (TBCs) for hot-section components has been more severely challenged. The doping of multi-element rare earth elements significantly improves the thermodynamic properties and chemical compatibility of [...] Read more.
With the development of high-efficiency gas turbine engines and increasing inlet temperatures, the performance of thermal barrier coatings (TBCs) for hot-section components has been more severely challenged. The doping of multi-element rare earth elements significantly improves the thermodynamic properties and chemical compatibility of thermal barrier coatings so that the application performance of coatings in high-temperature environments is enhanced considerably. In this work, the doped coatings prepared by REYSZ (RE = La, Sm, Nd) were investigated and characterized in terms of crystal structure, elastic properties, and thermal–mechanical properties based on the first-principles approach, combined with various empirical and semi-empirical formulations, and a predictive model for resistance to CMAS corrosion based on machine learning approaches. The results showed that the tetragonal phase REYSZ material was mechanically stable, had a large strain damage tolerance, and was not easy to fracture under applied loads and thermal shocks. In terms of CMAS corrosion resistance, the NdYSZ interfacial model had a lower surface energy (3.130 J/m2) and Griffith fracture energy (6.934 J/m2) compared with the conventional YSZ model, and Nd2O3 had the potential to improve the CMAS corrosion resistance of zirconia-based material for thermal barrier coatings. By evaluating the machine learning prediction models, the regression coefficients of the two algorithms were 0.9627 and 0.9740, and both these two prediction models showed high prediction accuracy and strong robustness. Ultimately, this work presented a novel mechanism–data hybrid method, which would facilitate the efficient development of TBC new materials for anti-CMAS corrosion. Full article
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17 pages, 10327 KiB  
Article
The Microstructure of Aluminide Coatings on 310S and 347H Steels Formed by Pack Aluminizing and Their Corrosion Behavior in Molten Chloride Salts
by Weiqian Chen, Peiqing La, Zengpeng Li, Yaming Li and Lei Wan
Coatings 2024, 14(12), 1507; https://doi.org/10.3390/coatings14121507 - 29 Nov 2024
Cited by 2 | Viewed by 802
Abstract
In order to enhance the resistance of superalloys to high-temperature molten chloride salt corrosion, Fe-Al coatings were prepared on 310S and 347H stainless-steel surfaces via pack aluminizing. Then, the coatings were annealed at different temperatures to explore the influence of temperature on their [...] Read more.
In order to enhance the resistance of superalloys to high-temperature molten chloride salt corrosion, Fe-Al coatings were prepared on 310S and 347H stainless-steel surfaces via pack aluminizing. Then, the coatings were annealed at different temperatures to explore the influence of temperature on their phase constitution, microstructure, microhardness, and corrosion resistance. The results showed that the annealing temperature had a considerable effect on the corrosion resistance of the Fe-Al coatings, which was related to the change in the phase composition of the coatings that occurred due to the annealing treatment. The growth rate of the coating on 347H steel was higher than that on 310S steel, and their thicknesses from aluminizing at 800 °C for 20 h were 209.6 and 153.5 µm, respectively. When annealing at 900 °C for 30 h, the phase composition of the coatings was completely transformed into (Fe, Cr, Ni) Al. The corrosion loss rate of the annealed coating was clearly reduced, the loss rate of the 310 coating was 6.0 and −0.25 mg/cm2 before and after annealing at 900 °C and that of the 347 coating was 4.89 and −0.7 mg/cm2 before and after annealing at 750 °C, respectively. The two coatings showed good corrosion resistance to molten chloride salts, as demonstrated by the oxide scale (Al2O3) that formed on the surface, which had a thickness of about 30~40 µm. Full article
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25 pages, 31111 KiB  
Article
Experimental Analysis of Cavitation Erosion: Parameter Sensitivity and Testing Protocols
by SeyedMehdi Mohammadizadeh, José Gilberto Dalfré Filho, Cassiano Sampaio Descovi, Ana Inés Borri Genovez and Thomaz Eduardo Teixeira Buttignol
Coatings 2024, 14(10), 1288; https://doi.org/10.3390/coatings14101288 - 9 Oct 2024
Cited by 6 | Viewed by 1666
Abstract
The scientific goal of this study was to investigate the effects of various parameters on cavitation-induced erosion, with the aim to enhance the understanding and assessment of cavitation resistance in hydraulic systems. Cavitation erosion poses significant challenges to the durability and efficiency of [...] Read more.
The scientific goal of this study was to investigate the effects of various parameters on cavitation-induced erosion, with the aim to enhance the understanding and assessment of cavitation resistance in hydraulic systems. Cavitation erosion poses significant challenges to the durability and efficiency of hydraulic components, such as those found in hydropower plants and pumping stations. Prompted by the need to improve the reliability of cavitation testing and material assessment, this research conducted a comprehensive sensitivity analysis of a cavitation jet apparatus (CJA). This study employed an experimental platform that consisted of a vertical cylindrical test tank, a submerged nozzle, and an aluminum sample. By examining a range of orifice diameters, this research identified that smaller diameters led to increased erosion intensity, with the most pronounced effects observed at a diameter of 2 mm. Furthermore, various standoff distances (SoDs) were tested, which revealed that shorter distances resulted in greater erosion, with the highest impact noted at an SoD of 5 cm. This study also evaluated different nozzle geometries, where it was found that a 132° conical sharped edges nozzle, combined with an orifice diameter of 2 mm and an SoD of 5 cm, produced the most severe erosion. Conversely, chamfered edges nozzles and a commercial nozzle (MEG2510) with an SoD of 10 cm or greater showed reduced erosion. These results highlight that by standardizing the testing duration to 1200 s, the CJA could reliably assess the cavitation resistance of materials. This study established a clear relationship between increased pressure and higher impact forces, which led to more severe erosion. The findings underscore the effectiveness of the CJA in evaluating material resistance under various cavitation conditions, thus addressing a critical need for reliable cavitation testing tools. Full article
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19 pages, 8757 KiB  
Article
Preparation and Properties of Conductive Aluminum Powder (Al@Si@C) for Water-Borne Heavy-Duty Anticorrosive Coatings
by Qingpeng Li, Jiaxing Liu, Tiancheng Jiang, Xiaoyun An, Na Wang, Zhixiu Xu, Wanyuan Guo, Liang Zhang and Xiaofeng Liu
Coatings 2024, 14(9), 1082; https://doi.org/10.3390/coatings14091082 - 23 Aug 2024
Viewed by 1226
Abstract
To improve the storage stability and conductivity of aluminum powder in an aqueous environment, the surface of aluminum powder was treated to form silica film by the sol–gel method, then was treated with conductive modification to introduce nanocarbon black particles so that conductive [...] Read more.
To improve the storage stability and conductivity of aluminum powder in an aqueous environment, the surface of aluminum powder was treated to form silica film by the sol–gel method, then was treated with conductive modification to introduce nanocarbon black particles so that conductive aluminum powder could be prepared to solve the application bottleneck of aluminum powder in water-borne heavy-duty anticorrosive coatings. The structure, surface morphology, and composition of the modified aluminum powder were characterized by Fourier transform infrared spectroscopy (FT-IR), scanning electron microscopy (SEM), energy dispersive spectrometry (EDS), X-ray photoelectron spectroscopy (XPS), and X-ray powder diffraction (XRD). The corrosion resistance and electrochemical properties were measured using a hydrogen evolution test and an 2electrochemical test. The results showed that there was a compact SiO2 film formed on the surface of the prepared conductive aluminum powder, and the conductive filler nanocarbon black was uniformly grafted on the surface. According to the hydrogen evolution test at 100 h/50 °C, conductive aluminum powder with 5 wt% carbon black exhibited the best hydrogen evolution effect, with a hydrogen evolution amount of only 0.5 mL. The prepared conductive aluminum powder was applied to the water-borne coatings, and the storage stability test, electrochemical polarization test, and neutral salt spray test were further conducted. The water-borne coatings prepared with conductive aluminum powder still showed good performance and had no reaction after 6 months of storage. Compared with the coating containing SiO2-modified aluminum powder, the coating exhibited better corrosion resistance. Full article
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13 pages, 5513 KiB  
Article
The Influence of Rust Layers on Calcareous Deposits’ Performance and Protection Current Density in the Cathodic Protection Process
by Wei Zhang, Xinran Wang, Haojie Li, Zhifeng Lin and Zhiwei Chen
Coatings 2024, 14(8), 1015; https://doi.org/10.3390/coatings14081015 - 10 Aug 2024
Viewed by 1347
Abstract
Calcareous deposits are a consequential outcome of cathodic protection in marine environments, exerting significant influence on the cathodic protection process and current density prerequisites. This study investigates the process of calcium deposition and its impact on the cathodic protection current density of carbon [...] Read more.
Calcareous deposits are a consequential outcome of cathodic protection in marine environments, exerting significant influence on the cathodic protection process and current density prerequisites. This study investigates the process of calcium deposition and its impact on the cathodic protection current density of carbon steel under the influence of a rust layer in different corrosion periods. This was investigated using electrochemical impedance spectroscopy (EIS), scanning electron microscopy (SEM), and energy-dispersive spectroscopy (EDS). The results demonstrate that the formation processes of calcareous deposits vary after exposure to the corrosive environment for 0, 7, and 30 days. While a longer corrosion period leads to thicker rust layers on the metal surface and a higher initial cathodic protection current, the presence of these rust layers facilitates the deposition of calcium and magnesium ions, resulting in a rapid decrease in cathodic protection current density after a certain period. Meanwhile, long-term cathodic protection facilitates the thickening and densification of the oxide layer, thereby enhancing its protective efficacy, effectively reducing the corrosion rate of the metal surface and stabilizing the cathodic protection current density at a lower level. This study provides theoretical data and experimental evidence to support the maintenance of corroded marine engineering equipment. Full article
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22 pages, 5062 KiB  
Article
Thermodynamic Analysis of Typical Alloy Oxidation and Carburization in High-Temperature CO2 Atmosphere
by Jing Xiong
Coatings 2024, 14(7), 869; https://doi.org/10.3390/coatings14070869 - 11 Jul 2024
Cited by 2 | Viewed by 1101
Abstract
The corrosion of structural materials is a crucial issue of the application of supercritical carbon dioxide in the Brayton power cycle system. The oxidation and carburization behaviors of typical alloy materials in high-temperature CO2 environments are studied based on thermodynamic analysis technology, [...] Read more.
The corrosion of structural materials is a crucial issue of the application of supercritical carbon dioxide in the Brayton power cycle system. The oxidation and carburization behaviors of typical alloy materials in high-temperature CO2 environments are studied based on thermodynamic analysis technology, including the analysis of the oxidation and carburization performance of the CO2 atmosphere as well as the corrosion behaviors of alloy elements under 500 °C, 600 °C, and 650 °C. In addition, the oxide film characteristics of T91 and 800H alloys, including phase composition and morphology structure, are studied at 500 °C and 650 °C. Research has found that for the T91, FeCr2O4 and Fe3O4 can form a continuous oxide film layer with coverage and SiO2, VO, and MnCr2O4 oxides are mainly in the inner layer of the oxide film. For the 800H, Cr2O3 and MnCr2O4 can form flakes of oxide film layers, while Al2O3, TiO2, and SiO2 are distributed as scattered grains near the interface between the oxide film and the matrix material. Both T91 and 800H will produce chromium carbides, which will reduce the toughness of the material. Full article
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17 pages, 12088 KiB  
Article
Effect of Temperature and Immersion Time on Corrosion of Pipeline Steel Caused by Sulfate-Reducing Bacteria
by Yulong Wei, Pei Li, Qingwen Liang, Baihong Wu, Junjie Shen, Huifang Jiang and Qingjian Liu
Coatings 2024, 14(7), 807; https://doi.org/10.3390/coatings14070807 - 28 Jun 2024
Cited by 1 | Viewed by 1352
Abstract
Sulfate-reducing bacteria (SRB) are the primary cause of corrosion in oil and gas pipeline steel. To understand how temperature and immersion time affect the SRB-induced corrosion of BG L450OQO-RCB pipe steel, the present study delved into the morphology and elemental composition of corrosion [...] Read more.
Sulfate-reducing bacteria (SRB) are the primary cause of corrosion in oil and gas pipeline steel. To understand how temperature and immersion time affect the SRB-induced corrosion of BG L450OQO-RCB pipe steel, the present study delved into the morphology and elemental composition of corrosion products, corrosion rate, corrosion solution composition, and electrochemical performance at different temperatures (25, 40, and 60 °C) and immersion times (5, 10, and 20 days). During the SRB corrosion of the investigated steel, extracellular polymeric substances (EPSs), iron sulfide, and iron phosphide were produced on the surfaces of the steel samples, along with the calcium carbonate product. Chloride ions in the corrosion solution contributed to the corrosion of steel and the formation of chlorides on steel surfaces. Over time, the quantities of EPSs, iron sulfide, and iron phosphide gradually decreased with immersion time. The presence of surface iron chloride initially increased and then decreased with immersion time. Conversely, the presence of calcium carbonate surface product initially decreased and then increased with immersion time. The content of SRB extracellular polymer, iron sulfide, and iron phosphide changed imperceptibly between 25 and 40 °C, but the overall content decreased at 60 °C. The content of surface ferric chloride remained practically unchanged between 25 and 40 °C but increased at 60 °C. The calcium carbonate surface product increased slightly with higher temperature. The corrosion of Cu-containing steel by SRB follows the cathodic depolarization theory. Full article
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Review

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17 pages, 12977 KiB  
Review
Current Status of Image Recognition Technology in the Field of Corrosion Protection Applications
by Xinran Wang, Wei Zhang, Zhifeng Lin, Haojie Li, Yuanqing Zhang, Weiyin Quan, Zhiwei Chen, Xueqiang You, Yang Zeng, Gang Wang, Bolin Luo and Zhenghua Yu
Coatings 2024, 14(8), 1051; https://doi.org/10.3390/coatings14081051 - 16 Aug 2024
Cited by 1 | Viewed by 1468
Abstract
Corrosion brings serious losses to the economy annually. Therefore, various corrosion protection and detection techniques are widely used in the daily maintenance of large metal engineering structures. The emergence of image recognition technology has brought a more convenient and faster way for nondestructive [...] Read more.
Corrosion brings serious losses to the economy annually. Therefore, various corrosion protection and detection techniques are widely used in the daily maintenance of large metal engineering structures. The emergence of image recognition technology has brought a more convenient and faster way for nondestructive testing. Existing image recognition technology can be divided into two categories according to the algorithm: traditional image recognition technology and image recognition technology based on deep learning. These two types of technologies have been widely used in the three fields of metal, coating, and electrochemical data images. A large amount of work has been carried out to identify defects in metals and coatings, and deep learning-based methods also show potential for identifying electrochemical data images. Matching electrochemical images with the detection of defect morphology will bring a deeper understanding of image recognition techniques for metals and coatings. A database of accumulated morphology and electrochemical parameters will make it possible to predict the life of steel and coatings using image recognition techniques. Full article
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