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Anti-Corrosion and Anti-Wear Coatings: Fundamentals, Technologies, and Applications
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Anti-Corrosion and Anti-Wear Coatings: Fundamentals, Technologies, and Applications

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

Deadline for manuscript submissions: 29 August 2025 | Viewed by 7632

Special Issue Editors

Dr. Wei Dai

E-Mail Website
Guest Editor
School of Electromechanical Engineering, Guangdong University of Technology, Guangzhou 510006, China
Interests: physical vapor deposition hard coatings; including the coating preparation; structure characterization, properties, and applications
Dr. Hao Wu

E-Mail Website
Guest Editor
Guangdong Key Laboratory of Materials and Equipment in Harsh Marine Environment and School of Naval Architecture and Ocean Engineering, Guangzhou Maritime University, Guangzhou 510725, China
Interests: surface engineering; functional thin film; plasma technology; corrosion
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Coatings have been widely used in many industries to improve the anti-corrosion and anti-wear properties of metallic substrates and extend the service life of metallic tools, molds, and parts in harsh environments. The properties of the coatings are affected by many factors such as the preparation technology, chemical composition, microstructure, and architectural structure. Numerous methods such as electrodeposition, thermal spraying, cladding, sol-gel, the chemical route, chemical vapor deposition (CVD), and physical vapor deposition (PVD) have been used to deposit various coatings. Recently, hybrid processes like the combinations of PVD and CVD, the chemical route and CVD or PVD, and sol-gel and PVD have been developed to build novel nanocomposite coatings. Meanwhile, the use of multi-elements, multi-phases, multi-structures (e.g. multi-layers), and multi-functions is becoming mainstream. Coatings must exhibit excellent overall performance, including mechanical and tribological performance. In addition, resistances to corrosion and oxidation are required for the coatings to meet the reliability and durability standards of metal products in complex and changing environments. Anti-wear and anti-corrosion properties are the basic and widely applied functions of coatings. Thus, this Special Issue is dedicated to contributing to the understanding of anti-wear and anti-corrosion coating fundamentals, technologies, and applications.

This Special Issue will serve as a forum for papers discussing the following concepts:

  • Theoretical and experimental research, knowledge, and new ideas in the design, preparation, and application of anti-wear and anti-corrosion coatings;
  • Recent developments in anti-wear and anti-corrosion coatings, including organic, inorganic, and hybrid coatings, as well as surface technology;
  • Anti-wear and anti-corrosion coatings produced via different processes, including, but not limited to, additive manufacturing processes, plating, thermal spray, PVD, CVD, etc.;
  • Research on the failure mechanisms of coatings through wear, corrosion, or wear/corrosion hybrid processes;
  • The latest characterization technologies and testing methods for the mechanical properties, corrosion, and wear of coatings, as well as the interplay between mechanical, electrochemical, and tribological behaviors;
  • Computer modeling, simulations regarding the preparation processes, properties, performance, and application of coatings.

Dr. Wei Dai
Dr. Hao Wu
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 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

  • anti-wear coatings
  • anti-corrosion coatings
  • coating preparation
  • microstructure.

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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

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17 pages, 31244 KiB  
Article
Mechanical Properties and High-Temperature Steam Oxidation of Cr/CrN Multi-Layers Produced by High-Power Impulse Magnetron Sputtering
by Ding Chen, Daoxuan Liang, Wei Dai, Qimin Wang, Jun Yan and Junfeng Wang
Coatings 2025, 15(2), 185; https://doi.org/10.3390/coatings15020185 - 6 Feb 2025
Viewed by 744
Abstract
In this study, Cr coatings, CrN coatings, and CrN/Cr multi-layer coatings were deposited on the surface of Zr-4 alloy by high-power impulse magnetron sputtering (HiPIMS). We have investigated the effect of coating structure on the microstructure, mechanical properties, and high-temperature steam oxidation properties [...] Read more.
In this study, Cr coatings, CrN coatings, and CrN/Cr multi-layer coatings were deposited on the surface of Zr-4 alloy by high-power impulse magnetron sputtering (HiPIMS). We have investigated the effect of coating structure on the microstructure, mechanical properties, and high-temperature steam oxidation properties of coatings. The results show that the single-layer CrN coating has higher hardness but performs poorly in high-temperature steam oxidation compared to the Cr coating due to its greater brittleness, which makes it prone to cracking and spalling in high-temperature steam environments and provides a channel for Zr diffusion. In multi-layer coatings, however, they form a fine columnar crystal structure and a smoother surface, and the more layers there are, the better the mechanical properties and resistance to high-temperature steam oxidation of the coating. In a high-temperature steam environment, the CrN layer decomposes to form Cr2N and N2, and the N atoms diffuse inwards and react with Zr to form an α-Zr(N) layer, which restricts interdiffusion between Cr and Zr and blocks the diffusion of O into the substrate. Therefore, (CrN/Cr)n coatings with a multi-layer structure have excellent high-temperature steam corrosion resistance. Full article
(This article belongs to the Special Issue Anti-Corrosion and Anti-Wear Coatings: Fundamentals, Technologies, and Applications)
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9 pages, 956 KiB  
Article
Atomic Layer Deposition of Y2O3 Thin Films Using Y(MeCp)2(iPr-nPrAMD) Precursor and H2O, and Their Erosion Resistance in CF4-Based Plasma
by Seong Lee, Hyunchang Kim and Sehun Kwon
Coatings 2025, 15(1), 22; https://doi.org/10.3390/coatings15010022 - 30 Dec 2024
Viewed by 890
Abstract
Atomic layer deposition (ALD) of Y2O3 thin films was investigated using Y(MeCp)2(iPr-nPrAMD) precursor and H2O reactant. The self-limiting reaction mechanism of ALD-Y2O3 thin films was confirmed at a growth temperature of 260 °C. [...] Read more.
Atomic layer deposition (ALD) of Y2O3 thin films was investigated using Y(MeCp)2(iPr-nPrAMD) precursor and H2O reactant. The self-limiting reaction mechanism of ALD-Y2O3 thin films was confirmed at a growth temperature of 260 °C. And, the saturated growth rate was confirmed to be ~0.11 nm/cycle. Also, it was demonstrated that a wide ALD temperature window from 150 °C to 290 °C maintains a consistent growth rate. ALD-Y2O3 thin films were found to have a typical cubic polycrystalline structure, independent of growth temperature, which can be attributed to their stoichiometric composition of Y2O3, negligible carbon impurity, and high film density, analogous to the Y2O3 bulk. Even at a low growth temperature of 150 °C, ALD-Y2O3 exhibited a markedly lower plasma etching rate (~0.77 nm/min) than that (~4.6 nm/min) of ALD-Al2O3 when using RIE at a plasma power of 400 W with a mixed gas of Ar/CF4/O2. Furthermore, the growth temperature of Y2O3 thin films had minimal impact on the etching rate. Full article
(This article belongs to the Special Issue Anti-Corrosion and Anti-Wear Coatings: Fundamentals, Technologies, and Applications)
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16 pages, 6813 KiB  
Article
Study on the Wear Performance of Surface Alloy Coating of Inner Lining Pipe under Different Load and Mineralization Conditions
by Yuntao Xi, Yucong Bi, Yang Wang, Lan Wang, Shikai Su, Lei Wang, Liqin Ding, Shanna Xu, Haitao Liu, Xinke Xiao, Ruifan Liu and Jiangtao Ji
Coatings 2024, 14(10), 1274; https://doi.org/10.3390/coatings14101274 - 4 Oct 2024
Viewed by 1166
Abstract
Testing was carried out in this study to evaluate the friction and wear performance of 45# steel inner liner pipes with cladding, along with four different types of centralizing materials (45# steel, nylon, polytetrafluoroethylene (PTFE), and surface alloy coating) in oil field conditions. [...] Read more.
Testing was carried out in this study to evaluate the friction and wear performance of 45# steel inner liner pipes with cladding, along with four different types of centralizing materials (45# steel, nylon, polytetrafluoroethylene (PTFE), and surface alloy coating) in oil field conditions. Under dry-friction conditions, the coefficients of friction and rates of wear are significantly higher than their counterparts in aqueous solutions. This is attributed to the lubricating effect provided by the aqueous solution, which reduces direct friction between contact surfaces, thereby lowering wear. As the degree of mineralization in the aqueous solution increases, the coefficient of friction tends to decrease, indicating that an elevated level of mineralization enhances the lubricating properties of the aqueous solution. The wear pattern in an aqueous solution is similar to that in dry-friction conditions under different loads, but with a lower friction coefficient and wear rate. The coating has played an important role in protecting the wear process of 45# steel, and the friction coefficient and wear rate of tubing materials under various environmental media have been significantly reduced. In terms of test load, taking into account the friction coefficient and wear rate, the suggested order for centralizing materials for lining oil pipes with the surface alloy coating is as follows: (i) surface alloy coating, (ii) nylon, (iii) PTFE, and (iv) 45# steel. Full article
(This article belongs to the Special Issue Anti-Corrosion and Anti-Wear Coatings: Fundamentals, Technologies, and Applications)
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15 pages, 3645 KiB  
Article
Comparison of Corrosion Behavior of a-C Coatings Deposited by Cathode Vacuum Arc and Filter Cathode Vacuum Arc Techniques
by Zhiqing Feng, Zhetong Zhou, Junhao Zeng, Ding Chen, Fengying Luo, Qimin Wang, Wei Dai and Ruiming Zhang
Coatings 2024, 14(8), 1053; https://doi.org/10.3390/coatings14081053 - 17 Aug 2024
Cited by 1 | Viewed by 1270
Abstract
This study explores the utilization of cathodic vacuum arc (CVA) technology to address the limitations of magnetron sputtering technology in preparing amorphous carbon (a-C) coatings, such as having a low ionization rate, low deposition rate, and insufficiently dense structure. Specifically, a-C coatings were [...] Read more.
This study explores the utilization of cathodic vacuum arc (CVA) technology to address the limitations of magnetron sputtering technology in preparing amorphous carbon (a-C) coatings, such as having a low ionization rate, low deposition rate, and insufficiently dense structure. Specifically, a-C coatings were prepared by the cathodic vacuum arc (CVA)and the filtered cathodic vacuum arc (FCVA) technology,, one with embedded carbon particles and one without, both having closely related carbon structures. Research is currently underway on bipolar plate coatings for fuel cells. The corrosion behavior of the prepared a-C coatings was examined through Tafel polarization analysis under simulated fuel cell operating conditions as well as potentiostatic analysis at 0.6 V under normal conditions and 1.6 V under start–stop conditions for 7200 s. The coatings before and after corrosion are characterized using scanning electron microscopy, energy-dispersive X-ray spectroscopy, Raman spectroscopy, and infrared spectroscopy. The results reveal that the incorporation of conductive graphite-like particles in the coatings reduces their contact resistance. However, the gaps between these particles and the coatings act as pathways for corrosive solution, exacerbating the corrosion of the coatings. After corrosion at 0.6 V, both sets of coatings with sp2-hybridized carbon structures are contaminated by elements such as hydrogen and oxygen, leading to an increase in their contact resistance. Under high potential conditions (1.6 V), large corrosion pits and defects appear at the locations of graphite-like carbon particles. Furthermore, both sets of samples exhibit more severe oxygen contamination and a transformation of broken carbon bonds from sp3- to sp2-hybridized forms, irrespective of whether embedded graphite particles are present. Full article
(This article belongs to the Special Issue Anti-Corrosion and Anti-Wear Coatings: Fundamentals, Technologies, and Applications)
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Review

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23 pages, 6499 KiB  
Review
A Review of Research on Improving Wear Resistance of Titanium Alloys
by Yazhou Chen, Honggang Zhang, Bitao Wang, Jianyong Huang, Meihong Zhou, Lei Wang, Yuntao Xi, Hongmin Jia, Shanna Xu, Haitao Liu, Lei Wen, Xinke Xiao, Ruifan Liu and Jiangtao Ji
Coatings 2024, 14(7), 786; https://doi.org/10.3390/coatings14070786 - 24 Jun 2024
Cited by 3 | Viewed by 2863
Abstract
Titanium alloy is widely used as oil drill pipe material because of its light weight, high strength, good toughness, corrosion resistance, fatigue resistance, and good process performance. However, due to its low hardness, poor wear resistance, serious oxidation at high temperature (700 °C), [...] Read more.
Titanium alloy is widely used as oil drill pipe material because of its light weight, high strength, good toughness, corrosion resistance, fatigue resistance, and good process performance. However, due to its low hardness, poor wear resistance, serious oxidation at high temperature (700 °C), and difficulty in lubrication, in oil and gas field exploration and development drilling, especially in deep wells, high displacement wells, horizontal wells, and highly deviated wells, wear and tear are prone to occur. The application and development of titanium alloys are greatly limited. This paper introduces the research status of the common surface modification technologies of titanium alloys, such as laser cladding, magnetron sputtering, plasma spraying, micro arc oxidation, etc. It points out the improvement effect of various modification technologies on the wear resistance and high-temperature oxidation resistance of titanium alloys and discusses the advantages and disadvantages of various modification technologies. A proposed method for enhancing the wear resistance and high-temperature oxidation resistance of titanium alloys was finally introduced, and its potential for future development was investigated. Full article
(This article belongs to the Special Issue Anti-Corrosion and Anti-Wear Coatings: Fundamentals, Technologies, and Applications)
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