Coatings

17 pages, 2459 KiB

Open AccessArticle

Comparative Life Cycle Assessment of Rubberized Warm-Mix Asphalt Pavements: A Cradle-to-Gate Plus Maintenance Approach

by Ana María Rodríguez-Alloza and Daniel Garraín

Coatings 2025, 15(8), 899; https://doi.org/10.3390/coatings15080899 (registering DOI) - 1 Aug 2025

In response to the escalating climate crisis, reducing greenhouse gas emissions (GHG) has become a top priority for both the public and private sectors. The pavement industry plays a key role in this transition, offering innovative technologies that minimize environmental impacts without compromising [...] Read more.

In response to the escalating climate crisis, reducing greenhouse gas emissions (GHG) has become a top priority for both the public and private sectors. The pavement industry plays a key role in this transition, offering innovative technologies that minimize environmental impacts without compromising performance. Among these, the incorporation of recycled tire rubber and warm-mix asphalt (WMA) additives represents a promising strategy to reduce energy consumption and resource depletion in road construction. This study conducts a comparative life cycle assessment (LCA) to evaluate the environmental performance of an asphalt pavement incorporating recycled rubber and a WMA additive—referred to as R-W asphalt—against a conventional hot-mix asphalt (HMA) pavement. The analysis follows the ISO 14040/44 standards, covering material production, transport, construction, and maintenance. Two service-life scenarios are considered: one assuming equivalent durability and another with a five-year extension for the R-W pavement. The results demonstrate environmental impact reductions of up to 57%, with average savings ranging from 32% to 52% across key impact categories such as climate change, land use, and resource use. These benefits are primarily attributed to lower production temperatures and extended maintenance intervals. The findings underscore the potential of R-W asphalt as a cleaner engineering solution aligned with circular economy principles and climate mitigation goals. Full article

(This article belongs to the Special Issue Surface Protection of Pavements: New Perspectives and Applications)

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46 pages, 4006 KiB

Open AccessReview

Solvent-Driven Electroless Nickel Coatings on Polymers: Interface Engineering, Microstructure, and Applications

by Chenyao Wang, Heng Zhai, David Lewis, Hugh Gong, Xuqing Liu and Anura Fernando

Coatings 2025, 15(8), 898; https://doi.org/10.3390/coatings15080898 (registering DOI) - 1 Aug 2025

Abstract

Electroless nickel deposition (ELD) is an autocatalytic technique extensively used to impart conductive, protective, and mechanical functionalities to inherently non-conductive synthetic substrates. This review systematically explores the fundamental mechanisms of electroless nickel deposition, emphasising recent advancements in surface activation methods, solvent systems, and [...] Read more.

Electroless nickel deposition (ELD) is an autocatalytic technique extensively used to impart conductive, protective, and mechanical functionalities to inherently non-conductive synthetic substrates. This review systematically explores the fundamental mechanisms of electroless nickel deposition, emphasising recent advancements in surface activation methods, solvent systems, and microstructural control. Critical analysis reveals that bio-inspired activation methods, such as polydopamine (PDA) and tannic acid (TA), significantly enhance coating adhesion and durability compared to traditional chemical etching and plasma treatments. Additionally, solvent engineering, particularly using polar aprotic solvents like dimethyl sulfoxide (DMSO) and ethanol-based systems, emerges as a key strategy for achieving uniform, dense, and flexible coatings, overcoming limitations associated with traditional aqueous baths. The review also highlights that microstructural tailoring, specifically the development of amorphous-nanocrystalline hybrid nickel coatings, effectively balances mechanical robustness (hardness exceeding 800 HV), flexibility, and corrosion resistance, making these coatings particularly suitable for wearable electronic textiles and smart materials. Furthermore, commercial examples demonstrate the real-world applicability and market readiness of nickel-coated synthetic fibres. Despite significant progress, persistent challenges remain, including reliable long-term adhesion, internal stress management, and environmental sustainability. Future research should prioritise environmentally benign plating baths, standardised surface activation protocols, and scalable deposition processes to fully realise the industrial potential of electroless nickel coatings. Full article

(This article belongs to the Section Surface Characterization, Deposition and Modification)

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13 pages, 1623 KiB

Open AccessArticle

Effect of Absolute Ethanol and Thermal Treatment on Shrinkage and Mechanical Properties of TPU Electrospun Nanofiber Membranes

by Lei Wang, Ming Kong, Shengchun Wang, Chunsheng Li and Min Yang

Coatings 2025, 15(8), 897; https://doi.org/10.3390/coatings15080897 (registering DOI) - 1 Aug 2025

Abstract

Thermoplastic polyurethane (TPU) electrospun fiber membranes possess unique micro-nano structures and excellent properties. Adjusting their wettability enables the directional transportation of lubricants. A conventional method for adjusting porosity and wettability involves inducing membrane shrinkage using absolute ethanol and heat treatment. However, the shrinkage [...] Read more.

Thermoplastic polyurethane (TPU) electrospun fiber membranes possess unique micro-nano structures and excellent properties. Adjusting their wettability enables the directional transportation of lubricants. A conventional method for adjusting porosity and wettability involves inducing membrane shrinkage using absolute ethanol and heat treatment. However, the shrinkage response and the corresponding changes in the tensile properties of TPU fiber membranes after induction remain unclear, limiting their applications. Thus, in this study, after being peeled off, the samples were first left to stand at room temperature (RT) for 24 h to release residual stress and stabilize their dimensions, and then treated with dehydrated ethanol at RT and high temperature, respectively, with their shrinkage behaviors observed and recorded. The results showed that TPU nanofiber membranes shrank significantly in absolute ethanol, and the degree of shrinkage was temperature-dependent. The shrinkage rates were 2% and 4% in dehydrated ethanol at room temperature and high temperature, respectively, and heating increased the shrinkage effect by 200%. These findings prove that absolute ethanol causes TPU fibers to shrink, and high temperatures further promote shrinkage. However, although the strong synergistic effect of heat and solvent accelerates shrinkage, it may induce internal structural defects, resulting in the deterioration of mechanical properties. The contraction response induced by anhydrous ethanol stimulation can be used to directionally adjust the local density and modulus of TPU nanofiber membranes, thereby changing the wettability. This approach provides new opportunities for applications in areas such as medium transportation and interface friction reduction in lubrication systems. Full article

(This article belongs to the Section Surface Characterization, Deposition and Modification)

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14 pages, 2138 KiB

Open AccessArticle

Comparison Between Bond Strengths of a Resin Cement on Traditional Prosthetic Substrates and a 3D-Printed Resin for Permanent Restorations

by Alessandro Vichi, Hanan Al-Johani, Dario Balestra and Chris Louca

Coatings 2025, 15(8), 896; https://doi.org/10.3390/coatings15080896 (registering DOI) - 1 Aug 2025

Abstract

Recently, 3D-printed resins have been introduced as materials for definitive indirect restorations. Herein, a comparative assessment of the bond strengths of 3D-printed resins to a resin cement was performed. Methods: four definitive restorative materials were selected, i.e., a Feldspar ceramic (VITA Mark II, [...] Read more.

Recently, 3D-printed resins have been introduced as materials for definitive indirect restorations. Herein, a comparative assessment of the bond strengths of 3D-printed resins to a resin cement was performed. Methods: four definitive restorative materials were selected, i.e., a Feldspar ceramic (VITA Mark II, VM), a polymer-infiltrated ceramic network (VITA Enamic, VE), a nanohybrid resin composite (Grandio Bloc, GB), and one 3D-printed resin (Crown Permanent, CP). VM and VE were etched and silanized, GB was sandblasted, and CP was glass bead blasted; for one further experimental group, this was followed by sandblasting (CPs). A resin cement (RelyX Unicem) was then used for bonding, and then a notched shear bond strength test (nSBS) was performed. Failure modes were observed and classified as adhesive, cohesive, or mixed, and SEM representative images were taken. Data were statistically analyzed with one-way ANOVA, Tukey, and Chi-square tests. Significant differences were detected in nSBS among materials (p < 0.001). The highest nSBS was found in VM (30.3 ± 1.8 MPa) a, followed by CP^b, GB^bc, CP^bc, and VE^c. Failure modes were significantly different (p < 0.001), and with different prevalent failure modes. The bond strength for 3D-printed permanent resin materials was shown to be lower than that of the felspathic ceramic but comparable to that of the resin block and PICN substrates. Full article

(This article belongs to the Special Issue Advanced Polymer Coatings: Materials, Methods, and Applications)

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8 pages, 3048 KiB

Open AccessCommunication

Layer-by-Layer Nanoassembly of Cu(OH)₂ Multilayer Membranes for Nanofiltration

by Wenbo Sun, Yanpeng Xue and Guozhi Liu

Coatings 2025, 15(8), 895; https://doi.org/10.3390/coatings15080895 (registering DOI) - 1 Aug 2025

Abstract

A facile way to prepare Cu(OH)₂ inorganic nanofiltration membranes with neatly arranged multilayers has been developed based on the reaction of a sodium hydroxide solution and a copper ammonia solution at the liquid–liquid interfaces. The effects of the concentration, temperature, and time [...] Read more.

A facile way to prepare Cu(OH)₂ inorganic nanofiltration membranes with neatly arranged multilayers has been developed based on the reaction of a sodium hydroxide solution and a copper ammonia solution at the liquid–liquid interfaces. The effects of the concentration, temperature, and time of the liquid–liquid reaction on membrane structure and pore sizes were studied by SEM, TEM, and X-ray diffraction. The growth mechanism of the membrane was discussed and the formation process model was proposed. It was found that the reaction temperature was a key factor in obtaining a Cu(OH)₂ monolayer, and this could be used to adjust the thickness and pore size of the monolayer. The as-prepared Cu(OH)₂ membranes exhibited excellent filtration performance with the pure water fluxes of 156.2 L·m⁻² h⁻¹ bar⁻¹ and retention rates of 100% for methylene blue (50 ppm) at a pressure of 0.1 MPa. This successfully opens up a new method of synthesizing multilayer nanoarrays’ Cu(OH)₂ structure for nanofiltration. Full article

(This article belongs to the Special Issue Deposition-Based Coating Solutions for Enhanced Surface Properties)

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15 pages, 1758 KiB

Open AccessArticle

Optimized Si-H Content and Multivariate Engineering of PMHS Antifoamers for Superior Foam Suppression in High-Viscosity Systems

by Soyeon Kim, Changchun Liu, Junyao Huang, Xiang Feng, Hong Sun, Xiaoli Zhan, Mingkui Shi, Hongzhen Bai and Guping Tang

Coatings 2025, 15(8), 894; https://doi.org/10.3390/coatings15080894 (registering DOI) - 1 Aug 2025

Abstract

A modular strategy for the molecular design of silicone-based antifoaming agents was developed by precisely controlling the architecture of poly (methylhydrosiloxane) (PMHS). Sixteen PMHS variants were synthesized by systematically varying the siloxane chain length (L1–L4), backbone composition (D₃T₁ vs. D [...] Read more.

A modular strategy for the molecular design of silicone-based antifoaming agents was developed by precisely controlling the architecture of poly (methylhydrosiloxane) (PMHS). Sixteen PMHS variants were synthesized by systematically varying the siloxane chain length (L1–L4), backbone composition (D₃T₁ vs. D₃₀T₁), and terminal group chemistry (H- vs. M-type). These structural modifications resulted in a broad range of Si-H functionalities, which were quantitatively analyzed and correlated with defoaming performance. The PMHS matrices were integrated with high-viscosity PDMS, a nonionic surfactant, and covalently grafted fumed silica—which was chemically matched to each PMHS backbone—to construct formulation-specific defoaming systems with enhanced interfacial compatibility and colloidal stability. Comprehensive physicochemical characterization via FT-IR, ¹H NMR, GPC, TGA, and surface tension analysis revealed a nonmonotonic relationship between Si-H content and defoaming efficiency. Formulations containing 0.1–0.3 wt% Si-H achieved peak performance, with suppression efficiencies up to 96.6% and surface tensions as low as 18.9 mN/m. Deviations from this optimal range impaired performance due to interfacial over-reactivity or reduced mobility. Furthermore, thermal stability and molecular weight distribution were found to be governed by repeat unit architecture and terminal group selection. Compared with conventional EO/PO-modified commercial defoamers, the PMHS-based systems exhibited markedly improved suppression durability and formulation stability in high-viscosity environments. These results establish a predictive structure–property framework for tailoring antifoaming agents and highlight PMHS-based formulations as advanced foam suppressors with improved functionality. This study provides actionable design criteria for high-performance silicone materials with strong potential for application in thermally and mechanically demanding environments such as coating, bioprocessing, and polymer manufacturing. Full article

(This article belongs to the Section Functional Polymer Coatings and Films)

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16 pages, 7560 KiB

Open AccessArticle

High-Performance Sodium Alginate Fiber-Reinforced Polyvinyl Alcohol Hydrogel for Artificial Cartilage

by Lingling Cui, Yifan Lu, Jun Wang, Haiqin Ding, Guodong Jia, Zhiwei Li, Guang Ji and Dangsheng Xiong

Coatings 2025, 15(8), 893; https://doi.org/10.3390/coatings15080893 (registering DOI) - 1 Aug 2025

Abstract

Hydrogels, especially Polyvinyl alcohols, have received extensive attention as alternative materials for articular cartilage. Aiming at the problems such as low strength and poor toughness of polyvinyl alcohol hydrogels in practical applications, an enhancement and modification strategy is proposed. Sodium alginate fibers were [...] Read more.

Hydrogels, especially Polyvinyl alcohols, have received extensive attention as alternative materials for articular cartilage. Aiming at the problems such as low strength and poor toughness of polyvinyl alcohol hydrogels in practical applications, an enhancement and modification strategy is proposed. Sodium alginate fibers were introduced into polyvinyl alcohol hydrogel network through physical blending and freezing/thawing methods. The prepared composite hydrogels exhibited a three-dimensional porous network structure similar to that of human articular cartilage. The mechanical and tribological properties of hydrogels have been significantly improved, due to the multiple hydrogen bonding interaction between sodium alginate fibers and polyvinyl alcohol. Most importantly, under a load of 2 N, the friction coefficient of the PVA/0.4SA hydrogel can remain stable at 0.02 when lubricated in PBS buffer for 1 h. This work provides a novel design strategy for the development of high-performance polyvinyl alcohol hydrogels. Full article

(This article belongs to the Section Surface Coatings for Biomedicine and Bioengineering)

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34 pages, 8425 KiB

Open AccessReview

Recent Advances in Non-Enzymatic Glucose Sensors Based on Nanomaterials

by Dongfang Yang, Yongjin Chen, Songtao Che and Kai Wang

Coatings 2025, 15(8), 892; https://doi.org/10.3390/coatings15080892 (registering DOI) - 1 Aug 2025

Abstract

The detection of glucose concentration has a wide range of applications and plays a significant role in the fields of the food industry, medical health, and illness diagnostics. The utilization of sensor technology for glucose concentration detection is an effective approach. Glucose sensors [...] Read more.

The detection of glucose concentration has a wide range of applications and plays a significant role in the fields of the food industry, medical health, and illness diagnostics. The utilization of sensor technology for glucose concentration detection is an effective approach. Glucose sensors utilizing nanomaterials, with high sensitivity, strong resistance to interference, and compact size, exhibit tremendous potential in glucose concentration detection. Traditional enzyme-based sensors exhibit superior selectivity and high sensitivity; however, they are deficient in terms of interference resistance capabilities. With the development of nanotechnology, the performance of glucose sensors has been significantly improved. This review discusses the research progress in non-enzymatic electrochemical glucose nanosensors, including noble metal-based glucose sensors and non-noble transition metal compound-based glucose sensors, as well as the applications of multimetallic materials in nanosensors. Additionally, the application of nanosensors based on fluorescence and colorimetric principles in the detection of glucose concentration is introduced in this review. Finally, a perspective on the challenges and prospects of nanosensors in the field of glucose detection is presented. Full article

(This article belongs to the Section Surface Engineering for Energy Harvesting, Conversion, and Storage)

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15 pages, 2324 KiB

Open AccessArticle

Influence of Aluminum Alloy Substrate Temperature on Microstructure and Corrosion Resistance of Cr/Ti Bilayer Coatings

by Yuqi Wang, Tao He, Xiangyang Du, Alexey Vereschaka, Catherine Sotova, Yang Ding, Kang Chen, Jian Li and Peiyu He

Coatings 2025, 15(8), 891; https://doi.org/10.3390/coatings15080891 (registering DOI) - 1 Aug 2025

Abstract

Cr/Ti bilayer coatings were deposited on 7050 aluminum alloy via magnetron sputtering at substrate temperatures of room temperature (RT), 150 °C, and 300 °C to investigate temperature effects on microstructure, hardness, and corrosion resistance. All coatings exhibited Cr(110) and Ti(002) phases. Temperature significantly [...] Read more.

Cr/Ti bilayer coatings were deposited on 7050 aluminum alloy via magnetron sputtering at substrate temperatures of room temperature (RT), 150 °C, and 300 °C to investigate temperature effects on microstructure, hardness, and corrosion resistance. All coatings exhibited Cr(110) and Ti(002) phases. Temperature significantly modulated corrosion resistance by altering pore density, grain boundary density, and passivation film composition. Increasing temperature from RT to 150 °C raised corrosion rates primarily due to increased pore density. Further increasing to 300 °C reduced corrosion rates mainly through decreased grain boundary density, while passivation film composition changes altered electrochemical reaction kinetics. Substrate-coating interface defect density primarily influenced hardness with minimal effect on corrosion. Consequently, the RT-deposited coating, despite lower hardness, demonstrated optimal corrosion resistance: polarization resistance (7.17 × 10⁴ Ω·cm²), charge transfer resistance (12,400 Ω·cm²), and corrosion current density (2.47 × 10⁻⁷ A/cm²), the latter being two orders of magnitude lower than the substrate. Full article

(This article belongs to the Special Issue Innovative Coatings for Corrosion Protection of Alloy Surfaces)

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12 pages, 2346 KiB

Open AccessArticle

SERS and Chiral Properties of Cinnamic Acid Derivative Langmuir-Blodgett Films Complexed with Dyes

by Xingdi Zhao, Xinyu Li, Pengfei Bian, Qingrui Zhang, Yuqing Qiao, Mingli Wang and Tifeng Jiao

Coatings 2025, 15(8), 890; https://doi.org/10.3390/coatings15080890 (registering DOI) - 1 Aug 2025

Abstract

Chiral molecules are crucial in the field of optical devices, molecular recognition, and other novel functional materials due to their unique spatially asymmetric configuration and optical activity. In this study, a chiral molecule, Cholest-3-yl (E)-3-(4-carbamoylphenyl)acrylate (CCA), was combined with dyes containing large conjugated [...] Read more.

Chiral molecules are crucial in the field of optical devices, molecular recognition, and other novel functional materials due to their unique spatially asymmetric configuration and optical activity. In this study, a chiral molecule, Cholest-3-yl (E)-3-(4-carbamoylphenyl)acrylate (CCA), was combined with dyes containing large conjugated structures, tetramethylporphyrin tetrasulfonic acid (TPPS), and Nickel(II) phthalocyanine-tetrasulfonic acid tetrasodium salt (TsNiPc), and composite LB films of CCA/TPPS and CCA/TsNiPc were successfully prepared by using Langmuir-Blodgett (LB) technology. The circular dichroism (CD) test proved that the CCA/TPPS composite film had a strong CD signal at 300–400 nm, and the composite film showed chirality. This significant optical activity provides a new idea and option for the application of LB films in chiral sensors. In the Surface Enhanced Raman Spectroscopy (SERS) test, the CCA/TPPS composite film was sensitive to signal sensing, in which the enhancement factor EF = 2.28 × 10⁵, indicating that a large number of effective signal response regions were formed on the surface of the film, and the relative standard deviation (RSD) = 12.08%, which demonstrated that the film had excellent uniformity and reproducibility. The high sensitivity and low signal fluctuation make the CCA/TPPS composite LB film a promising SERS substrate material. Full article

(This article belongs to the Special Issue Surface Wetting and Functionalization of Composite Films and Coatings for Modern Applications)

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23 pages, 6098 KiB

Open AccessArticle

Performance Optimization of Stacked Weld in Hydrogen Production Reactor Based on Response Surface Methodology–Genetic Algorithm

by Yu Liu, Hongtao Gu, Jincheng Zhang, Zhiyi Leng, Ziguang Wang and Shengfang Zhang

Coatings 2025, 15(8), 889; https://doi.org/10.3390/coatings15080889 (registering DOI) - 31 Jul 2025

Abstract

To address the issues of hydrogen embrittlement, creep, and fatigue that commonly occur in the welds of hydrogen production reactor operating under hydrogen exposure, high temperature and high pressure, this study proposes adding Si and Mo as reinforcing elements to the welding materials [...] Read more.

To address the issues of hydrogen embrittlement, creep, and fatigue that commonly occur in the welds of hydrogen production reactor operating under hydrogen exposure, high temperature and high pressure, this study proposes adding Si and Mo as reinforcing elements to the welding materials to enhance weld performance. Given the varying performance requirements of different weld layers in the stacked weld, a gradient performance optimization method for the stacked weld of hydrogen production reactors based on the response surface methodology (RSM)–genetic algorithm (GA) is proposed. Using tensile strength, the hydrogen embrittlement sensitivity index, fatigue strain strength, creep rate and weld performance evaluation indices, a high-precision regression model for Si and Mo contents and weld performance indices was established through RSM and analysis of variance (ANOVA). A multi-objective optimization mathematical model for gradient improvement of the stacked weld was also established. This model was solved using a GA to obtain the optimal element content combination added to the welding wire and the optimal weld thickness for each weld layer. Finally, submerged arc welding experiments of the stacked weld were conducted according to the optimization results. The results show that the tensile strength of the base layer, filling layer and cover layer of the stacked weld increased by 5.60%, 6.16% and 4.53%, respectively. Hydrogen embrittlement resistance increased by 70.56%, 52.40% and 45.16%, respectively. The fatigue and creep resistance were also improved. The experimental results validate the feasibility and accuracy of the proposed optimization method. Full article

(This article belongs to the Section Surface Engineering for Energy Harvesting, Conversion, and Storage)

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15 pages, 2057 KiB

Open AccessArticle

Machine Learning-Based Prediction of Atmospheric Corrosion Rates Using Environmental and Material Parameters

by Saurabh Tiwari, Khushbu Dash, Nokeun Park and Nagireddy Gari Subba Reddy

Coatings 2025, 15(8), 888; https://doi.org/10.3390/coatings15080888 (registering DOI) - 31 Jul 2025

Abstract

Atmospheric corrosion significantly impacts infrastructure worldwide, with traditional assessment methods being time-intensive and costly. This study developed a comprehensive machine learning framework for predicting atmospheric corrosion rates using environmental and material parameters. Three regression models (Linear Regression, Random Forest, and Gradient Boosting) were [...] Read more.

Atmospheric corrosion significantly impacts infrastructure worldwide, with traditional assessment methods being time-intensive and costly. This study developed a comprehensive machine learning framework for predicting atmospheric corrosion rates using environmental and material parameters. Three regression models (Linear Regression, Random Forest, and Gradient Boosting) were trained on a scientifically informed synthetic dataset incorporating established corrosion principles from ISO 9223 standards and peer-reviewed literature. The Gradient Boosting model achieved superior performance with cross-validated R² = 0.835 ± 0.024 and RMSE = 98.99 ± 16.62 μm/year, significantly outperforming the Random Forest (p < 0.001) and Linear Regression approaches. Feature importance analysis revealed the copper content (30%), exposure time (20%), and chloride deposition (15%) as primary predictors, consistent with the established principles of corrosion science. Model diagnostics demonstrated excellent predictive accuracy (R² = 0.863) with normally distributed residuals and homoscedastic variance patterns. This methodology provides a systematic framework for ML-based corrosion prediction, with significant implications for protective coating design, material selection, and infrastructure risk assessment, pending comprehensive experimental validation. Full article

(This article belongs to the Special Issue Advanced Anticorrosion Coatings and Coating Testing)

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13 pages, 3341 KiB

Open AccessArticle

Regulation of Electrochemical Activity via Controlled Integration of NiS₂ over Co₃O₄ Nanomaterials for Hydrogen Evolution Reaction

by Mrunal Bhosale, Rutuja U. Amate, Pritam J. Morankar and Chan-Wook Jeon

Coatings 2025, 15(8), 887; https://doi.org/10.3390/coatings15080887 - 30 Jul 2025

Abstract

Electrochemical water splitting represents a sustainable approach for hydrogen production, yet efficient hydrogen evolution reaction (HER) catalysts operating in alkaline environments remain critically needed. Herein, we report the fabrication of Co₃O₄–NiS₂ nanocomposites synthesized through a facile coprecipitation and [...] Read more.

Electrochemical water splitting represents a sustainable approach for hydrogen production, yet efficient hydrogen evolution reaction (HER) catalysts operating in alkaline environments remain critically needed. Herein, we report the fabrication of Co₃O₄–NiS₂ nanocomposites synthesized through a facile coprecipitation and subsequent thermal treatment method. Detailed characterization via physicochemical techniques confirmed the successful formation of a hybrid Co₃O₄–NiS₂ heterostructure with tunable compositional and morphological characteristics. Among the synthesized catalysts (Co–Ni–1, Co–Ni–2, and Co–Ni–3), the Co–Ni–2 sample demonstrated optimal structural integration, displaying interconnected nanosheet morphologies and balanced elemental distribution. Remarkably, Co–Ni–2 achieved exceptional HER performance in 1 M KOH electrolyte, requiring an ultralow overpotential of only 84 mV at 10 mA cm⁻² and exhibiting a favorable Tafel slope of 67.5 mV dec⁻¹. Electrochemical impedance spectroscopy and electrochemical surface area measurements further substantiated the superior electrocatalytic kinetics, rapid charge transport, and abundant active site accessibility in the optimized Co–Ni–2 composite. Additionally, Co–Ni–2 demonstrated outstanding durability with negligible activity decay over 5000 cycles. This study not only highlights the strategic synthesis of Co₃O₄–NiS₂ nanostructures but also provides valuable insights for designing advanced, stable, and efficient non-noble electrocatalysts for sustainable hydrogen generation. Full article

(This article belongs to the Section Surface Engineering for Energy Harvesting, Conversion, and Storage)

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18 pages, 3967 KiB

Open AccessArticle

A Thorough Investigation of the Mechanism of theAntagonistic Effect Between Phosphorus and Basic Oxide-Forming Minerals as Flame Retardants of PolymericComposite Coatings

by Evangelia Mitropoulou, Georgios N. Mathioudakis, Amaia Soto Beobide, Athanasios Porfyris, Vassilios Dracopoulos, Kerim Kılınç, Theodosios Chatzinikolaou, Deniz Savci, Cem Gunesoglu, Joannis Kallitsis and George A. Voyiatzis

Coatings 2025, 15(8), 886; https://doi.org/10.3390/coatings15080886 - 30 Jul 2025

Abstract

Halogenated flame retardants have been amongst the most widely used and effective solutions for enhancing fire resistance. However, their use is currently strictly regulated due to serious health and environmental concerns. In this context, phosphorus-based and mineral flame retardants have emerged as promising [...] Read more.

Halogenated flame retardants have been amongst the most widely used and effective solutions for enhancing fire resistance. However, their use is currently strictly regulated due to serious health and environmental concerns. In this context, phosphorus-based and mineral flame retardants have emerged as promising alternatives. Despite this, their combined use is neither straightforward nor guaranteed to be effective. This study scrutinizes the interactions between these two classes of flame retardants (FR) through a systematic analysis aimed at elucidating the antagonistic pathways that arise from their coexistence. Specifically, this study focuses on two inorganic fillers, mineral huntite and chemically precipitated magnesium hydroxide, both of which produce basic oxides upon thermal decomposition. These fillers were incorporated into a poly(butylene terephthalate) (PBT) matrix to be utilized as advanced-mattress FR coating fabric and were subjected to a series of flammability tests. The pyrolysis products of the prepared polymeric composite compounds were isolated and thoroughly characterized using a combination of analytical techniques. Thermogravimetric analysis (TGA) and differential thermogravimetric analysis (dTGA) were employed to monitor decomposition behavior, while the char residues collected at different pyrolysis stages were examined spectroscopically, using FTIR-ATR and Raman spectroscopy, to identify their structure and the chemical reactions that led to their formation. X-ray diffraction (XRD) experiments were also conducted to complement the spectroscopic findings in the chemical composition of the resulting char residues and to pinpoint the different species that constitute them. The morphological changes of the char’s structure were monitored by scanning electron microscopy with energy dispersive X-ray spectroscopy (SEM-EDS). Finally, the Limited Oxygen Index (LOI) and UL94 (vertical sample mode) methods were used to assess the relative flammability of the samples, revealing a significant drop in flame retardancy when both types of flame retardants are present. This reduction is attributed to the neutralization of acidic phosphorus species by the basic oxides generated during the decomposition of the basic inorganic fillers, as confirmed by the characterization techniques employed. These findings underscore the challenge of combining organophosphorus with popular flame-retardant classes such as mineral or basic metal flame retardants, offering insight into a key difficulty in formulating next-generation halogen-free flame-retardant composite coatings. Full article

(This article belongs to the Special Issue Innovative Flame-Retardant Coatings for High-Performance Materials)

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21 pages, 3340 KiB

Open AccessArticle

Simulation and Experimental Investigation on the Performance of Co-, Bi-, and La-Doped AgSnO₂ Contact Interface Models

by Yihong Lv, Jingqin Wang, Yuxuan Wang, Yancai Zhu and Ying Zhang

Coatings 2025, 15(8), 885; https://doi.org/10.3390/coatings15080885 - 29 Jul 2025

Abstract

The inferior electrical conductivity and elevated hardness of AgSnO₂ electrical contact materials have impeded their development. To investigate the effects of Co, Bi, and La doping on the stability and electrical properties of AgSnO₂, this study established interfacial models of [...] Read more.

The inferior electrical conductivity and elevated hardness of AgSnO₂ electrical contact materials have impeded their development. To investigate the effects of Co, Bi, and La doping on the stability and electrical properties of AgSnO₂, this study established interfacial models of doped AgSnO₂ based on first-principles calculations initiated from the atomic structures of constituent materials, subsequently computing electronic structure parameters. The results indicate that doping effectively enhances the interfacial stability and bonding strength of AgSnO₂ and thereby predicted improved electrical contact performance. Doped SnO₂ powders were prepared experimentally using the sol–gel method, and AgSnO₂ contacts were fabricated using high-energy ball milling and powder metallurgy. Testing of wettability and electrical contact properties revealed reductions in arc energy, arcing time, contact resistance, and welding force post-doping. Three-dimensional profilometry and scanning electron microscopy (SEM) were employed to characterize electrical contact surfaces, elucidating the arc erosion mechanism of AgSnO₂ contact materials. Among the doped variants, La-doped electrical contact materials exhibited optimal performance (the lowest interfacial energy was 1.383 eV/Å² and wetting angle was 75.6°). The mutual validation of experiments and simulations confirms the feasibility of the theoretical calculation method. This study provides a novel theoretical method for enhancing the performance of AgSnO₂ electrical contact materials. Full article

(This article belongs to the Section Surface Engineering for Energy Harvesting, Conversion, and Storage)

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19 pages, 4549 KiB

Open AccessArticle

Synthesis, Structure, and Magnetic Properties of (Co/Eu) Co-Doped ZnO Nanoparticles

by Adil Guler

Coatings 2025, 15(8), 884; https://doi.org/10.3390/coatings15080884 - 29 Jul 2025

Abstract

Transition-metal and rare-earth element co-doped ZnO nanoparticles have attracted significant attention due to their potential applications in spintronics and optoelectronics. In this study, Zn_0.95Co_0.01EuxO (x = 0.01–0.05) nanoparticles were synthesized using the sol–gel technique. The estimated stress, strain, and [...] Read more.

Transition-metal and rare-earth element co-doped ZnO nanoparticles have attracted significant attention due to their potential applications in spintronics and optoelectronics. In this study, Zn_0.95Co_0.01EuxO (x = 0.01–0.05) nanoparticles were synthesized using the sol–gel technique. The estimated stress, strain, and crystallite sizes of the synthesized Co/Eu co-doped ZnO nanoparticles were calculated using the Williamson–Hall method, and their electron spin resonance (ESR) properties were investigated to examine the effect on their magnetic and structural properties. X-ray diffraction (XRD) analysis confirmed the presence of a single-phase structure. Surface morphology, elemental composition, crystal quality, defect types, density, and magnetic behavior were characterized using scanning electron microscope (SEM), electron-dispersive spectroscopy (EDS), and ESR techniques, respectively. The effect of Eu concentration on the linewidth (ΔBpp) and g-factor in the ESR spectra was studied. By correlating ESR results with the obtained structural properties, room-temperature ferromagnetic behavior was identified. Full article

(This article belongs to the Section Surface Engineering for Energy Harvesting, Conversion, and Storage)

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25 pages, 9707 KiB

Open AccessArticle

Mesoscale Mechanical Analysis of Concrete Based on a 3D Random Aggregate Model

by Shuaishuai Wei, Huan Zhang, Ding Wang, Xuchun Wang and Mengdi Cao

Coatings 2025, 15(8), 883; https://doi.org/10.3390/coatings15080883 - 29 Jul 2025

Abstract

The shape, size, and interfacial transition zone (ITZ) of aggregates significantly impact the nonlinear mechanical behavior of concrete. This study investigates concrete’s mechanical response and damage mechanisms by developing a three-dimensional, three-phase mesoscale model comprising coarse aggregates, mortar, and ITZ to explore the [...] Read more.

The shape, size, and interfacial transition zone (ITZ) of aggregates significantly impact the nonlinear mechanical behavior of concrete. This study investigates concrete’s mechanical response and damage mechanisms by developing a three-dimensional, three-phase mesoscale model comprising coarse aggregates, mortar, and ITZ to explore the compressive performance of concrete. A method for simulating the random distribution of aggregates based on three-dimensional grid partitioning is proposed, where the value of each grid point represents the maximum aggregate radius that can be accommodated if the point serves as the aggregate center. Aggregates are generated by randomly selecting grid points that meet specific conditions, avoiding overlapping distributions and significantly improving computational efficiency as the generation progresses. This model effectively enhances the precision and efficiency of aggregate distribution and provides a reliable tool for studying the random distribution characteristics of aggregates in concrete. Additionally, an efficient discrete element model (DEM) was established based on this mesoscale model to simulate the compressive behavior of concrete, including failure modes and stress–strain curves. The effects of aggregate shape and maximum aggregate size on the uniaxial compressive failure behavior of concrete specimens were investigated. Aggregate shape has a particular influence on the compressive strength of concrete, and the compressive strength decreases with an increase in maximum aggregate size. Combined with existing experimental results, the proposed mesoscale model demonstrates high reliability in analyzing the compressive performance of concrete, providing valuable insights for further research on the mechanical properties of concrete. Full article

(This article belongs to the Special Issue Advances in Pavement Materials and Civil Engineering)

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11 pages, 4704 KiB

Open AccessArticle

The Effect of Low-ΣCSL Grain Boundary Proportion on Molten Salt-Induced Hot Corrosion Behavior in Nickel-Based Alloy Welds

by Tingxi Chai, Youjun Yu, Hongtong Xu, Jing Han and Liqin Yan

Coatings 2025, 15(8), 882; https://doi.org/10.3390/coatings15080882 - 28 Jul 2025

Abstract

To enhance the molten salt corrosion resistance of Ni200 alloy plasma arc welds, the welds were subjected to tensile deformation followed by heat treatment. The grain boundary character distribution (GBCD) was analyzed using electron backscatter diffraction (EBSD) in conjunction with orientation imaging microscopy [...] Read more.

To enhance the molten salt corrosion resistance of Ni200 alloy plasma arc welds, the welds were subjected to tensile deformation followed by heat treatment. The grain boundary character distribution (GBCD) was analyzed using electron backscatter diffraction (EBSD) in conjunction with orientation imaging microscopy (OIM). A constant-temperature corrosion test at 900 °C was conducted to evaluate the impact of GBCD on the corrosion resistance of the welds. Results demonstrated that after processing with 6% tensile deformation, and annealing at 950 °C for 30 min, the fraction of low-ΣCSL grain boundaries increased from 1.2% in the as-welded condition to 57.3%, and large grain clusters exhibiting Σ3ⁿ orientation relationships were formed. During the heat treatment, an increased number of recrystallization nucleation sites led to a reduction in average grain size from 323.35 μm to 171.38 μm. When exposed to a high-temperature environment of 75% Na₂SO₄-25% NaCl mixed molten salt, the corrosion behavior was characterized by intergranular attack, with oxidation and sulfidation reactions resulting in the formation of NiO and Ni₃S₂. The corrosion resistance of Grain boundary engineering (GBE)-treated samples was significantly superior to that of Non-GBE samples, with respective corrosion rates of 0.3397 mg/cm²·h and 0.8484 mg/cm²·h. These findings indicate that grain boundary engineering can effectively modulate the grain boundary character distribution in Ni200 alloy welds, thereby enhancing their resistance to molten salt corrosion. Full article

(This article belongs to the Section Corrosion, Wear and Erosion)

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17 pages, 3329 KiB

Open AccessArticle

Mechanistic Insights into Corrosion and Protective Coating Performance of X80 Pipeline Steel in Xinjiang’s Cyclic Freeze–Thaw Saline Soil Environments

by Gang Cheng, Yuqi Wang, Yiming Dai, Shiyi Zhang, Bin Wei, Chang Xiao and Xian Zhang

Coatings 2025, 15(8), 881; https://doi.org/10.3390/coatings15080881 - 28 Jul 2025

Abstract

This study systematically investigated the corrosion evolution and protective mechanisms of X80 pipeline steel in Xinjiang’s saline soil environments under freeze–thaw cycling conditions. Combining regional soil characterization with laboratory-constructed corrosion systems, we employed electrochemical impedance spectroscopy, potentiodynamic polarization, and surface analytical techniques to [...] Read more.

This study systematically investigated the corrosion evolution and protective mechanisms of X80 pipeline steel in Xinjiang’s saline soil environments under freeze–thaw cycling conditions. Combining regional soil characterization with laboratory-constructed corrosion systems, we employed electrochemical impedance spectroscopy, potentiodynamic polarization, and surface analytical techniques to quantify temporal–spatial corrosion behavior across 30 freeze–thaw cycles. Experimental results revealed a distinctive corrosion resistance pattern: initial improvement (cycles 1–10) attributed to protective oxide layer formation, followed by accelerated degradation (cycles 10–30) due to microcrack propagation and chloride accumulation. Synchrotron X-ray diffraction analyses identified sulfate–chloride ion synergism as the primary driver of localized corrosion disparities in heterogeneous soil matrices. A comparative evaluation of asphalt-coated specimens demonstrated a 62%–89% corrosion rate reduction, with effectiveness directly correlating with coating integrity and thickness (200–500 μm range). Molecular dynamics simulations using Materials Studio revealed atomic-scale ion transport dynamics at coating–substrate interfaces, showing preferential Cl⁻ permeation through coating defects. These multiscale findings establish quantitative relationships between environmental stressors, coating parameters, and corrosion kinetics, providing a mechanistic framework for optimizing protective coatings in cold-region pipeline applications. Full article

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