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Advanced Coating Research for Metal Surface Protection
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Advanced Coating Research for Metal Surface Protection

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Thin Films and Interfaces".

Deadline for manuscript submissions: 20 January 2026 | Viewed by 4406

Special Issue Editors

Dr. Nadia Ucciardello

E-Mail Website
Guest Editor
Dipartimento di Ingegneria dell’Impresa “Mario Lucertini”, Università degli Studi di Roma "Tor Vergata", via del Politecnico, 1, 00133 Roma, Italy
Interests: heat treatment; welding; microstructure; mechanical properties; mechanical behavior of materials; metallurgical engineering; material characterization; mechanical testing; metals; materials; materials processing; advanced materials; corrosion; material characteristics; grain boundaries; plasticity; metal forming; materials testing; solidification; surface engineering; corrosion testing; dislocation mechanics; corrosion engineering; corrosion science; foundry; micromechanical testing; coating technology; compression; coatings science; recrystallisation; aluminium
Dr. Daniele Almonti

E-Mail Website
Guest Editor
Dipartimento di Ingegneria dell’Impresa “Mario Lucertini”, Università degli Studi di Roma "Tor Vergata", via del Politecnico, 1, 00133 Roma, Italy
Interests: graphene; electrodeposition technologies of innovative materials; simulation of manufacturing processes; additive manufacturing; characterization of coatings; foundry technologies, thermal management components

Special Issue Information

Dear Colleagues,

Metal surface protection is a critical area of research due to the wide range of applications in which it can be applied. Industries such as aerospace, automotive, marine, and electronics are constantly looking for innovative and high-performance solutions. With the increasing demand for materials that can withstand harsh environments and corrosion, there is a growing need for advanced coating solutions that offer superior protection and durability. From enhancing the longevity of critical infrastructure to revolutionizing the performance of next-generation electronics, coatings play a pivotal role in safeguarding metal surfaces against corrosion, wear, and environmental degradation.

This Special Issue aims to collect scientific contributions related to conventional or unconventional processes and highlight new aspects of processing and manufacturing methods, coating technology, and materials that can be used to produce high-performance components. Furthermore, characterization methods and computational approaches for modeling the process and material properties (such as numerical simulations, mathematical modeling, optimization, control, etc.) and contributions featuring an environmental impact analysis (LCA) are of interest.

Dr. Nadia Ucciardello
Dr. Daniele Almonti
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. Materials is an international peer-reviewed open access semimonthly 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

  • coating
  • surface protection
  • FEA
  • LCA
  • processing
  • manufacturing
  • filler
  • abrasive resistance
  • corrosion resistance
  • graphene

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Published Papers (5 papers)

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Research

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25 pages, 12591 KB  
Article
Electrochemical Synthesis of Mesoporous Alumina as an Adsorbent of Corrosion Inhibitors for Active Corrosion Protection in Organic Coatings
by Abenchara M. Betancor-Abreu, Javier Izquierdo, Raquel Rodríguez-Raposo, Ricardo A. Liria-Romero, Juan J. Santana and Ricardo M. Souto
Materials 2025, 18(18), 4375; https://doi.org/10.3390/ma18184375 - 19 Sep 2025
Viewed by 167
Abstract
This work describes a simple and economical electrochemical route for the generation of mesoporous alumina (MA) particles that can serve as containers for corrosion inhibitors for the active corrosion protection elements of metals when dispersed in organic coatings. The synthesis of precursor slurries [...] Read more.
This work describes a simple and economical electrochemical route for the generation of mesoporous alumina (MA) particles that can serve as containers for corrosion inhibitors for the active corrosion protection elements of metals when dispersed in organic coatings. The synthesis of precursor slurries was carried out in an electrochemical reactor with aluminum electrodes operating alternately as anodes and cathodes to facilitate metal dissolution and prevent passivation of the electrode surface. The obtained slurries were thermally treated to produce mesoporous alumina particles with adsorbent characteristics suitable for loading corrosion inhibitors. Benzotriazole (BTA) and 8-hydroxyquinoline (8HQ) were chosen as corrosion inhibitors. Dispersed in a commercial polymer matrix and applied to the coating of mild steel samples, the loaded MA improved the corrosion resistance of the coated metal exposed to a simulated marine environment. When physical damage is intentionally caused to expose the underlying metal, the polymer matrix containing BTA-loaded alumina particles retards the corrosion process due to the swelling of the inhibitor from the particles to the exposed bare metal in the scratch. Electrochemical impedance spectroscopy (EIS) measurements showed a marked increase in low-frequency impedance in coatings containing alumina particles, with the BTA-loaded system providing the most durable protection over extended immersion times (with a 50% improvement in corrosion resistance of steel exposed within the scratch). This demonstrates the potential of this approach for long-term corrosion protection applications. Full article
(This article belongs to the Special Issue Advanced Coating Research for Metal Surface Protection)
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14 pages, 1366 KB  
Article
Screw Coating as a Solution to Solve Screw Loosening Complications: An In Vitro Study
by Lara Coelho, Maria-Cristina Manzanares-Céspedes, Joana Mendes, Carlos Aroso and José Manuel Mendes
Materials 2025, 18(12), 2921; https://doi.org/10.3390/ma18122921 - 19 Jun 2025
Viewed by 576
Abstract
Background: This study aimed to evaluate the influence of a screw coating on the screw preload and removal torque value (RTV) with and without the application of a cyclic load (CL) to make screws with greater untightening resistance to prevent screw loosening. Methods [...] Read more.
Background: This study aimed to evaluate the influence of a screw coating on the screw preload and removal torque value (RTV) with and without the application of a cyclic load (CL) to make screws with greater untightening resistance to prevent screw loosening. Methods: Ninety complexes composed of implants, abutments, and prosthetic screws were examined and tested under CL oral conditions (n = 45) and non-CL conditions (nCL, n = 45). Each group was divided into three subgroups (n = 15): a control group (CG) without a screw coating, a GapSeal®-coated screw group (GG), and a polytetrafluoroethylene (PTFE) tape-wrapped screw group (PG). All screws were tightened at 30 Ncm, and the preload was recorded. In the nCL group, the screws were untightened to record the RTV. In the CL group, the screws were tightened, subjected to a CL in distillated water at a temperature of 37 °C, and then untightened to record the RTV. Micro-Ct analysis was conducted on two samples from each group before CL. SEM analyses of two samples per subgroup before and after CL were also performed. Results: The preload in the PG was significantly lower under nCL (29.92 Ncm) compared with CG (30.95 Ncm) and GG (31.19 Ncm) and also under a CL (PG: 30.92 Ncm) compared with CG (31.72 Ncm) and GG (31.42 Ncm). The RTVs of the PG were significantly lower under nCL (15.30 Ncm) compared with CG (27.98 Ncm) and GG (28.46 Ncm). Under CL, the RTVs of the PG were significantly higher (31.50 Ncm) compared with CG (26.00 Ncm) and GG (27.44 Ncm). Conclusions: Wrapping the screw with PTFE tape significantly reduced the preload but resulted in a significantly greater RTV under CL conditions in the simulated oral environment, suggesting that this could be a solution to decrease the risk of screw loosening. Full article
(This article belongs to the Special Issue Advanced Coating Research for Metal Surface Protection)
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19 pages, 33714 KB  
Article
Microstructure and Wear Behavior of WMoTaNbV Refractory High-Entropy Alloy Coating on Ti6Al4V Alloy Surface Prepared by Laser Cladding
by Jiazhu Liang, Hongxi Liu, Qinghua Zhang, Ling Zhou and Yuanrun Peng
Materials 2025, 18(8), 1770; https://doi.org/10.3390/ma18081770 - 12 Apr 2025
Cited by 1 | Viewed by 697
Abstract
WMoTaNbV refractory high-entropy alloys (RHEAs) have received widespread attention due to their excellent low-temperature toughness, hardness, and wear resistance. In recent years, the rapid development of surface modification technology represented by laser cladding has provided a new technological path for RHEA surface forming, [...] Read more.
WMoTaNbV refractory high-entropy alloys (RHEAs) have received widespread attention due to their excellent low-temperature toughness, hardness, and wear resistance. In recent years, the rapid development of surface modification technology represented by laser cladding has provided a new technological path for RHEA surface forming, and at the same time put forward higher requirements for raw material powder. In this study, WMoTaNbV RHEA spherical powder was prepared by radiofrequency plasma spheronization, and then WMoTaNbV RHEA coating was prepared on the surface of Ti6Al4V (TC4) alloy by laser cladding technique. The experimental results show that the prepared alloy powders have very high sphericity and are almost free of agglomeration and oxidation. Coatings with laser powers of 3.1–3.9 kW (gradient setting of 2 kW) were tested, with the 3.3, 3.5, and 3.7 kW coatings showing the best of the abrasion resistance. The microhardness of the 3.3 kW, 3.5 kW, and 3.7 kW coatings was 1.72, 1.97, and 1.76 times higher than that of the substrate, and the wear resistance was 1.83, 3.42, and 2.13 times higher than that of the TC4 substrate, respectively. This experimental result shows that the surface hardness and wear resistance of WNbMoTaV RHEA coating can be effectively improved by precisely regulating the laser power, thus improving the surface hardness and friction and wear properties of TC4 titanium alloy. Full article
(This article belongs to the Special Issue Advanced Coating Research for Metal Surface Protection)
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18 pages, 9431 KB  
Article
Enhanced Wear Resistance and Thermal Dissipation of Copper–Graphene Composite Coatings via Pulsed Electrodeposition for Circuit Breaker Applications
by Daniele Almonti, Daniel Salvi, Nadia Ucciardello and Silvia Vesco
Materials 2024, 17(23), 6017; https://doi.org/10.3390/ma17236017 - 9 Dec 2024
Cited by 7 | Viewed by 1461
Abstract
Copper, though highly conductive, requires improved wear resistance and thermal dissipation in applications that involve continuous movement and current-induced vibrations, such as power breakers. Conventional solutions, such as copper–tungsten alloys or lubricant use, face limitations in durability, friction, or environmental impact. This study [...] Read more.
Copper, though highly conductive, requires improved wear resistance and thermal dissipation in applications that involve continuous movement and current-induced vibrations, such as power breakers. Conventional solutions, such as copper–tungsten alloys or lubricant use, face limitations in durability, friction, or environmental impact. This study explores the development of copper–graphene (Cu-GNPs) composite coatings using pulsed electrodeposition to enhance the tribological, thermal, and mechanical properties of circuit breaker components by adopting an industrially scalable technique. The influence of deposition bath temperature, duty cycle, and frequency on coating morphology, hardness, wear resistance, and heat dissipation was systematically evaluated using a 23 full factorial design and an Analysis of Variance (ANOVA). The results revealed that optimized pulsed electrodeposition significantly improved coating performance: hardness increased by 76%, wear volume decreased by more than 99%, and friction coefficient stabilized at 0.2, reflecting effective graphene integration. The addition of graphene further improved thermal diffusivity by 19.5%, supporting superior heat dissipation. These findings suggest that pulsed copper–graphene composite coatings offer a promising alternative to traditional copper alloys, enhancing the lifespan and reliability of electronic components through improved wear resistance, lower friction, and superior heat transfer. Full article
(This article belongs to the Special Issue Advanced Coating Research for Metal Surface Protection)
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Review

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37 pages, 14524 KB  
Review
Recent Developments in Layered Double Hydroxides as Anticorrosion Coatings
by Alessandra Varone, Riccardo Narducci, Alessandra Palombi, Subhan Rasulzade, Roberto Montanari and Maria Richetta
Materials 2025, 18(15), 3488; https://doi.org/10.3390/ma18153488 - 25 Jul 2025
Viewed by 776
Abstract
To date, one of the main problems associated with the engineering application of metallic materials is corrosion protection. To increase their durability and reduce damage, a variety of protection methods have been studied and applied. In recent decades, coating techniques have become increasingly [...] Read more.
To date, one of the main problems associated with the engineering application of metallic materials is corrosion protection. To increase their durability and reduce damage, a variety of protection methods have been studied and applied. In recent decades, coating techniques have become increasingly important. Among these coatings, Layered Double Hydroxides (LDHs) have shown unique properties, such as ion exchange, high adhesion, and hydrophobicity, particularly useful for biomedical applications. In this review, after a detailed exposition of the LDHs’ synthesis processes, the most recent corrosion protection methods are illustrated. Intercalation of corrosion inhibitors and release kinetics of intercalates are presented. Although this work is mainly focused on laboratory-scale investigations and fundamental research, the problems inherent to large-scale industrial manufacturing and application are outlined and briefly discussed. Full article
(This article belongs to the Special Issue Advanced Coating Research for Metal Surface Protection)
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