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Protective Coatings for Metallic Materials
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Protective Coatings for Metallic Materials

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

Deadline for manuscript submissions: 20 October 2026 | Viewed by 4355

Editors

Dr. Krzysztof Szymkiewicz

E-Mail Website
Guest Editor
Department of Applied Mechanics and Biomechanics, Cracow University of Technology, 31-155 Cracow, Poland
Interests: titanium alloy; surface treatment; biomaterial; solid-state mechanics; microstructure analysis; numerical analysis; micromechanical modelling; composite
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Marek Goral

E-Mail Website
Guest Editor
Department of Material Science, Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, Powstancow Warszawy 12, 35-959 Rzeszow, Poland
Interests: thermal spraying process; hard coatings; diffusion coating; wear resistant coatings; plasma nitriding and pack boriding processes; coatings properties; superalloys; intermetallics (TiAl)
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Metallic materials such as titanium alloys, steels, aluminum and magnesium alloys are employed in many fields, such as the automotive industry, aviation or biomedical engineering. However,  their performance and longevity are often compromised by corrosion, wear, and extreme environmental conditions. Protective coatings offer a critical solution, enhancing the durability, functionality, and sustainability of metal substrates. Recent advances in coating technologies—such as nanostructured films, self-healing polymers, and eco-friendly alternatives—have provided new opportunities for innovation. We welcome the submission of original research articles and reviews that address fundamental challenges and emerging trends in this field. Contributions that highlight interdisciplinary approaches or industrial case studies are particularly welcome. Join us in advancing the science and technology of protective coatings in order to meet the demands of modern engineering applications.

Dr. Krzysztof Szymkiewicz
Prof. Dr. Marek Goral
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 250 words) can be sent to the Editorial Office for assessment.

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-anonymized 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

  • metallic materials
  • surface treatment
  • coating materials
  • corrosion
  • wear

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Published Papers (4 papers)

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Research

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13 pages, 19654 KB  
Article
Effect of Cu2P2O7 on the Formation of Black Micro-Arc Oxidation Coating on AZ31 Magnesium Alloy
by Jian Chen, Hongtao Li, Bo Chen and Kun Wang
Materials 2026, 19(4), 811; https://doi.org/10.3390/ma19040811 - 20 Feb 2026
Viewed by 729
Abstract
Magnesium alloys require protective surface coatings for widespread application, with micro-arc oxidation (MAO) being a prominent technique. However, conventional MAO coatings are typically gray or light-colored, necessitating secondary treatments for specific colors like black, which complicates the process. This study aims to develop [...] Read more.
Magnesium alloys require protective surface coatings for widespread application, with micro-arc oxidation (MAO) being a prominent technique. However, conventional MAO coatings are typically gray or light-colored, necessitating secondary treatments for specific colors like black, which complicates the process. This study aims to develop a one-step method for fabricating black MAO coatings on AZ31 magnesium alloy by introducing cupric pyrophosphate (Cu2P2O7) as a colorant into a silicate-based electrolyte. As the Cu2P2O7 concentration increased from 0 to 5 g/L, the coating color transitioned from grayish-white to pink, then brownish-black, achieving a uniform black appearance at 4–5 g/L. XPS and EDS analyses confirmed the incorporation of copper as CuO, identified as the primary coloring agent. XRD indicated that the phase composition remained MgO, MgSiO3, and Mg, although the MgO content decreased. Microstructural analysis showed that an optimal concentration of 4 g/L enhanced coating compactness by thickening the dense layer and reducing pore size. However, electrochemical tests revealed that the incorporation of CuO significantly increased the corrosion current density, thereby reducing the coating’s corrosion resistance compared to the unmodified coating. This work successfully demonstrates the one-step fabrication of black MAO coatings, elucidates the coloration mechanism involving CuO formation, and provides insights into the trade-off between aesthetic functionalization and corrosion performance. Full article
(This article belongs to the Special Issue Protective Coatings for Metallic Materials)
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22 pages, 7932 KB  
Article
Preparation and Characterization of Oxide Coatings with LDH Nanosheets on AZ91 Magnesium Alloy by a One-Step Low Voltage Microarc Oxidation Process
by Longfeng Shi, Xuchen Lu, Peixuan Li, Cancan Liu and Jun Liang
Materials 2026, 19(2), 216; https://doi.org/10.3390/ma19020216 - 6 Jan 2026
Viewed by 1112
Abstract
In this study, oxide coatings with layered double hydroxide (LDH) nanosheets were prepared on AZ91 magnesium alloy by a one-step low-voltage microarc oxidation (MAO) process. The microstructure and composition of the coatings were characterized using SEM, EDS, XRD, FT-IR, and XPS. The corrosion [...] Read more.
In this study, oxide coatings with layered double hydroxide (LDH) nanosheets were prepared on AZ91 magnesium alloy by a one-step low-voltage microarc oxidation (MAO) process. The microstructure and composition of the coatings were characterized using SEM, EDS, XRD, FT-IR, and XPS. The corrosion protection performance of the coatings was evaluated by electrochemical analysis and hydrogen evolution tests. The results showed that oxide coatings with Mg-Al-LDH nanosheets are successfully produced by microarc oxidation at a voltage of less than 100 V. The coating with a higher density of Mg-Al LDH nanosheets exhibited enhanced corrosion resistance. Moreover, after modification with stearic acid, the coatings displayed high hydrophobicity and corrosion resistance. Full article
(This article belongs to the Special Issue Protective Coatings for Metallic Materials)
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18 pages, 8789 KB  
Article
Optimization of Plasma-Sprayed CeScYSZ Thermal Barrier Coating Parameters and Investigation of Their CMAS Corrosion Resistance
by Rongbin Li, Keyu Wang and Ziyan Li
Materials 2025, 18(22), 5114; https://doi.org/10.3390/ma18225114 - 11 Nov 2025
Cited by 2 | Viewed by 990
Abstract
Thermal barrier coatings (TBCs) are critical for protecting hot-section components in gas turbines and aero-engines. Traditional yttria-stabilized zirconia (YSZ) coatings are prone to phase transformation and sintering-induced failure at elevated temperatures. This study fabricated CeScYSZ (4 mol% CeO2 and 6 mol% Sc [...] Read more.
Thermal barrier coatings (TBCs) are critical for protecting hot-section components in gas turbines and aero-engines. Traditional yttria-stabilized zirconia (YSZ) coatings are prone to phase transformation and sintering-induced failure at elevated temperatures. This study fabricated CeScYSZ (4 mol% CeO2 and 6 mol% Sc2O3 co-doped YSZ)/NiCrAlY TBCs using atmospheric plasma spraying (APS). A five-factor, four-level orthogonal experimental design was employed to optimize spraying parameters, investigating the influence of powder feed rate, spray distance, current, hydrogen flow rate and primary gas flow rate on the coating’s microstructure and mechanical properties. The resistance to calcium–magnesium–alumino–silicate (CMAS) corrosion was compared between CeScYSZ and YSZ coatings. The results indicate that the optimal parameters are a spray distance of 100 mm, current of 500 A, argon flow rate of 30 L/min, hydrogen flow rate of 6 L/min, and powder feed rate of 45 g/min. Coatings produced under these conditions exhibited moderate porosity and excellent bonding strength. After exposure to CMAS corrosion at 1300 °C for 2 h, the CeScYSZ coating demonstrated significantly superior corrosion resistance compared to YSZ. This enhancement is attributed to the formation of a CaZrO3 physical barrier and the synergistic effect of Ce and Sc in suppressing deleterious phase transformations. This study provides an experimental basis for the preparation and application of high-performance TBCs. Full article
(This article belongs to the Special Issue Protective Coatings for Metallic Materials)
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Review

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25 pages, 437 KB  
Review
Oxidation-Resistant Coatings for TiAl Intermetallics—Short Review
by Marek Góral and Krzysztof Szymkiewicz
Materials 2026, 19(7), 1408; https://doi.org/10.3390/ma19071408 - 1 Apr 2026
Viewed by 1008
Abstract
This article presents a review of current trends in the development of protective coatings for TiAl alloys. These materials have been indicated as potential replacements for nickel-based alloys for several decades; however, many problems related to their application have not yet been solved, [...] Read more.
This article presents a review of current trends in the development of protective coatings for TiAl alloys. These materials have been indicated as potential replacements for nickel-based alloys for several decades; however, many problems related to their application have not yet been solved, such as low resistance to oxidation and high-temperature corrosion, limited wear and erosion resistance, as well as susceptibility to microstructural changes under demanding conditions. Research in this area has been conducted for many years; nevertheless, new concepts and types of coatings are constantly being developed, particularly for third- and fourth-generation TiAl alloys. This article presents a review and classification of protective coatings used for TiAl alloys, with particular emphasis on research results published in the scientific literature of the last decade. In addition to a literature review concerning coating types and applied technologies, new trends and concepts in this field proposed by the co-authors will also be presented. Full article
(This article belongs to the Special Issue Protective Coatings for Metallic Materials)
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