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Metals
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Surface Treatments and Coating of Metallic Materials
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Surface Treatments and Coating of Metallic Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Corrosion and Protection".

Deadline for manuscript submissions: 30 November 2025 | Viewed by 3251

Special Issue Editor

Dr. Luca Pezzato

E-Mail Website
Guest Editor
Institute of Condensed Matter Chemistry and Energy Technologies (ICMATE), National Research Council of Italy, 35127 Padova, Italy
Interests: corrosion; coatings; steels; light alloys
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Surface treatments and coating technologies are of extremely high interest in the metallurgical sector because they permit the functionalization of the metal surface, thus modifying the part of the metal that interacts with the environment and permitting the obtaining of particular properties that cannot be obtained with only the bulk material. The properties that can be modified with surface treatments are of a very wide range; the most common treatments are performed in order to improve the wear and corrosion properties of the metals, but treatments are also often performed in order to give some particular functionality to the metal surfaces. Classification of the surface treatments is generally performed on the basis of the thickness of the coating (thick or thin coating) or on the basis of the type of deposition (deposition from the liquid, solid, or vapor phase). The type of coating generally depends both on the type of application of the final product and on the composition of the metallic substrate.

The purpose of this Special Issue is to publish studies that deal with the surface treatments of metallic materials. These may include, but are not limited to, the following:

-Coatings deposited from the vapor phase (PVD, CVD, and PA-CVD);

-Coatings deposited from the liquid phase: anodizing, plasma electrolytic oxidation, other conversion treatments, electroplating of metallic coatings, hot-dip galvanizing, or electroless deposition;

-Coatings deposited from the solid phase: thermal spray coating, laser cladding, or welded coatings; <>I invite you to submit both original contributions and review works on these topics, with papers that deal both with the production method and with the characterization of the coatings produced on the different metal substrates.

Dr. Luca Pezzato
Guest Editor

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. Metals 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

  • coatings
  • surface treatments
  • corrosion resistance
  • wear resistance
  • PVD
  • CVD
  • PEO
  • anodizing
  • electroplating
  • hot-dip galvanizing
  • thermal spray
  • laser cladding

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Published Papers (5 papers)

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Research

17 pages, 3897 KB  
Article
Physical–Mechanical and Corrosion Resistance Characterization of a Water-Based Epoxy Primer Applied to Galvanized Steel
by Rosalia Galiotto, Solidea Zanetti, Rocco Traini and Luca Pezzato
Metals 2025, 15(11), 1196; https://doi.org/10.3390/met15111196 - 27 Oct 2025
Abstract
This study presents a comprehensive characterization of a commercial water-based epoxy primer applied to galvanized steel sheets, which are commonly used in building and construction applications. The investigation focused on evaluating the primer’s adhesion, mechanical strength, chemical resistance, and corrosion protection under various [...] Read more.
This study presents a comprehensive characterization of a commercial water-based epoxy primer applied to galvanized steel sheets, which are commonly used in building and construction applications. The investigation focused on evaluating the primer’s adhesion, mechanical strength, chemical resistance, and corrosion protection under various environmental and thermal conditions. Particular attention was given to the effect of substrate sanding prior to application, which was found to influence the coating thickness and surface adaptation. The results demonstrated that the primer provides effective barrier properties and good adhesion to the metal surface, with average pull-off strengths remaining consistent across aged and unaged samples. Electrochemical impedance spectroscopy (EIS) confirmed high polarization resistance values, indicating strong corrosion protection, while SEM-EDS analysis revealed the presence of zinc phosphate and titanium dioxide fillers contributing to both passive and active inhibition mechanisms. However, the primer exhibited sensitivity to ultraviolet (UV) radiation, as evidenced by FT-IR spectra showing increased absorbance in the hydroxyl and carbonyl regions after prolonged exposure. A preliminary estimation of the photodegradation rate, based on FT-IR data at the carbonyl peak (1739 cm−1), yielded a value of approximately 2 × 10−6 absorbance units per hour between 3000 h and 5000 h of UV exposure. This value suggests a gradual degradation process, although further quantitative validation is required. Additional limitations were observed, including variability in coating thickness due to manual application and localized blistering at cut edges under salt spray conditions. These findings contribute to a deeper understanding of the primer’s behavior and suggest improvements for its practical use, such as the application of a protective topcoat and optimization of the coating process. Full article
(This article belongs to the Special Issue Surface Treatments and Coating of Metallic Materials)
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35 pages, 3189 KB  
Article
In Situ and Laboratory Investigation of the Anti-Corrosion and Anti-Fouling Efficacy of an Innovative Biocide-Free Coating for Naval Steels
by Polyxeni Vourna, Pinelopi P. Falara and Nikolaos D. Papadopoulos
Metals 2025, 15(9), 1000; https://doi.org/10.3390/met15091000 - 9 Sep 2025
Viewed by 637
Abstract
This study presents an in situ and laboratory evaluation of an innovative biocide-free nanocomposite coating designed to provide dual anti-corrosion and anti-fouling protection for EH36 naval steel in marine environments. The coating, comprising polyaniline nanorods, titanium dioxide nanoparticles, and Fe3O4 [...] Read more.
This study presents an in situ and laboratory evaluation of an innovative biocide-free nanocomposite coating designed to provide dual anti-corrosion and anti-fouling protection for EH36 naval steel in marine environments. The coating, comprising polyaniline nanorods, titanium dioxide nanoparticles, and Fe3O4-functionalized multiwalled carbon nanotubes embedded in a robust resin matrix, was systematically assessed through electrochemical, microscopic, and field-based methods. Laboratory immersion tests and extended exposures at two Mediterranean sea sites (Thessaloniki and Heraklion) revealed substantial improvements in corrosion resistance and significant suppression of marine biofouling over periods of up to 24 months. Electrochemical measurements demonstrated that coated specimens maintained a corrosion inhibition efficiency exceeding 93% throughout the study, exhibiting markedly lower corrosion current densities and higher charge transfer resistances than uncoated controls. Impedance spectroscopy and equivalent circuit modeling confirmed sustained barrier properties, while digital imaging and qualitative biological assessments showed reduced colonization by both micro- and macrofouling organisms. Comparative analysis with conventional biocidal and alternative eco-friendly coatings underscored the superior durability, environmental compatibility, and anti-fouling efficacy of the developed system. The results highlight the coating’s promise as a sustainable, high-performance solution for long-term protection of naval steels against the combined challenges of corrosion and biofouling in harsh marine settings. Full article
(This article belongs to the Special Issue Surface Treatments and Coating of Metallic Materials)
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13 pages, 2701 KB  
Article
Surface Enhancement of CoCrMo Bioimplant Alloy via Nanosecond and Femtosecond Laser Processing with Thermal Treatment
by Hsuan-Kai Lin, Po-Wei Chang, Yu-Ming Ding, Yu-Ting Lyu, Yuan-Jen Chang and Wei-Hua Lu
Metals 2025, 15(9), 980; https://doi.org/10.3390/met15090980 - 1 Sep 2025
Viewed by 580
Abstract
With an aging population, the number of joint replacement surgeries is on the rise. One of the most common implant materials is cobalt–chromium–molybdenum (CoCrMo) alloy. Hence, the surface properties of this alloy have attracted increasing attention. In this study, nanosecond and femtosecond laser [...] Read more.
With an aging population, the number of joint replacement surgeries is on the rise. One of the most common implant materials is cobalt–chromium–molybdenum (CoCrMo) alloy. Hence, the surface properties of this alloy have attracted increasing attention. In this study, nanosecond and femtosecond laser processing, followed by annealing, was employed to modify the CoCrMo surface. The effects of the treatment conditions on the surface morphology, structure, composition, hardness, roughness, contact angle, wear properties, and corrosion current were studied. Femtosecond laser processing with an energy density of 1273 mJ/cm2, followed by heat treatment at 160 °C for 2 h, produced laser-induced periodic surface structures (LIPSS) without altering the chemical composition of the alloy and rendered the surface superhydrophobic. In contrast, nanosecond laser treatment at higher laser energy densities promoted the formation of an oxide layer, which improved the hardness and corrosion resistance of the substrate. Overall, the CoCrMo samples processed using the femtosecond laser system exhibited superior corrosion and wear resistance, with a protection efficiency of approximately 92%. Full article
(This article belongs to the Special Issue Surface Treatments and Coating of Metallic Materials)
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20 pages, 6318 KB  
Article
Mechanical, Tribological, and Corrosion Behavior of Magnetron-Sputtered VN Coatings Deposited at Different Substrate Temperatures
by Stanislava Rabadzhiyska, Dimitar Dechev, Nikolay Ivanov, Maria Shipochka, Genoveva Atanasova, Velichka Strijkova, Vesela Katrova and Nina Dimcheva
Metals 2025, 15(9), 955; https://doi.org/10.3390/met15090955 - 28 Aug 2025
Viewed by 772
Abstract
Vanadium nitride (VN) ceramic layers were deposited on 304L stainless steel specimens by direct current (DC) magnetron sputtering in an Ar/N2 gas mixture at substrate temperatures of 250 °C, 300 °C, and 350 °C. The obtained films were evaluated by X-ray diffraction [...] Read more.
Vanadium nitride (VN) ceramic layers were deposited on 304L stainless steel specimens by direct current (DC) magnetron sputtering in an Ar/N2 gas mixture at substrate temperatures of 250 °C, 300 °C, and 350 °C. The obtained films were evaluated by X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), and atomic force microscopy (AFM). The results showed the existence of VN and V2N phases in the as-deposited coatings. It was found that the surface roughness parameter (Ra = 10 nm) decreased with increasing substrate temperatures up to 350 °C. The highest hardness (10.6 GPa) was achieved in the layer produced at 300 °C. The low values of plastic and elastic deformation, as well as a low friction coefficient (0.38), led to an enhancement in the coatings’ tribological properties. The film’s thickness increased with increasing temperature due to the presence of nucleation centers in the films. The highest thickness (557 nm) was achieved in the layer deposited at 350 °C. The electrochemical tests exhibited reliable protection against corrosion in strongly aggressive electrolytes. It has been proven that the temperature significantly affects the ceramic coatings’ structural, morphological, tribological, and corrosion properties. Full article
(This article belongs to the Special Issue Surface Treatments and Coating of Metallic Materials)
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14 pages, 3669 KB  
Article
Facile Approach for Fabrication of Hydrophobic Aluminum Alloy Surfaces Using Fatty Acids
by Alina Matei, Oana Brincoveanu and Vasilica Ţucureanu
Metals 2025, 15(8), 884; https://doi.org/10.3390/met15080884 - 7 Aug 2025
Viewed by 616
Abstract
Alloys and metals exhibit high sensitivity to corrosion and aggressive environments. Hence, the development of protective treatments through accessible methods with a high degree of protection has become a necessity. This paper presents a method for treating the hydrophilic surface of aluminum alloys [...] Read more.
Alloys and metals exhibit high sensitivity to corrosion and aggressive environments. Hence, the development of protective treatments through accessible methods with a high degree of protection has become a necessity. This paper presents a method for treating the hydrophilic surface of aluminum alloys using two types of unsaturated fatty acids, thereby increasing the degree of hydrophobicity and protecting the material. The samples were cleaned by a chemical process, followed by immersion in oleic acid (C18H34O2, 18:1 cis-9) and elaidic acid (C18H34O2, 18:1 trans-9), and they were then treated at a temperature of 80 °C. Morphological and microstructural analyses were conducted using OM, FE-SEM, EDX, and FTIR to understand the influence of unsaturated monocarboxylic fatty acids on the alloy surfaces. The wettability capacity of the alloys was investigated by measuring the contact angle (CA). The results revealed that the cleaning step and modification treatment with fatty acids are essential steps for increasing the hydrophobic character of the surface. This study can be applied to various types of metallic substrates to enhance their corrosion resistance and long-term chemical stability in aggressive environments, making it adaptable for use in different industrial fields. Full article
(This article belongs to the Special Issue Surface Treatments and Coating of Metallic Materials)
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