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Surface Treatments and Coating of Metallic Materials

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

Deadline for manuscript submissions: closed (30 November 2025) | Viewed by 11018

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Dr. Luca Pezzato

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Institute of Condensed Matter Chemistry and Energy Technologies, National Research Council of Italy, 35127 Padova, Italy
Interests: metallurgy; corrosion; coatings
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 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-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 (12 papers)

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Editorial

Jump to: Research, Review

5 pages, 174 KB

Open AccessEditorial

Surface Treatments and Coating of Metallic Materials

by Luca Pezzato

Metals 2026, 16(4), 386; https://doi.org/10.3390/met16040386 - 31 Mar 2026

Viewed by 313

Abstract

The growing demand for high-performance materials in sectors such as aerospace, automotive, biomedical engineering, and energy systems has elevated surface engineering to a key discipline of modern materials science [...] Full article

(This article belongs to the Special Issue Surface Treatments and Coating of Metallic Materials)

Research

Jump to: Editorial, Review

20 pages, 3861 KB

Open AccessArticle

Picolinoyl N4-Phenylthiosemicarbazide-Modified ZnAl and ZnAlCe Layered Double Hydroxide Conversion Films on Hot-Dip Galvanized Steel for Enhancing Corrosion Protection in Saline Solution

by Thu Thuy Pham, Anh Son Nguyen, Chien Thang Pham, Hong Nhung Nguyen, Maurice Gonon, Lisa Dangreau, Xavier Noirfalise, Thuy Duong Nguyen, Thi Xuan Hang To and Marie-Georges Olivier

Metals 2026, 16(1), 115; https://doi.org/10.3390/met16010115 - 19 Jan 2026

Viewed by 457

Abstract

ZnAl and ZnAlCe layered double hydroxide (LDH) conversion layers modified with picolinoyl N4-phenylthiosemicarbazide (HL) are fabricated on hot-dip galvanized steel (HDG) to improve corrosion protection. X-ray diffraction (XRD) confirms that HL molecules are not intercalated within the LDH interlayers, whereas Fourier transform infrared spectroscopy (FT-IR), X-ray photoelectron spectroscopy (XPS), and energy-dispersive X-ray spectroscopy (EDS) analyses reveal their surface adsorption. Moreover, scanning electron microscopy (FE-SEM) observations reveal that HL modification induces changes in surface morphology. After 168 h in 0.1 M NaCl, the LDH structure remains intact, and N and S signals are still detected, confirming the persistence of both the LDH layer and adsorbed HL molecules under corrosive conditions. During 168 h immersion in NaCl, electrochemical measurements indicate that the modified LDH layers exhibit higher corrosion resistance than the unmodified ones, with the ZnAlCe LDH/HL coating providing the most effective protection. Full article

(This article belongs to the Special Issue Surface Treatments and Coating of Metallic Materials)

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13 pages, 2505 KB

Open AccessArticle

An Experimental Investigation of the Influence of Deposition Power and Pressure on the Anti-Icing and Wettability Properties of Al-Doped ZnO Thin Films Prepared by Magnetron Sputtering

by Vandan Vyas, Kamlesh V. Chauhan, Sushant Rawal and Noor Mohammad Mohammad

Metals 2025, 15(12), 1389; https://doi.org/10.3390/met15121389 - 18 Dec 2025

Viewed by 451

Abstract

In the presented research, aluminum-doped zinc oxide (AZO) thin films were synthesized on high-power transmission lines using the RF magnetron sputtering process. The impact of deposition power (160 W to 280 W) and deposition pressure (2 Pa to 5 Pa), on key characteristics like material composition, wettability, anti-icing behavior, and average crystal size were analyzed. The optimization of wettability and anti-icing performance was carried out using two-factor, four-level design of the Taguchi method to study the combined effects of multiple parameters rather than the effect of a single parameter. Considerable variation in the water contact angle, from 92.3° to 123.6°, has been observed, suggesting an enhancement in hydrophobic nature with optimized condition. Anti-icing tests demonstrated that the coated surface delayed ice accumulation by approximately 4.56 times compared to the uncoated surface. X-ray diffraction (XRD) analysis was carried out to confirm notable changes in the intensity of the (002) peak along the c-axis, directly correlating with grain size modification. The change in surface roughness was studied using AFM and the results were compared to establish a relationship between surface roughness and average grain size. Overall, the findings highlight the critical role of deposition parameters and their interactions in modifying the surface and structural properties of AZO thin films, which demonstrates their potential application for improving the anti-icing performance of transmission lines. Full article

(This article belongs to the Special Issue Surface Treatments and Coating of Metallic Materials)

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17 pages, 4340 KB

Open AccessArticle

Corrosion Behavior upon Laser Surface Texturing AISI 430 Stainless Steel

by Edit Roxana Moldovan, Liana Sanda Baltes, Catalin Croitoru, Alexandru Pascu and Mircea Horia Tierean

Metals 2025, 15(12), 1387; https://doi.org/10.3390/met15121387 - 18 Dec 2025

Viewed by 542

Abstract

Laser surface texturing (LST) is an effective method for enhancing surface functionality, but its effect on corrosion resistance highly depends on texture design and processing parameters. This study investigates the influence of two LST patterns—orthogonal ellipses and concentric octo-donuts—applied with 1 to 20 repetitions on the corrosion resistance of AISI 430 ferritic stainless steel. Corrosion behavior was evaluated using potentiodynamic polarization in a 3.5 wt.% NaCl solution at room temperature, complemented by SEM and EDS analysis. The results indicate that while a single laser pass can maintain good corrosion resistance, increasing the number of repetitions significantly degrades performance. This is attributed to the disruption of the protective oxide layer, the introduction of residual stress, and the creation of localized sites for galvanic corrosion. Consequently, the study concludes that a low number of laser repetitions is crucial for preserving the corrosion resistance of LST-processed AISI 430 steel. Full article

(This article belongs to the Special Issue Surface Treatments and Coating of Metallic Materials)

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17 pages, 3850 KB

Open AccessArticle

Effect of Cryogenic Treatment on Microstructural Evolution and Tribological Properties of Ni-Co-Cr/SiC Nanocomposite Coatings

by Xinyi Yuan, Rongcheng Sheng, Yizhe Du, Dengfu Chen, Mujun Long and Huamei Duan

Metals 2025, 15(12), 1320; https://doi.org/10.3390/met15121320 - 29 Nov 2025

Viewed by 586

Abstract

To address the demands of modern high-speed and high-quality continuous casting production, depositing high-performance coatings on the surface of mold copper plates is critically important for extending the service life of continuous casting molds. To this end, a Ni-Co-Cr/SiC nanocomposite coating was developed, and cryogenic treatment was applied to further improve its hardness and wear resistance. This work systematically investigates the microstructural evolution and performance enhancement of the Ni-Co-Cr/SiC nanocomposite coating under different cryogenic treatment parameters, with special emphasis on the effects of treatment temperature on the coating’s microstructure, hardness, wear resistance, and adhesion to the substrate. The results demonstrate that decreasing the cryogenic treatment temperature and extending the holding time effectively refine the grains of the coating while simultaneously promoting the accumulation of microstrain and dislocation density. These changes lead to significant improvements in hardness, wear resistance, and interfacial bonding performance. Specifically, after direct immersion at −196 °C for 16 h, the coating reached a hardness value of 946.5 HV, and the wear rate was reduced to 0.032 mm³·(N·m)⁻¹, representing only 54.6% of that of the untreated coating. The dominant wear mechanism transitioned to a mixed mode of abrasive wear and oxidative wear. Moreover, the cryogenic treatment enhanced the stability of the coating-substrate adhesion. Full article

(This article belongs to the Special Issue Surface Treatments and Coating of Metallic Materials)

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20 pages, 30027 KB

Open AccessArticle

New Model for Estimating the Volume of Martensite Transformed Using Acoustic Emission Measurements During an Induction Hardening Process

by Erlantz Sola Llanos, Rafael Rodríguez, Marcos Aguirre, Carmelo Javier Luis-Pérez and Mario Javier Cabello

Metals 2025, 15(11), 1228; https://doi.org/10.3390/met15111228 - 7 Nov 2025

Viewed by 866

Abstract

The accurate detection and quantification of martensitic transformation in steel during quenching are essential for controlling the resulting material properties. Numerous studies have investigated this phenomenon using Acoustic Emission (AE) techniques, owing to the significant energy release associated with the transformation. However, no model based on acoustic emission currently exists that can estimate the martensite volume formed during induction hardening. In this work, a novel model is proposed to estimate the transformed martensite volume in induction hardening treatment, focused on the material, geometry, and AE settings used. By integrating acoustic emission data with conventional Vickers hardness measurements, the model parameters can be calibrated. Induction quenching experiments were carried out on cylindrical 42CrMo4 (AISI 4140) steel bars equipped with acoustic emission sensors to capture transformation-related events during heat treatment. The martensite volume after quenching was estimated from hardness values. Model calibration using the experimental acoustic emission data and martensite volume demonstrated strong agreement between predictions and experimental observations. The proposed model offers the potential for in-process monitoring of induction quenching, thereby reducing reliance on conventional characterization techniques. Full article

(This article belongs to the Special Issue Surface Treatments and Coating of Metallic Materials)

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17 pages, 3897 KB

Open AccessArticle

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

Viewed by 907

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 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

Open AccessArticle

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

Cited by 4 | Viewed by 1375

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-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

Open AccessArticle

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

Cited by 1 | Viewed by 970

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 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

Open AccessArticle

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 1194

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 (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

Open AccessArticle

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 1206

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 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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Review

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29 pages, 12009 KB

Open AccessFeature PaperEditor’s ChoiceReview

Anode Protection Strategies for Next-Generation Lithium–Oxygen Batteries: Toward Dendrite-Free Lithium Metal at Practical Current Densities

by Myeong-Chang Sung, Minhe Kim, Jiyoon Yu and Changhoon Choi

Metals 2025, 15(12), 1373; https://doi.org/10.3390/met15121373 - 15 Dec 2025

Cited by 1 | Viewed by 1084

Abstract

The promise of lithium–oxygen batteries lie not merely in their record-breaking theoretical energy density, but in the challenge of making such energy truly reversible. Rising as the key obstacle is the lithium metal anode, whose remarkable capacity and low potential come at the cost of dendritic growth, unstable solid electrolyte interphases, and relentless reactions with oxygen species. These instabilities, once overshadowed by cathode-related limitations, now define the frontier of research as current densities and energy demands approach practical levels. This review highlights recent progress in two complementary directions for anode protection: physical approaches, such as artificial protective layers, solid or functional separators, and oxygen-blocking interlayers that isolate and stabilize the surface; and chemical strategies, including electrolyte and additive design that enable in situ formation of LiF- and Li₃N-rich interfaces with high ionic conductivity and chemical robustness. Together, these approaches establish a unified framework for achieving dendrite-free and oxygen-resistant lithium interfaces. Mastering solid electrolyte interfacial stability rather than only cathode catalysis will ultimately determine whether lithium oxygen battery can evolve from laboratory prototypes to truly viable high-energy systems. Full article

(This article belongs to the Special Issue Surface Treatments and Coating of Metallic Materials)

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