Search Results (218)

This study was conducted to explore how varying the concentration of nano-La₂O₃ particles in the plating bath influences the morphology, constitution, and corrosion resistance of Ni-B composite coatings deposited on N80 carbon steel via electroless plating. The novelty of this work lies in the systematic investigation on the co-deposition behavior and grain refinement mechanism of nano-La₂O₃ in electroless Ni-B system, which has been rarely reported in previous studies. The microstructure and chemical composition of the coatings were characterized through a combination of SEM, EDS, XPS and XRD analyses. SEM confirmed that a dense Ni-B/La₂O₃ composite coating was formed, with a uniform thickness of approximately 10 μm, and the nano-La₂O₃ particles were evenly distributed. XPS analysis verified the presence of B, C, O, Ni and La, while XRD analysis revealed a refinement in crystalline size due to the addition of the nanoparticles. The corrosion resistance enhancement mechanism is attributed to the triple synergistic effect: nano-La₂O₃ pins grain boundaries and refines Ni-B grains to the minimum average size of 12.943 nm at the optimal concentration of 8 g·L⁻¹; the refined grain structure promotes the formation of a continuous and dense Ni(OH)₂ passive film; the uniformly dispersed nanoparticles act as physical barriers to block the penetration of corrosive media. Electrochemical measurements demonstrated that this coating exhibited outstanding anti-corrosion performance, as confirmed by a remarkably positive corrosion potential (E_corr = −0.37189 V) and a minimal corrosion current density (I_corr = 3.7524 μA/cm²). The results conclusively show that nano-La₂O₃ reinforcement effectively enhances the corrosion protection performance of electroless Ni-B alloy coatings. Full article

In this study, Fe₇₀Ni₃₀ metal was deposited onto continuous glass fiber composites via magnetron sputtering, followed by surface coating with SiO₂. The effects of key process parameters-including Fe₇₀Ni₃₀ sputtering duration (2, 5, 10, 20, and 30 min) and SiO₂ surface coating-on the electromagnetic properties and microwave absorption performance of the materials were systematically investigated. Scanning electron microscopy (SEM) characterization revealed that as sputtering time increased, the metal coating evolved from discrete small particles into a continuous film. Cross-sectional SEM analysis further demonstrated the formation of a bilayer structure after SiO₂ introduction. X-ray diffraction (XRD) patterns confirmed the presence of diffraction peaks corresponding to the Fe₇₀Ni₃₀ alloy solid solution. Electromagnetic parameter measurements indicated that the influence of sputtering time on electromagnetic properties was primarily pronounced during the metal layer growth stage; once a continuous film was formed, the variation in electromagnetic parameters diminished. Concurrently, the SiO₂ coating exhibited a significant regulatory effect on dielectric parameters. Reflection coefficient calculations showed that the optimal absorption thickness for the single-layer material ranged from 2.5 to 3.0 mm, with the absorption peak shifting toward lower frequencies as thickness increased. However, the effective absorption bandwidth (EAB) was only 3–5 GHz, failing to meet wideband requirements. In contrast, the three-layer composite structure (total thickness: 3.8 mm) optimized via genetic algorithm achieved impedance gradient and loss synergy, expanding the EBW (R < −10 dB) from 4.8 GHz (single layer) to 10 GHz (8–18.0 GHz)-a substantial improvement over the single-layer configuration. This work provides experimental evidence and technical support for the structural design and process optimization of lightweight, high-efficiency, wideband microwave-absorbing materials. Full article

Worn roller mill roll shafts made of Steel 45 require cost-effective surface restoration; plasma transferred arc (PTA) deposition of Ni–Cr–B–Si + WC composite coatings is a promising approach, yet the effect of arc current on coating quality remains insufficiently characterised for this substrate. Six coatings were deposited from PS-12NVK-01 powder (65 wt.% PG-10N-01 + 35 wt.% WC) at arc currents of 50–100 A on Steel 45 substrates using a ZTW3501DC PTA system; coatings were characterised by SEM, EDS mapping, XRD (HighScore Plus, PDF-2), Vickers microhardness profiling, and ball-on-flat tribological testing. EDS analysis revealed that compositional dilution increases from 18.1% at 60 A to 46.6% at 100 A; XRD identified WC + Cr₃C₂ + Ni₃B + Ni₂B + (Fe,Ni)γ at 50 A, transitioning through Cr₇C₃ + W₂C dominance at 80 A to an Fe₀.₆₄Ni₀.₃₆ matrix at 100 A; and coating thickness peaked at 2.70 mm at 80 A. The 60 A coating yielded the highest surface hardness (887 ± 76 HV, >4× the substrate), the lowest specific wear rate (4.00 × 10⁻⁶ mm³/(N·m), ~22× lower than uncoated Steel 45), and minimum dilution (18.1%), identifying 60 A as the most favourable deposition current for the restoration of roller mill roll shafts under the process parameters employed. Full article

Lightweight high-entropy alloy (HEA) coatings are highly desirable for advanced surface protection. This study presents a novel fabrication method for Al-Mg-Ti-Cu-Ni-Cr lightweight HEA coatings via laser cladding combined with in situ alloying, using a specially designed cable-type composite wire consisting of an Al-Mg core sheathed with Cu, Ti, Ni, and Cr-Ni wires. The fabricated coatings exhibit homogeneous composition, high microhardness, and excellent corrosion resistance. Notably, the Al_43.5Mg₂Ni₂₈Cu₁₅Ti_11.5 coating achieves a microhardness of 627 HV_0.1 and a corrosion current density of 5.5 × 10⁻⁶ A/cm², while the Al_43.6Mg_2.1Cr_2.5Ni_25.2Cu_15.2Ti_11.4 coating shows 523 HV_0.1 and a lower current density of 2.8 × 10⁻⁶ A/cm². Mechanical analysis reveals that the enhanced hardness stems from synergistic strengthening effects—severe lattice distortion, B2 phase coherent precipitation, and grain refinement. The superior corrosion resistance is primarily attributed to a compact Cr₂O₃ passive film. This work provides a new strategy for designing and additively manufacturing lightweight HEA coatings. Full article

The functional valorization of waste fabrics, particularly their conversion into flexible low-cost, high-performance electrodes, holds significant promise for resource sustainability and the development of advanced energy technologies. Here, a NiB/Cu/polyester fabric (PF) composite electrode was fabricated via two-step electroless plating on waste PF and was demonstrated as a bifunctional electrocatalyst for methanol oxidation (MOR) and urea oxidation (UOR). The morphology, crystal structure, surface chemical state, and wettability of the electrodes were characterized using SEM, TEM, XRD, XPS, and contact angle measurements. The Cu interlayer critically enhanced interfacial wettability, intrinsic catalytic activity and stability. At 0.8 V, the NiB/Cu/PF electrode delivered average current densities of 312 mA·cm⁻² for MOR and 288 mA·cm⁻² for UOR, outperforming NiB/PF by 27.9% and 9.1%, respectively. After 2000 accelerated degradation cycles with electrolyte renewal, MOR and UOR activities were retained at 91.6% and 105.0%, respectively. Remarkably, the Cu interlayer conferred exceptional mechanical–electrochemical robustness: following 100 sequential bending and twisting deformations, current density retention ranged from 84.6% to 96.7% across multiple test configurations. The Cu interlayer acted as a flexible stress buffer during mechanical deformation, effectively improving the adhesion between the coating and the substrate. Full article

High-speed laser cladding shows significant potential for application in the field of high-performance surface hardening due to its low heat input and high cladding efficiency. However, the pool solidification time is significantly reduced at high scanning speeds, resulting in a narrower process window and making it more difficult to ensure coating formation stability and control performance. Therefore, this study employed high-speed laser cladding technology to prepare FeCrNiB alloy coatings, and systematically conducted research on process parameter optimization and friction properties. Firstly, the response surface method (RSM) was used to establish quantitative relationship models between laser power, scanning speed, and powder feed rate and the dilution ratio, forming coefficient, and microhardness. Then, the hybrid differential evolution and NSGA-II algorithm (DE-NSGA-II) was employed for multi-objective optimization. Finally, a systematic analysis was conducted on the friction and wear properties of the coatings produced under the optimal process parameters. The results indicate that the interaction between laser power and scanning speed has a significant impact on the dilution behavior of the coating, while the coupling between scanning speed and powder feed rate governs the formation characteristics and microhardness evolution of the coating. The experiment verified that the prediction error for the optimal parameters is controlled within 5%, demonstrating good engineering applicability. Further analysis indicates that grain refinement and the formation of strengthening phases in the optimal coating are the key mechanisms behind the significant improvement in hardness and wear resistance, and the coating primarily exhibits a mild abrasive wear mechanism. This work realizes the multi-objective optimization of the high-speed laser cladding process via RSM and DE-NSGA-II algorithm, which provides a novel and efficient method for parameter optimization and engineering application of high-speed laser cladding. Full article

Three Ni-based composite coatings with varying TiCN/h-BN contents were fabricated on the surface of Ti-6Al-4V (TC4) alloy by laser cladding. The coatings were formulated with a fixed 15% TiCN and 0%, 2% and 5% h-BN, corresponding to L1–L3 coatings. The microstructure and phase composition were fully characterized and investigated. In addition, the microhardness and wear resistance of the coating were evaluated too. The analysis revealed that the L1–L3 coatings primarily consisted of Ti, TiNi, Ti(C, N) and TiAl₃ phases. Microstructural analysis indicated that the top region of the coating was predominantly composed of granular crystals, while the middle and bonding regions featured a combination of dendrites and white granular crystals. The average microhardness values for the L1–L3 coatings were measured at 1203.8, 1216.8 and 1235.5 HV_0.2, respectively, while the corresponding wear volumes were 0.098, 0.094 and 0.086 mm³. As the h-BN content increased, the microstructure of the Ni-based composite coating became finer and finer. Some TiB particles were also generated in the coating, which made the average microhardness and wear resistance increase gradually. Notably, the coating with 5% h-BN demonstrated the highest average microhardness and optimal wear resistance. Compared with the substrate, 5% h-BN increased the wear resistance of the substrate by 47.6%. The primary wear mechanism observed was abrasive wear. Full article

Under the conditions of laser power of 1500 W, scanning speed of 5 mm/s, spot diameter of 3.5 mm, and powder feeding rate of 10 r/min, this study systematically investigated the influence of different tempering temperatures (200 °C and 600 °C) on the microstructure, friction and wear properties, and corrosion resistance of laser cladding Ni25 coatings, as well as the underlying mechanisms. The phase composition, microstructure, chemical composition, wear resistance, and corrosion resistance of the coatings were characterized and analyzed using X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), pin-on-disk friction and wear tests, and electrochemical workstations. The results showed that the as-clad coating was composed of γ-Ni supersaturated solid solution and various metastable borides/carbides (such as Cr₃B₄), presenting fine-grained and non-equilibrium features. Tempering at 200 °C mainly achieved stress relaxation, enhancing and shifting the diffraction peaks to the left without changing the phase composition, while tempering at 600 °C drove significant diffusion-type phase transformation, leading to the decomposition of metastable Cr₃B₄ and the precipitation of stable phases such as Ni₂Si, accompanied by grain growth and microstructure coarsening. Friction tests indicated that the coating tempered at 600 °C exhibited the lowest average friction coefficient (0.679) and wear volume (0.0582 mm³) due to stable microstructure and hard phase strengthening, demonstrating the best wear resistance. However, electrochemical tests revealed a “trade-off” effect: the fine-grained microstructure of the as-clad coating, with its uniform composition, had the lowest corrosion current density (8.10 × 10⁻⁵ A/cm²) in 3.5% NaCl solution, showing the best resistance to uniform corrosion, while tempering, especially at 600 °C, caused grain growth, coarsening of the second phase, and micro-galvanic effects, slightly reducing the anodic dissolution resistance and increasing the corrosion current. This study clarified that heat treatment can significantly enhance the mechanical and tribological properties of Ni25 coatings by regulating their transformation from metastable to stable states, but at the potential cost of some corrosion resistance, providing a theoretical basis for optimizing post-treatment processes for different service conditions (wear resistance or corrosion resistance). Full article

Layered nickel-rich cathodes are regarded as promising cathode materials for lithium-ion batteries (LIBs) due to their higher electrochemical capacities and lower cost. However, the development and commercial application of nickel-rich cathodes are severely hindered by significant capacity fading under a high charge cut-off voltage (4.5 V), which arises from interfacial instability and bulk structural degradation during charge–discharge processes. In this study, a two-step double-coating strategy was innovatively adopted to successfully synthesize Al₂O₃/LiBO₂ co-coated LiNi_0.71Co_0.09Mn_0.2O₂ cathode material (denoted as NCM-Al/B). X-ray photoelectron spectroscopy (XPS) verified that Al existed stably in the form of Al³⁺, and B formed B-O-M covalent bonds with transition metals (Ni/Co/Mn), constructing a dual-element synergistic interface. This interface significantly reduced the surface Ni³⁺ content and enhanced the structural stability by suppressing the H₂→H₃ phase transition. The NCM-Al/B material exhibits excellent electrochemical performance: it maintains a remarkable cycling stability with a capacity retention of 91.6% after 100 cycles at 1 C and 25 °C and delivers a discharge capacity of 156.6 mAh·g⁻¹ with a capacity retention of 75.4% after 100 cycles at a high rate of 1 C. This work establishes a chemically driven double-coating strategy and provides a new paradigm for optimizing the performance of high-nickel cathode materials. Full article

This study investigated the properties of a composite NiCrFeSiB coating with fine-dispersed WC additives, deposited by the HVOF method. The NiCrFeSiB powder alloy with WC additives was applied to a steel substrate. The WC content in the coating was 10, 15, and 20% by weight. The particle size distribution of the mixture ranged from 3 to 10 µm. The WC used was the WC8 alloy (92% WC, 8% Co). The levels of stress, phase composition, hardness, wear resistance, and coating structure were investigated. The studies revealed that the structure was primarily composed of the γ-Ni-Fe solid solution phase, with secondary phases including Ni₃B, Fe₃B, (Cr,)₂B, and carbides of the W₂C, WC, M₇C₃ type. A small amount of the initial WC particles was also present. The use of a fine-dispersed NiCrFeSiB powder mixture with WC particles resulted in a nearly twofold increase in hardness and wear resistance compared to the same parameters of the coating without WC. The coating with 20% WC exhibited the highest hardness. However, its wear resistance was lower than that of the coating with 15% WC. This fact could be explained by a slight difference in the phase composition and an increase in the proportion of the unsolidified WC phase in the structure. This led to the spalling of fine particles and a reduction in wear resistance. The study demonstrated the feasibility of using a fine-dispersed NiCrFeSiB coating with WC additives without additional remelting. Similar hardness and wear resistance results were achieved immediately after HVOF spraying when using a fine-dispersed NiCrFeSiB + 15% WC/Co mixture with a 92/8 composition. This simplification of the technology reduced the coating application process time. It also lowered production costs by eliminating the remelting stage. Full article

The antimicrobial activity of multicomponent, magnetron-sputtered glass coatings was evaluated against phytopathogenic fungi (Botrytis cinerea, Fusarium oxysporum, Cladosporium fulvum, Alternaria solani) and the chromista Phytophthora infestans, with Aspergillus fumigatus included as a model opportunistic pathogen. Fourteen Cu-based multicomponent coatings were deposited on glass using multi-alloy targets composed of Sn, Zn, Al, Ni, Fe, Ti, Mn, Nb, or Co in two high-transmittance variants (≥85% and ≥88%). Antimicrobial activity was assessed in two assays: (A) spore survival after 24–72 h contact, and (B) hyphal growth over 7 days following coating exposure under light and dark conditions. Spore viability decreased after incubation on high-Cu coatings, which showed inhibition for most strains, particularly B. cinerea, F. oxysporum, and P. infestans. The effects on spore germination were independent of the direct transmittance value of the coated glass. Hyphal growth was generally less affected by a high Cu content for most strains. Hyphal growth of F. oxysporum, C. fulvum, A. solani and B. cinerea was reduced by up to 30% on selected multicomponent coatings. For most strains, hyphal growth showed no inhibition after light incubation on coatings. However, light-dependent effects were observed for A. solani, A. fumigatus and P. infestans, while B. cinerea and C. fulvum showed reduced sensitivity during the first two days. High-Cu coatings were most effective at inhibiting spore germination, whereas hyphal growth on multicomponent coatings may respond to different ions. Therefore, high-Cu, two-component coatings may be recommended for practical greenhouse applications. Full article

To address the growing problem of electromagnetic pollution, the development of intelligent, multifunctional electromagnetic shielding materials is essential. The objective of this work is to fabricate an intelligent, low-reflection and high-absorption electromagnetic shielding composite via direct ink writing. In this study, epoxy resin (EP) was employed as the matrix, with nickel powder (Ni), multi-walled carbon nanotubes (MWCNTs), and silver powder (Ag) serving as functional fillers. Direct-ink printing enabled the fabrication of uniformly structured composites and layered gradient-structured composites. By precisely varying the filler content through layer-by-layer printing, the gradient-structured composite exhibited an increasing electrical conductivity gradient and a decreasing magnetic permeability gradient along the direction of electromagnetic wave incidence. Comprehensive characterization of microstructure, electrical, magnetic, and dielectric properties, and electromagnetic shielding effectiveness revealed that the uniformly structured composites exhibited higher total shielding effectiveness (SE_T) and reflection coefficient (R) with increased electrical conductivity. The layered gradient-structured composite achieved an electrical conductivity of 5.44 S/m and an SE_T of 17.74 dB, with the R value reduced to 0.53. Compared to the highly conductive homogeneous composite used in the bottom layer (R = 0.87), this represents a reduction in reflectivity of approximately 39.1%, thereby mitigating secondary pollution from excessive reflection. Under a DC voltage of 200 V, all composites recovered their original shape within 63 s, with shape fixity (R_f) and recovery (R_r) ratios exceeding 92%. This strong shape memory capability supports conformal coating on complex devices and facilitates material recycling, offering a practical foundation for next-generation multifunctional electromagnetic shielding materials. Full article

In this study, amorphous Fe₆₀Nb₃B₁₇Si₆Cr₆Ni₄Mo₄ coatings were prepared using the high-velocity air fuel method. The microstructure, wear resistance, and corrosion resistance of the Fe₆₀Nb₃B₁₇Si₆Cr₆Ni₄Mo₄ coatings were examined for various levels of nanocrystallization. In contrast to the as-sprayed coating, the samples that were heat-treated formed partial α-Fe and crystalline Cr₂O₃. The generated nanocrystals exerted a dispersion-strengthening effect on the coatings, leading to enhanced hardness and fracture toughness. When the annealing temperature was below the initial crystallization temperature, the wear resistance improved by approximately 1.65 times, the wear rate decreased to half of that in the as-sprayed state, and the depth of the wear scar reduced. However, the resistance of the coatings to corrosion deteriorated as the degree of crystallization increased. X-ray photoelectron spectroscopy analysis revealed that heat treatment modified the composition of the passive film, thereby influencing its corrosion resistance. These results provide crucial insights into the application of Fe-based amorphous coatings in wear- and corrosion-resistant environments. Full article

This study systematically investigates the influence of laser power (1000 W, 1400 W, 1800 W) on the microstructure and properties of Ni25 alloy coatings prepared by laser cladding to optimize process parameters for enhanced comprehensive performance. Through the analysis of multi-dimensional characterization, it is found that the laser power significantly changes the thermal cycle, thus determining the evolution of microstructure. At 1000 W, a fine dendritic structure with dispersed hard phases (BNi₃, BFe₃Ni₃, CrB₂, Cr₇C₃) yielded the highest hardness (442.52 HV) but poor wear (volume loss: 0.3346 mm³) and corrosion resistance (Icorr: 2.75 × 10⁻⁴ A·cm⁻²) due to microstructural inhomogeneity. The 1400 W coating, featuring a uniform γ-Ni dendrite/eutectic network and increased B solid solubility, achieved an optimal balance with the lowest wear rate (0.0685 mm³), superior corrosion resistance (Icorr: 2.34 × 10⁻⁵; A·cm⁻²), and a stable friction coefficient (0.816), despite lower hardness (342.00 HV). At 1800 W, grain coarseness and Cr₇C₃ decomposition led to blocky hard phases, recovering hardness (415.36 HV) and reducing the friction coefficient (0.757), but resulting in intermediate wear and corrosion resistance. This study demonstrates that the uniformity and continuity of the microstructure are the key determinants governing the comprehensive service properties of the laser cladding layer, with their importance outweighing a single hardness index. 1400 W is identified as the optimal laser power, providing critical insights for fabricating high-performance Ni25 coatings in demanding service environments. Full article

In this study, a multiphysics coupling numerical model was developed to investigate the thermal-fluid dynamics and microstructure evolution during the laser metal deposition of AlCoCrFeNi high-entropy alloy (HEA) coatings on 430 stainless steel substrates. The model integrated laser-powder interactions, temperature-dependent material properties, and the coupled effects of buoyancy and Marangoni convection on melt pool dynamics. The simulation results were compared with experimental data to validate the model’s effectiveness. The simulations revealed a strong bidirectional coupling between temperature and flow fields in the molten pool: the temperature distribution governed surface tension gradients that drove Marangoni convection patterns, while the resulting fluid motion dominated heat redistribution and pool morphology. Initially, the Peclet number (Pe_T) remained below 5, indicating conduction-controlled heat transfer with a hemispherical melt pool. As the process progressed, Pe_T exceeded 50 at maximum flow velocities of 2.31 mm/s, transitioning the pool from a circular to an elliptical geometry with peak temperatures reaching 2850 K, where Marangoni convection became the primary heat transfer mechanism. Solidification parameter distributions (G and R) were computed and quantitatively correlated with scanning electron microscopy (SEM)-observed microstructures to elucidate the columnar-to-equiaxed transition (CET). X-ray diffraction (XRD) analysis identified body-centered cubic (BCC), face-centered cubic (FCC), and ordered B2 phases within the coating. The resulting hierarchical microstructure, transitioning from fine equiaxed surface grains to coarse columnar interfacial grains, synergistically enhanced surface properties and established robust metallurgical bonding with the substrate. Full article