Search Results (20)

This work demonstrates the possibility of creating effective composite coatings with a complex structure and phase composition on carbon steel C45 via electrospark deposition (ESD) with multicomponent electrodes with a bonding mass composition of Co-Ni-Cr-B-Si semi-self-fluxing alloys and superhard compounds WC, B₄C and TiB₂. The variation in the roughness, thickness, composition, structure, microhardness and wear at the friction of the coatings as a function of the ratios between the bonding mass and the high-hardness components in the composition of the electrode and of the pulse energy for ESD has been studied. It has been established that with a content of the bonding mass in the electrode of 25–35%, coatings with improved adhesion and simultaneously higher hardness and toughness are obtained. Suitable electrode compositions and optimal pulse energy have been defined, which provide dense and uniform coatings with an increased amount of crystalline-amorphous structures, as well as intermetallic and wear-resistant phases, with thickness, roughness and microhardness that can be changed by the ESD modes in the ranges of δ = 8–65 µm, Ra = 1.5–7 µm, and HV 8.5–15.0 GPa, respectively, and minimal wear of the coated surfaces that is up to 5 times lower than that of the substrate and up to 1.5 times lower than that obtained with conventional WC-Co electrodes. Full article

CoCrFeNiMn high-entropy alloy (HEA) composite coatings with 0, 10, and 20 wt% TiC are synthesized through laser cladding technology, and their corrosion and wear resistance are systematically investigated. The X-ray diffraction (XRD) results show that with the addition of TiC, the phases of TiC and M₂₃C₆ are introduced, and lattice distortion occurs simultaneously (accompanied by the broadening and leftward shift of the main Face-Centered Cubic (FCC) peak). Scanning electron microscopy (SEM) reveals that the incompletely melted TiC particles in the coating (S2) are uniformly distributed in the matrix with 20 wt% TiC, while in the coating (S1) with 10 wt% TiC, due to gravitational sedimentation and decomposition during laser processing, the distribution of the reinforcing phase is insufficient. When rubbed against Si₃N₄, with the addition of TiC, S2 exhibits the lowest friction coefficient of 0.699 and wear volume of 0.0398 mm³. The corrosion resistance of S2 is more prominent in the simulated seawater (3.5 wt% NaCl). S2 shows the best corrosion resistance: it has the largest self-corrosion voltage (−0.425 V vs. SCE), the lowest self-corrosion current density (1.119 × 10⁻⁷ A/cm²), and exhibits stable passivation behavior with a wide passivation region. Electrochemical impedance spectroscopy (EIS) confirms that its passivation film is denser. This study shows that the addition of 20 wt% TiC optimizes the microstructural homogeneity and synergistically enhances the mechanical strengthening and electrochemical stability of the coating, providing a new strategy for the making of HEA-based layers in harsh wear-corrosion coupling environments. Full article

High-Power Impulse Magnetron Sputtering (HiPIMS) has emerged as an excellent technology for producing high-quality nitride coatings, such as aluminum nitride (AlN), titanium nitride (TiN), chromium nitride (CrN), and silicon nitride (SiN), and composite nitride coatings such as titanium aluminum nitride (TiAlN), TiAlNiCN, etc. These coatings are known for their exceptional hardness, thermal stability, and corrosion resistance. These make them ideal for high-performance applications. HiPIMS distinguishes itself by generating highly ionized plasmas that facilitate intense ion bombardment, leading to nitride films with superior mechanical strength, durability, and enhanced thermal properties compared to traditional deposition techniques. Critical HiPIMS parameters, including pulse duration, substrate bias, and ion energy, are analyzed for their influence on enhancing coating density, adhesion, and hardness. The review contrasts HiPIMS with other deposition methods, highlighting its unique ability to create dense, uniform coatings with improved microstructures. While HiPIMS offers substantial benefits, it also poses challenges in scalability and process control. This review addresses these challenges and discusses hybrid, bipolar, and synchronized HiPIMS solutions designed to optimize nitride coating processes. Hybrid HiPIMS, for instance, combines HiPIMS with other sputtering techniques like DCMS or RF sputtering to achieve balanced deposition rates and high-quality film properties. Bipolar HiPIMS enhances process stability and film uniformity by alternating the polarity, which helps mitigate charge accumulation issues. Synchronized HiPIMS controls precise pulse timing to maximize ion energy impact and improve substrate interaction, further enhancing the structural properties of the coatings. Hence, to pave the way for future research and development in this area, insights of the HiPIMS have been presented that underline the role of HiPIMS in meeting the demanding requirements of advanced industrial applications. Overall, this review article comprehensively analyzes the recent strategies and technological innovations in HiPIMS and highlights the significant potential of HiPIMS for advancing the nitride coating field. Full article

Nickel electrodeposition is a widely utilized method for creating thin films on various substrates with various desirable attributes. Recently, there has been a growing interest in developing nickel composite coatings that incorporate additional elements or particles into the nickel matrix to enhance their properties. These composite coatings offer superior corrosion resistance, hardness, tribological, and other functional benefits compared with pure nickel coatings. Some of the recent advancements in electrodeposited nickel composite coatings include improved wear resistance, enhanced mechanical properties, and better corrosion resistance. Researchers have discovered that reinforcing the nickel matrix with Al₂O₃, SiC, ZrO₂, WC, and TiO₂ particles to obtain nickel composite coatings can significantly enhance all these important functional properties of various substrates. The uniform distribution of these particles within the nickel matrix acts as a barrier to wear and tear. Studies have also shown that nickel composite coatings with those particles exhibit superior mechanical properties, including increased hardness. These particles help to refine the grain size of the nickel matrix and deter movements that may cause defects, leading to greater mechanical strength. Moreover, nickel composite coatings offer improved protection against corrosion compared with pure nickel coatings. This review provides a detailed discussion of nickel composite coatings with regard to their comparative advantages compared with pure nickel coatings on different substrates. Full article

This research aimed to investigate the effects of input power and gas flow rate on the composition, microstructure, and mechanical properties of TiZrHfNiCuCo metallic coatings. These metallic coatings were deposited on a p-type Si wafer using a direct current magnetron sputtering system with varying input powers (100–300 W) and Ar flow rates (5–20 sccm). It was observed that increasing input power and decreasing Ar flow rate led to TiZrHfNiCuCo metallic coatings with higher hardness and smoother surfaces. The experiment resulted in the formation of a metallic amorphous coating. This study describes the mechanism by which the mechanical properties of the TiZrHfNiCuCo coating change according to sputtering parameters. Based on these results, the effects of sputter variables, such as input power and gas flow rate properties, on the properties of coatings are discussed. Full article

TiAl alloys are used in high-temperature components such as the turbine blades of aeroengines because of their excellent properties. However, TiAl alloys are prone to thermal corrosion when in near-ocean service. In order to solve this problem, a hot-corrosion-resistant CrAl/NiCoCrAlY/AlSiY gradient composite coating was prepared on the surface of the TiAl alloy. The phase composition and morphology of the coating were analyzed. Hot corrosion tests of the traditional NiCoCrAlY coating and CrAl/NiCoCrAlY/AlSiY gradient composite coating on a TiAl substrate were performed. The samples were coated with 75%Na₂SO₄ + 25%NaCl salt film and treated at 950 °C for 100 h, and the corrosion products were analyzed. The results indicate that compared with the TiAl substrate and traditional NiCoCrAlY-coated samples, the composite coating showed better hot corrosion resistance, only slightly cracking, and no corrosion loss occurred. This is mainly because the continuous Al₂O₃ layer can effectively resist the damage caused by the melting reaction in salt, and the Cr-rich layer can not only slow the mutual diffusion of elements but also generate a good corrosion resistance chromium oxide protective layer under serious corrosion. Moreover, the corrosion mechanism of the TiAl substrate, traditional NiCoCrAlY coating, and experimental composite coating was analyzed in detail. Full article

The functionality of the NiTi shape memory alloy was improved through engineering Ag-SiO₂-TiO₂ nanocomposite coatings. For this purpose, an anaphoretic deposition process, conducted at a constant voltage of 40 V and deposition times ranging from 1 to 10 min, was used. Scanning electron microscopy (SEM) analysis demonstrated that the deposition parameters significantly impacted the morphology of the coatings. Complementary Raman Spectroscopy and X-ray diffraction (XRD) analyses confirmed the successful formation of distinct nanocomposite layers, and revealed the details of their crystalline structure and chemical composition. After that, the adhesion between the NiTi substrate and the electrophoretically deposited ceramic coatings was improved through a post-deposition heat treatment. To prevent excessive shrinkage and cracking of the coating, tests were carried out to characterize the behavior of the coating material at elevated temperatures. The nanocomposite coatings were exposed to a temperature of 800 °C for 2 h. The annealing induced significant structural and morphological transformations, resulting in layers that were distinctly different from both the original materials and those produced solely through electrophoretic deposition. The thermal treatment resulted in the formation of a new kind of nanocomposite structure with enhanced reactivity. Full article

In this paper, Ni60/WC wear-resistant coatings have been created on the Ti6Al4V substrate surface using a pre-layered powder laser cladding method by deploying various scanning speeds of 8, 10, 12, and 14 mm/s. The coatings are characterized through X-ray diffraction (XRD), scanning electron microscopy (SEM), and a high-speed reciprocating fatigue wear tester. It is found that the phase composition of the coating comprises the synthesized, hard phase TiC and TiB₂, the silicides WSi₂ and W5Si₃, and NiTi and γ-Ni solid solutions. At different scanning speeds, there is a metallurgical fusion line in the bonding area of the fused cladding layer, indicating a good metallurgical bonding between the substrate and the powder. At a low scanning speed, the coating develops into coarse dendrites, which shows significant improvement with scanning speed. The microhardness first increases and then decreases with the scanning speed, and the coating’s average microhardness was 2.75–3.13 times higher than that of the substrate. The amount of mass wear has been reduced by 60.1–79.7% compared to the substrate. The wear behavior of the coatings was studied through detailed analysis of wear surfaces’ microstructures and the amount of wear to identify the optimum scanning speed. Full article

Surface-enhanced Raman scattering (SERS) spectroscopy is used to investigate a composition of wash swabs from the Cu-TiO₂/TiO₂-modified filters with disinfecting ability. Macroporous Si chips coated with conformal 800 nm thick Ni layer and Ag particles (Ag/Ni) are engineered to act as SERS-active substrates. Such substrates are characterized by a moderate reflection band in the visible range and provide an improved heat dissipation from contaminants in wash swabs during SERS study. This prevents thermal-induced destruction of analyzing media for reliable assessment of its composition. The anatase Cu-TiO₂ and TiO₂ nanoparticles are synthesized using the sol-gel method and characterized via Raman spectroscopy and X-ray diffractometry. The filters are modified with Cu-TiO₂/TiO₂ nanoparticles and embedded in three-valve facial masks that are worn by a volunteer to breathe for 4 h. Comparative SERS analysis of the filters shows that they slightly destroy chemical bonds in the molecules constituting airborne contaminations upon ceiling day lights, which can be associated with Cu-TiO₂ photocatalytic activity. The filters additionally exposed to near-ultraviolet light prominently decrease the intensity of Raman signatures of airborne contaminant due to the presence of pure TiO₂. Full article

In the present work, abrasive and erosive wear of wear-resistant composite coatings with a complex structure and different phase compositions deposited on titanium surfaces was studied. The coatings were obtained by electrospark deposition (ESD) using two types of hard-alloy compositions: WC–TiB₂–B₄C–Co–Ni–Cr–Si–B and TiB₂–TiAl reinforced with dispersed nanoparticles of ZrO₂ and NbC. The influence of the ESD process parameters on the roughness, thickness, composition, structure and coefficient of friction of the coated surfaces was investigated, and their role in protecting the titanium surfaces from wear was clarified. Dense coatings with the presence of newly formed wear-resistant phases and crystalline-amorphous structures were obtained, with roughness, thickness and microhardness that can be varied by the ESD modes in the range Ra = 2.5 ÷ 4.5 µm, δ = 8 ÷ 30 µm and HV 8.5 ÷ 14.0 GPa. The new coatings were found to reduce the abrasive and erosive wear of the coated surfaces by up to four times. The influence of the geometric characteristics, composition and structure of coatings on the wear intensity and wear resistance of coatings was studied. Full article

Achieving a higher quality in wire arc additive manufacturing (WAAM) is a result of the development of welding metallurgy, the development of filler wires, and the control of the thermophysical properties of the electric arc. In this paper, the authors developed composite wires for WAAM with a Ni-LaF₃, Ni-LaB₆ coating. The addition of LaF₃, LaB₆, and SF₆ increases specific heat, thermal conductivity, enthalpy, and degree of plasma ionization, which leads to the increase in the transfer of heat from the arc plasma to the wire and to the change in the balance of forces during wire melting. The increase in the Lorentz electromagnetic force and the decrease in the surface tension force made it possible to reduce the droplet diameter and the number of short circuits during wire melting. The change in the thermophysical properties of the plasma and droplet transfer with the addition of LaF₃, LaB₆, and SF₆ made it possible to increase the welding current, penetration depth, accuracy of the geometric dimensions of products in WAAM, reduce the wall thickness of products, and refine the microstructure of the weld metal using G3Si1, 316L, AlMg5Mn1Ti, and CuCr0.7 wires. Full article

The aim of this paper is to conduct an experimental study in order to obtain a roughness (Ra) prediction model for dry end-milling (with an AlTiCrSiN PVD-coated tool) of the Co–28Cr–6Mo and Co–20Cr–15W–10Ni biomedical alloys, a model that can contribute to more quickly obtaining the desired surface quality and shortening the manufacturing process time. An experimental plan based on the central composite design method was adopted to determine the influence of the axial depth of cut, feed per tooth and cutting speed process parameters (input variables) on the Ra surface roughness (response variable) which was recorded after machining for both alloys. To develop the prediction models, statistical techniques were used first and three prediction equations were obtained for each alloy, the best results being achieved using response surface methodology. However, for obtaining a higher accuracy of prediction, ANN models were developed with the help of an application made in LabView for roughness (Ra) prediction. The primary results of this research consist of the Co–28Cr–6Mo and Co–20Cr–15W–10Ni prediction models and the developed application. The modeling results show that the ANN model can predict the surface roughness with high accuracy for the considered Co–Cr alloys. Full article

The study is devoted to the development and testing of technological principles for the manufacture of solid end mills from ceramics based on a powder composition of α-SiAlON, β-SiAlON, and TiN additives, including spark plasma sintering powder composition, diamond sharpening of sintered ceramic blanks for shaping the cutting part of mills and deposition of anti-friction Si-containing diamond-like carbon (DLC) coatings in the final stage. A rational relationship between the components of the powder composition at spark plasma sintering was established. The influence of optimum temperature, which is the most critical sintering parameter, on ceramic samples’ basic physical and mechanical properties was investigated. DLC coatings’ role in changing the surface properties of ceramics based on SiAlON, such as microrelief, friction coefficient, et cetera, was studied. A comparative analysis of the efficiency of two tool options, such as developed samples of experimental mills made of SiAlON/TiN and commercial samples ceramic mills based on SiAlON, doped with stabilizing additives containing Yb when processing nickel alloys (NiCr20TiAl alloy was used as an example). DLC coatings’ contribution to the quantitative indicators of the durability of ceramic mills and the surface quality of machined products made of nickel alloy is shown. Full article

Recent years have seen the dynamic development of methods for functionalizing the surface of implants using biomaterials that can mimic the physical and mechanical nature of native tissue, prevent the formation of bacterial biofilm, promote osteoconduction, and have the ability to sustain cell proliferation. One of the concepts for achieving this goal, which is presented in this work, is to functionalize the surface of NiTi shape memory alloy by an atypical glass-like nanocomposite that consists of SiO₂-TiO₂ with silver nanoparticles. However, determining the potential medical uses of bio(nano)coating prepared in this way requires an analysis of its surface roughness, tribology, or wettability, especially in the context of the commonly used reference coat-forming hydroxyapatite (HAp). According to our results, the surface roughness ranged between (112 ± 3) nm (Ag-SiO₂)—(141 ± 5) nm (HAp), the water contact angle was in the range (74.8 ± 1.6)° (Ag-SiO₂)—(70.6 ± 1.2)° (HAp), while the surface free energy was in the range of 45.4 mJ/m² (Ag-SiO₂)—46.8 mJ/m² (HAp). The adhesive force and friction coefficient were determined to be 1.04 (Ag-SiO₂)—1.14 (HAp) and 0.247 ± 0.012 (Ag-SiO₂) and 0.397 ± 0.034 (HAp), respectively. The chemical data showed that the release of the metal, mainly Ni from the covered NiTi substrate or Ag from Ag-SiO₂ coating had a negligible effect. It was revealed that the NiTi alloy that was coated with Ag-SiO₂ did not favor the formation of E. coli or S. aureus biofilm compared to the HAp-coated alloy. Moreover, both approaches to surface functionalization indicated good viability of the normal human dermal fibroblast and osteoblast cells and confirmed the high osteoconductive features of the biomaterial. The similarities of both types of coat-forming materials indicate an excellent potential of the silver-silica composite as a new material for the functionalization of the surface of a biomaterial and the development of a new type of functionalized implants. Full article

Titanium alloy has extensive applications in numerous fields, such as in aerospace, shipbuilding, petrochemical, and bio-medical. However, under the condition of high temperature (above 700 °C), it is difficult to meet the requirements of the performance of the turbine blades, piston rings, valves, etc. In this paper, the alloy powder is composed of Ni60A, TiN, Al, and Si in accordance with the proportion of 1:3:4:2 (mass ratio), and the composite coating, such as TiN, TiB, Ti₅Si₃, and Al₃Ti were synthesized on Ti-6Al-4V alloy by Yttrium Aluminium Garnet(YAG) laser. The friction and wear experiments were carried out on Ti-6Al-4V alloy and alloyed coatings at different loads (3N, 6N, 9N), and different temperatures (25 °C, 350 °C, 700 °C). The impact of load and temperature on wear performance were analyzed by analyzing the friction traces. The results showed that the abrasion loss, wear width, and depth, wear volume, and wear ratio of the alloyed coatings were less than Ti-6Al-4V alloy, and the surface of furrow was shallow and the wear was less. However, under high temperature conditions, the alloy coating wears worse than Ti-6Al-4V alloy, and the high temperature wear resistance is not ideal. Full article