Search Results (60)

Hydrogen possesses distinctive characteristics that position it as a potential energy carrier to substitute fossil fuels. Nonetheless, there is still an essential need to create secure and effective storage solutions prior to its broad application. The use of hydride-forming metals (HFMs) for hydrogen storage is a method that has been researched thoroughly over the past several decades. This study investigates the structural and chemical modifications in titanium (Ti) and zirconium (Zr) thin coatings over aluminum hydroxide (AlO₃) granules before and after hydrogenation. The materials were subjected to hydrogenation at 400 °C and 5 atm of hydrogen pressure for 2 h, with a hydrogen flow rate of 0.8 L/min. The SEM analysis revealed significant morphological changes, including surface roughening, a grain boundary separation, and microcrack formations, indicating the formation of metal hydrides. The EDS analysis showed a reduction in Ti and Zr contents post-hydrogenation, likely due to the formation of hydrides. The presence of hydride phases, with shifts in diffraction peaks indicating structural modifications due to hydrogen absorption, is confirmed by the XRD analysis. The FTIR analysis revealed dihydroxylation, with the removal of surface hydroxyl groups and the formation of new metal–hydride bonds, further corroborating the structural changes. The formation of metal hydrides was confirmed by the emergence of new peaks within the 1100–1200 cm⁻¹ range, suggesting the incorporation of hydrogen. Mathematical modeling based on the experimental parameters was conducted to assess the hydride formation and the rate of hydrogen penetration. The hydride conversion rate for Ti- and Zr-coated AlO₃ granules was determined to be 3.5% and 1.6%, respectively. While, the hydrogen penetration depth for Ti- and Zr-coated AlO₃ granules over a time of 2 h was found to be 1200 nm and 850 nm approximately. The findings had a good agreement with the experimental results. These results highlight the impact of hydrogenation on the microstructure and chemical composition of Ti- and Zr-coated AlO₃, shedding light on potential applications in hydrogen storage and related fields. Full article

Hybrid silane-based coatings were developed via the sol–gel process using two precursors, vinyltrimethoxysilane (VTMS) and tetraethoxysilane (TEOS), and subsequently deposited onto three titanium-based substrates: commercially pure titanium Grade 2, Ti6Al4V, and Ti13Nb13Zr. Comprehensive physicochemical characterization was performed, including microstructural (optical and SEM), topographical (3D roughness), spectroscopic (FTIR), and electrochemical (potentiodynamic) analyses. The coatings were continuous, transparent, smooth, and exhibited high gloss with no visible cracks or surface defects. Surface roughness (Sa ≈ 0.3 μm) was consistent across all samples and remained unaffected by both the VTMS to TEOS ratio and the substrate type. Coating thickness ranged from 8 to 15 μm, as confirmed by both digital microscopy and thickness gauge measurements. All coatings demonstrated strong adhesion to the substrates. FTIR analysis confirmed the presence of key functional groups, such as CH₂, C=C, C–H, Si–O–Si, Si–OH, Si–O–Ti, CH=CH₂, and O–Si–O, regardless of the substrate type. Electrochemical tests in Ringer’s solution showed excellent corrosion resistance, particularly for coatings with a VTMS to TEOS ratio of 1:1. Post-corrosion imaging confirmed the integrity of the coatings and their effectiveness as protective barriers in simulated physiological environments. These findings support the potential of VTMS/TEOS sol–gel coating as a surface modification strategy for biomedical titanium implants. Full article

This study investigates the role of Al alloying in tailoring the oxidation resistance of AlTiCrZrNbTa refractory high-entropy alloy (RHEA) coatings on Zry-4 substrates under high-temperature steam environments. Coatings with varying Al contents (0–25 at.%) were deposited via magnetron sputtering and subjected to oxidation tests at 1000–1100 °C. The results demonstrate that Al content critically governs oxidation kinetics and coating integrity. The optimal performance was achieved at 10 at.% Al, above which a dense, continuous composite oxide layer (Al₂O₃, TiO₂, Cr₂O₃) formed, effectively suppressing oxygen penetration and maintaining strong interfacial adhesion. Indentation tests confirmed enhanced mechanical integrity in Al-10 coatings, with minimal cracking post-oxidation. Excessive Al alloying (≥17 at.%) led to accelerated coating oxidation. This work establishes a critical Al threshold for balancing oxidation and interfacial bonding, providing a design strategy for developing accident-tolerant fuel cladding coatings. Full article

This study attempts to use fly ash as the brazing filler additive to increase the sustainable use of coal-fired power plant by-product materials. The experimental results show that adding 5 wt% fly ash into the Ag paste filler contributes to the interfacial reactions in heterogeneous reactive air brazing (RAB) of the ZrO₂ and Crofer alloy. The Ag-rich phase dominates the brazed zone. The interfacial reaction layers contain oxidation of the Cu-Ti coating layer, Crofer alloy, and the Si/Al-rich oxides from the fly ash particles. The 5% fly ash RAB joint maintained airtightness for 280 h under 2 psig helium at room temperature. When the test temperature was raised to 600 °C for 24 h, the pressure of the joint assembly still did not drop. When the fly ash addition was increased to 10 wt%, the joint assembly was no longer leak-free at room temperature. Many visible voids and cracks exist in the brazed zone and at the ZrO₂/braze and braze/Crofer interfaces. A high volume fraction of the fly ash particles results in many brittle Si/Al-rich oxides in the joint after RAB, and the fracture of these oxides significantly deteriorates the airtightness of the joint. This study shows the feasibility and potential of introducing 5 wt% fly ash particles to the Ag-rich paste filler during the RAB of ZrO₂ and Crofer for airtight applications. Full article

The article presents the results of a comparison of the wear resistance of coatings with a two-layer architecture (adhesion layer–wear-resistant layer) of Zr-ZrN, Zr-(Zr,Ti)N, Zr,Hf-(Zr,Hf)N, Zr,Nb-(Zr,Nb)N, Zr,Hf-(Ti,Zr,Hf)N, and Zr,Nb-(Ti,Zr,Nb)N coatings, deposited on a titanium alloy substrate. The wear resistance was studied using two different counterbodies: Al₂O₃ and steel. When in contact with the Al₂O₃ counterbodies, the best wear resistance was demonstrated by samples with Zr,Hf-(Zr,Hf)N and Zr,Nb-(Zr,Nb,Ti)N coatings. In tests conducted in contact with the steel counterbody, the best resistance was demonstrated by samples with Zr-ZrN and Zr,Hf-(Ti,Zr,Hf)N coatings. The wear resistance of samples with (Zr,Hf)N and (Zr,Nb,Ti)N coatings was 2.5–3.3 times higher than that of the uncoated sample. The Zr,Nb adhesion layer ensures better adhesion of the coating to the substrate. It was found that not only the adhesion strength of the adhesion layer to the substrate and coating is of significant importance but also the strength of the adhesion layer itself. The surface film of titanium oxide must be completely etched off to ensure maximum strength of the adhesive bond between the coating and the substrate. It has been established that the adhesion of the coating and the titanium substrate is also affected by the characteristics of the outer (wear-resistant) coating layer, which is the composition and structure of the wear-resistant coating layer. Delamination can occur both at the boundary of the adhesive layer with the substrate and at the boundary of the wear-resistant and adhesive layers of the coating depending on the strength of the adhesive bonds in the corresponding pair. It is necessary to ensure a good combination of properties both in the substrate–adhesion layer system and in the adhesion layer–wear-resistant layer system. Full article

Today, the machining of heat-resistant alloys based on triple, quad, or penta equilibria high-entropy alloy systems of elements (ternary, quaternary, quinary iron-, titanium-, or nickel-rich alloys), including dual-phase by Gibb’s phase rule, steels of the austenite class, and nickel- and titanium-based alloys, are highly relevant for the airspace and aviation industry, especially for the production of gas turbine engines. Cutting tools in contact with those alloys should withstand intensive mechanical and thermal loads (tense state of 1.38·10⁸–1.54·10⁸ N/m², temperature up to 900–1200 °C). The most spread material for those tools is cutting ceramics based on oxides, nitrides of the transition and post-transition metals, and metalloids. This work considers the wear resistance of the cutting insert of silicon nitride with two unique development coatings — titanium–zirconium nitride coating (Ti,Zr)N and complex quad nitride coating with TiN content up to 70% (Ti,Al,Cr,Si)N with a thickness of 3.8–4.0 µm on which microtextures were produced by the assisted electric discharge machining with the electrode-tool of ø0.25 mm. The microtextures were three parallel microgrooves of R0.13^+0.02 mm at a depth of 0.025₋₀.₀₅. The operational life was increased by ~1.33 when the failure criterion in turning nickel alloy was 0.4 mm. Full article

This article compares the properties of the diamond-like carbon (DLC) coating with those of ZrN and (Zr,Hf)N coatings deposited on the Ti-6Al-4V titanium alloy substrate. To improve substrate adhesion during the deposition of the DLC coating, preliminary etching with chromium ions was conducted, ensuring the formation of a chromium-saturated diffusion surface layer in the substrate. A Si-DLC layer followed by a pure DLC layer was then deposited. The hardness of the coatings, their surface morphology, fracture strength in the scratch test, and tribological properties and wear resistance in the pin-on-disk test in contact with Al₂O₃ and steel indenters were investigated. The structure of the DLC coating was studied using transmission electron microscopy, and its corrosion resistance in an environment simulating blood plasma was also investigated. In the pin-on-disk test in contact with Al₂O₃ and AISI 52100 indenters, the DLC-coated sample demonstrates a much lower friction coefficient and significantly better wear resistance compared to the nitride-coated and uncoated samples. Both nitride coatings—(Zr,Hf)N and ZrN—and the DLC coating slow down the corrosive dissolution of the base compared to the uncoated sample. The corrosion currents of the (Zr,Hf)N-coated samples are 37.01 nA/cm², 20% higher than those of the ZrN-coated samples. The application of (Zr,Hf)N, ZrN, and DLC coatings on the Ti-6Al-4V alloy significantly inhibits dissolution currents (by 30–40%) and increases polarization resistance 1.5–2.0-fold compared to the uncoated alloy in 0.9% NaCl at 40 °C. Thus, the DLC coating of the described structure simultaneously provides effective wear and corrosion resistance in an environment simulating blood plasma. This coating can be considered in the manufacture of medical products (in particular, implants) from titanium alloys, including those functioning in the human body and subject to mechanical wear (e.g., knee joint endoprostheses). 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

Titanium alloys have a high cost of production and exhibit low resistance to abrasive wear. The objective of this work was to carry out diamond-like carbon (DLC) coating, with dissimilar thicknesses, on Ti-22Nb-6Zr titanium alloys produced by powder metallurgy, and to evaluate its microabrasive wear resistance. The samples were compacted, cold pressed, and sintered, producing substrates for coating. The DLC coatings were carried out by PECVD (plasma-enhanced chemical vapor deposition). Free sphere microabrasive wear tests were performed using alumina (Al₂O₃) abrasive suspension. The DLC-coated samples were characterized by scanning electron microscopy (SEM), Vickers microhardness, coatings adhesion tests, confocal laser microscopy, atomic force microscopy (AFM), and Raman spectroscopy. The coatings did not show peeling-off or delamination in adhesion tests. The PECVD deposition was effective, producing sp2 and sp3 mixed carbon compounds characteristic of diamond-like carbon. The coatings provided good structural quality, homogeneity in surface roughness, excellent coating-to-substrate adhesion, and good tribological performance in microabrasive wear tests. The low wear coefficients obtained in this work demonstrate the excellent potential of DLC coatings to improve the tribological behavior of biocompatible titanium alloy parts (Ti-22Nb-6Zr) produced with a low modulus of elasticity (closer to the bone) and with near net shape, given by powder metallurgy processing. Full article

The coatings of ZrN, (Zr,Ti)N, (Ti,Zr,Hf)N and (Ti,Zr,Nb)N deposited on the titanium alloy substrate were compared. The wear resistance in the pin-on-disk test together with the Al₂O₃ indenter and the corrosion resistance in 3.5% NaCl solution were studied. It was found that the (Zr,Nb,Ti)N coating has the best resistance to wear, but has low corrosion resistance. The (Ti,Zr,Hf)N coating, on the contrary, has the best corrosion resistance, but low resistance to wear. The ZrN coating has good corrosion resistance combined with good resistance to wear. This coating is best suited for use in friction conditions with a ceramic counterbody under the influence of seawater. An important resource for increasing the properties of coatings is increasing their adhesion to the substrate, which can be achieved in two combined ways: (1) complete removal of the original oxide layer from the surface of the substrate and (2) the use of optimal compositions of the adhesive sublayer, which have not only high adhesive properties in relation to both the substrate and the coating, but also high strength. While the introduction of Nb into the ZrN coating composition increases wear resistance and the introduction of Hf increases corrosion resistance, the ZrN coating without additives best resists wear and corrosion simultaneously. Full article

In this study, a NiCr/YSZ coating was applied to a γ-TiAl surface using multi-arc ion plating technology to enhance its high-temperature performance and explore the mechanisms of high-temperature oxidation and thermal corrosion. The thermal corrosion properties of the γ-TiAl matrix and NiCr/YSZ coating were investigated at 850 °C and 950 °C using a constant-temperature corrosion test in a 75% Na₂SO₄ + 25% NaCl mixture. The results indicate that after 100 h, the thermal corrosion weight gain of the coating samples was 70.1 mg/cm² at 850 °C and 118.2 mg/cm² at 950 °C. At these temperatures, sulfide formation on the surface increases, leading to a loose and porous surface. After 100 h of high-temperature corrosion at 850 °C, the primary oxidation product on the surface of the coating was tetragonal-ZrO₂. At 950 °C, Y₂O₃, which mainly acts as a stabilizer in YSZ, reacted with Na₂SO₄, resulting in the continuous consumption of Y₂O₃. This reaction caused a substantial amount of tetragonal-ZrO₂ to transform into monoclinic-ZrO₂, altering the volume of the ceramic layer, which induced internal stress, crack propagation, and minor spallation. A continuous and dense internal thermally grown oxide (TGO) layer effectively impeded the diffusion of molten salt substances and oxygen, thereby significantly improving the thermal corrosion resistance of the thermal barrier coating. Full article

Ti and its alloys have been vastly employed in the manufacturing of biomedical implants for orthopedy and dentistry, especially the Ti-6Al-4V alloy (wt%), which is the most-used Ti alloy worldwide. However, the ion release of Al and V in the long term has been related to harmful effects on the human body. In this scenario, surface modification strategies, such as plasma electrolytic oxidation (PEO), have often been performed in Ti alloys to match the clinical needs. This study evaluated the effect of electrical AC parameters on the surface of the commercial Ti-6Al-4V alloy immersed in ZrO₂-rich electrolytic solution regarding the chemical, physical, structural, and topographical aspects. Then, the selected PEO-treated samples surpassed the electrochemical test in saline solution. The results indicated that the electrical AC parameters affect the duration and intensity of the oxidative reactions and plasma micro-discharge steps, resulting in porous and thick oxide layers. PEO treatment promoted bio-camouflage of the surface, enriching it with TiO₂, ZrO₂, and ZrTiO₄ compounds and depleting it of Al and V. After screening the PEO-treated samples and their corrosion behavior, the results indicated that the porous ZrO₂–TiO₂ ceramic coatings in the Ti-6Al-4V alloy can be a viable alternative for the manufacturing of biomedical implants. Full article

(AlCrTiZrMo_x)N coatings with varying Mo content were successfully prepared using a multi-target co-deposition magnetron sputtering system. The results reveal that the Mo content significantly affects the microstructure, hardness, fracture toughness, and tribological behavior of the coatings. As the Mo content in the coatings increases gradually, the preferred orientation changes from (200) to (111). The coatings consistently exhibit a distinct columnar structure. Additionally, the hardness of the coatings increases from 24.39 to 30.24 GPa, along with an increase in fracture toughness. The friction coefficient is reduced from 0.72 to 0.26, and the wear rate is reduced by 10 times. During the friction process, the inter-column regions of the coatings are initially damaged, causing the wear track to exhibit a wavy pattern. Greater frictional heat is generated at the crest of the wave, resulting in the formation of a MoO₂ lubricating layer. The friction reaction helps to reduce the shear force during friction, demonstrating the lower friction coefficient of the (AlCrTiZrMo_x)N coatings. Both the hardness and fracture toughness work together to reduce the wear rate, and the (AlCrTiZrMo_x)N coatings show excellent wear resistance. Most notably, although the columnar structure plays a negative role in the hardness, it contributes greatly to the wear resistance. Full article

In recent years, antibacterial coatings have become an important approach in the global fight against bacterial pathogens. Developments in materials science, chemistry, and biochemistry have led to a plethora of materials and chemical compounds that have the potential to create antibacterial coatings. However, insufficient attention has been paid to the analysis of the techniques and technologies used to apply these coatings. Among the various inorganic coating techniques, atomic layer deposition (ALD) is worthy of note. It enables the successful synthesis of high-purity inorganic nanocoatings on surfaces of complex shape and topography, while also providing precise control over their thickness and composition. ALD has various industrial applications, but its practical application in medicine is still limited. In recent years, a considerable number of papers have been published on the proposed use of thin films and coatings produced via ALD in medicine, notably those with antibacterial properties. The aim of this paper is to carefully evaluate and analyze the relevant literature on this topic. Simple oxide coatings, including TiO₂, ZnO, Fe₂O₃, MgO, and ZrO₂, were examined, as well as coatings containing metal nanoparticles such as Ag, Cu, Pt, and Au, and mixed systems such as TiO₂-ZnO, TiO₂-ZrO₂, ZnO-Al₂O₃, TiO₂-Ag, and ZnO-Ag. Through comparative analysis, we have been able to draw conclusions on the effectiveness of various antibacterial coatings of different compositions, including key characteristics such as thickness, morphology, and crystal structure. The use of ALD in the development of antibacterial coatings for various applications was analyzed. Furthermore, assumptions were made about the most promising areas of development. The final section provides a comparison of different coatings, as well as the advantages, disadvantages, and prospects of using ALD for the industrial production of antibacterial coatings. Full article

Thermomechanical action during high-performance diamond grinding of sintered cutting Al₂O₃/TiC and SiAlON ceramics leads to increased defectiveness of the surface layer of the deposited TiZrN and CrAlSiN/DLC coatings. It predetermines the discontinuous and porous coatings and reduces its effectiveness under abrasive exposure and fretting wear. The developed technological approach is based on “dry” etching with beams of accelerated argon atoms with an energy of 5 keV for high-performance removal of defects. It ensures the removal of the defective layer on ceramics and reduces the index of defectiveness (the product of defects’ density per unit surface area) by several orders of magnitude, compared with diamond grinding. There are no pronounced discontinuities and pores in the microstructure of coatings. Under mechanical loads, the coatings ensure a stable boundary anti-friction film between the ceramics and counter body that significantly increases the wear resistance of samples. The treatment reduces the volumetric wear under 20 min of abrasive action by 2 and 6 times for TiZrN and CrAlSiN/DLC coatings for Al₂O₃/TiC and by 5 and 23 times for SiAlON. The volumetric wear under fretting wear at 105 friction cycles is reduced by 2–3 times for both coatings for Al₂O₃/TiC and by 3–4 times for SiAlON. Full article