Search Results (226)

Metal materials are widely used in power grid infrastructure, but they are prone to metal corrosion due to long-term exposure to various environmental conditions, resulting in significant losses. The existing superhydrophobic coatings have good anti-corrosion performance, but poor wear resistance. Therefore, it is extremely important to improve the wear resistance of superhydrophobic coatings. In this study, a kind of fluorine-modified SiO₂ particle was prepared with pentafluorooctyltrimethoxysilane (FAS-13) as the low surface energy modifier, following the fabrication of a superhydrophobic coating on metal substrate via a PDMS-doped spray deposition method to reinforcement wear resistance property. XPS, FT-IR and Raman spectra confirmed the successful introduction of FAS-13 on SiO₂ particles, as evidenced by the characteristic fluorine-related peaks. TGA revealed that the fluorine modified SiO₂ (F-SiO₂) particles exhibited excellent thermal stability, with an initial decomposition temperature of 354 °C. From the perspective of surface morphology, the relevant data indicated a peak-to-valley height difference of only 88.7 nm, with Rq of 11.9 nm and Ra of 8.86 nm. And it also exhibited outstanding superhydrophobic property with contact angle (CA) of 164.44°/159.48°, demonstrating remarkable self-cleaning performance. And it still maintained CA of over 150° even after cyclic abrasion of 3000 cm with 800 grit sandpaper under a 100 g load, showing exceptional wear resistance. In addition, it was revealed that the coated electrode retained a high impedance value of 8.53 × 10⁸ Ω·cm² at 0.1 Hz after 480 h of immersion in 5 wt% NaCl solution, with the CPE exponent remaining close to unity (from 1.00 to 0.97), highlighting its superior anti-corrosion performance and broad application prospects for metal corrosion prevention. Full article

This article presents an in-depth analysis of the application of thermal deposition techniques, in particular thermal spraying, to improve the properties of materials used in agricultural components that work the soil, such as agricultural plows (mainshare and foreshare). Due to the difficult operating conditions, characterized by abrasive wear, mechanical shocks, and chemical exposure from various soils, these surface coatings aim to increase the durability and corrosion resistance of the materials of components intended for working with the soil. The study investigates thermal deposition methods and their effects on the microstructure, hardness, and friction resistance of the obtained layers. The study highlights experiments that reveal significant improvements in mechanical properties, highlighting superior behavior in real conditions of agricultural use. Nevertheless, soil types significantly influence the abrasive wear rate of the components and also their corrosion, which depends on the soil pH. The results confirm that the use of thermal deposition represents a sustainable and effective solution for extending the life of plows, thus reducing maintenance costs and increasing the efficiency of agricultural processes. This research contributes to the optimization of agricultural equipment, providing an innovative approach for adapting plows to the increasing demands of agricultural exploitation. Full article

This work presents a microstructural characterization methodology for Diamalloy 3001 metallic powders sprayed onto Inconel 718 substrates by flame combustion. Hence, two flame stoichiometric (acetylene/oxygen) rates and specified thermal spray distances were performed in order to study their effects on the developed microstructure of the sprayed coatings. The morphology and chemical composition of the developed coatings were evaluated with microscopy, and a comparison of microstructural quality was performed. The findings indicated that spray distance affected coating quality, which is composed of morphology-type lamellar with elongated features, while gravel-like morphologies related to semi-solid powder particles were observed. Moreover, X-ray diffraction analyses established that chemical content of phases rich in oxides increased proportionally with spray distance. Vickers hardness measures and three-point bending tests were correlated with the microstructure and spray distance. These characteristics show that cobalt-based coatings could be proposed for commercial applications requiring high mechanical resistance. Full article

Metallic implants used in orthopedics, such as titanium alloys, possess excellent mechanical strength but suffer from corrosion and poor bio-integration, often necessitating revision surgeries. Bioactive coatings, particularly hydroxyapatite, can enhance implant osteoconductivity, but high-purity synthetic hydroxyapatite is costly. This study investigates the development and characterization of a low-cost, biocompatible coating using hydroxyapatite derived from an unconventional natural source dromedary bone applied onto a titanium substrate via plasma spraying. Hydroxyapatite powder was synthesized from dromedary femurs through a thermal treatment process at 1000 °C. The resulting powder was then deposited onto a sandblasted titanium dioxide substrate using an atmospheric plasma spray technique. The physicochemical, structural, and morphological properties of both the source powder and the final coating were comprehensively analyzed using Scanning Electron Microscopy, Energy Dispersive X-ray Spectroscopy, X-ray Diffraction, and Fourier-Transform Infrared Spectroscopy. Characterization of the powder confirmed the successful synthesis of pure, crystalline hydroxyapatite, with Fourier-Transform Infrared Spectroscopy analysis verifying the complete removal of organic matter. The plasma-sprayed coating exhibited good adhesion and a homogenous, lamellar microstructure typical of thermal spray processes, with an average thickness of approximately 95 μm. X-ray Diffraction analysis of the coating revealed that while hydroxyapatite remained the primary phase, partial decomposition occurred during spraying, leading to the formation of secondary phases, including tricalcium phosphate and calcium oxide. Scanning Electron Microscopy imaging showed a porous surface composed of fully and partially melted particles, a feature potentially beneficial for bone integration. The findings demonstrate that dromedary bone is a viable and low-cost precursor for producing bioactive hydroxyapatite coatings for orthopedic implants. The plasma spray method successfully creates a well-adhered, porous coating, though process-induced phase changes must be considered for biomedical applications. Full article

In many industrial applications, engine, turbine, and rotor components are coated with thin layers that protect them from corrosion, high temperatures, or pressure. This paper presents a fast and effective method for testing such protective coatings. For this purpose, an eddy current probe consisting of a single coil was designed and constructed. The high sensitivity of the probe was achieved by using a pot core, which significantly reduced magnetic flux losses. In addition to the substrate, the test samples also contained carbide coatings or thermal barrier coatings (TBCs), which were sprayed with an Axial III triple-plasma torch or a single-electrode torch. The use of different process parameters made it possible to obtain coatings of varying thickness, which were determined using a scanning electron microscope (SEM). Measurements of the probe impedance components were performed in the frequency range from 500 Hz to 50 kHz. In all cases, based on the analysis of changes in resistance and reactance, it was possible to distinguish each of the tested samples. Even slight changes in thickness of only 9 μm caused significant changes in probe impedance, enabling effective testing of carbide coatings and TBCs. Full article

Modified tuber starches have gained relevance as innovative and versatile materials for the encapsulation of bioactive compounds, distinguishing themselves from synthetic polymers due to their biocompatibility, biodegradability, and tunable functionality. This review analyzes the effects of physical, chemical, and biochemical modifications on the composition and morphological, rheological, thermal, and techno-functional properties of tuber starches, as well as their development prospects as coating materials in encapsulation techniques such as spray drying, freeze-drying, electrospinning, and emulsification. The evidence reviewed indicates that modified tuber starches exhibit reduced retrogradation, higher thermal resistance, improved solubility, and better digestibility, facilitating their application as protective agents. The main challenges for their industrial implementation are identified and analyzed, including the standardization of processes, scalability, and the ambiguous regulatory framework. In the future, research in this area should be directed toward the optimization of “clean-label” methodologies and the valorization of non-conventional tuber sources, thereby consolidating the development of safer, more effective, and more sustainable encapsulation systems for the food industry. Full article

This review article summarizes the most widely used and effective technologies for producing protective and functional bilayer coatings. Particular attention is given to methods such as electroplating and electroless metallization, chemical vapor deposition, thermal spray and vacuum arc deposition, conversion treatments, laser modification, and organic layer deposition. Bilayer architectures are highlighted for their ability to overcome the limitations of single-layer coatings by combining complementary functionalities, resulting in enhanced adhesion, improved corrosion resistance through pore sealing or superhydrophobic surface states, and increased wear and crack resistance. This article is intended for researchers, materials scientists, and engineers engaged in surface engineering, corrosion protection, and advanced manufacturing, providing them with a clear understanding of the mechanisms, advantages, and practical applications of bilayer coatings. By synthesizing recent developments, comparative analyses, and performance data, the review enables readers to make informed decisions about the selection, design, and implementation of bilayer coatings for diverse industrial applications, ranging from aerospace and automotive components to medical devices and energy systems. Full article

This paper addresses ballistic protection, which is an important element in the performance of any military equipment. Improving ballistic properties is a necessity for individual protection through the use of protective vests. In this study, plasma jet thermal deposition was performed on ballistic protection materials, steel plates from the ARMOX category, using both metallic and ceramic powders. The samples with appropriate dimensions, covered with these types of powders, were analyzed from a microstructural point of view to determine their mechanical properties and evaluate the improvement in ballistic protection level. Microstructural analyses by optical and electronic microscopy, SEM (Scanning Electron Microscopy), allowed the performance of complex analyses regarding the adhesion of the deposits to the base material. It was possible to evaluate the microstructure, thickness, uniformity, and porosity of the deposits and the microstructural aspects at the interface between the base material and the deposit. For the efficient use of these deposits, tribological studies were carried out on the mechanical properties through scratch and microindentation analyses. The paper concludes the results obtained for the two types of deposits, metallic and ceramic, to streamline their use to increase the ballistic protection of bulletproof vests used in individual protection in military equipment. Full article

Thermal barrier coatings (TBCs) are critical for protecting hot-section components in gas turbines and aero-engines. Traditional yttria-stabilized zirconia (YSZ) coatings are prone to phase transformation and sintering-induced failure at elevated temperatures. This study fabricated CeScYSZ (4 mol% CeO₂ and 6 mol% Sc₂O₃ co-doped YSZ)/NiCrAlY TBCs using atmospheric plasma spraying (APS). A five-factor, four-level orthogonal experimental design was employed to optimize spraying parameters, investigating the influence of powder feed rate, spray distance, current, hydrogen flow rate and primary gas flow rate on the coating’s microstructure and mechanical properties. The resistance to calcium–magnesium–alumino–silicate (CMAS) corrosion was compared between CeScYSZ and YSZ coatings. The results indicate that the optimal parameters are a spray distance of 100 mm, current of 500 A, argon flow rate of 30 L/min, hydrogen flow rate of 6 L/min, and powder feed rate of 45 g/min. Coatings produced under these conditions exhibited moderate porosity and excellent bonding strength. After exposure to CMAS corrosion at 1300 °C for 2 h, the CeScYSZ coating demonstrated significantly superior corrosion resistance compared to YSZ. This enhancement is attributed to the formation of a CaZrO₃ physical barrier and the synergistic effect of Ce and Sc in suppressing deleterious phase transformations. This study provides an experimental basis for the preparation and application of high-performance TBCs. Full article

The impingement of a molten droplet on a solid surface, forming a “splat,” is a fundamental phenomenon observed across numerous industrial surface engineering techniques. For example, thermal spray deposition is widely used to create metal, ceramic, polymer, and composite coatings that are vital for aerospace, biomedical, electronics, and energy applications. Significant progress has been made in understanding droplet impact behavior, largely driven by advancements in high-resolution and high-speed imaging techniques, as well as computational resources. Although droplet impact dynamics, splat morphology, and interfacial bonding mechanisms have been extensively reviewed, a comprehensive overview of the mechanical behaviors of single splats, which are crucial for coating performance, has not been reported. This review bridges that gap by offering an in-depth analysis of bonding strength and residual stress in single splats. The various experimental techniques used to characterize these properties are thoroughly discussed, and a detailed review of the analytical models and numerical simulations developed to predict and understand residual stress evolution is provided. Notably, the complex interplay between bonding strength and residual stress is then discussed, examining how these two critical mechanical attributes are interrelated and mutually influence each other. Subsequently, effective strategies for improving interfacial bonding are explored, and key factors that influence residual stress are identified. Furthermore, the fundamental roles of splat flattening and formation dynamics in determining the final mechanical properties are critically examined, highlighting the challenges in integrating fluid dynamics with mechanical analysis. Thermal spraying serves as the primary context, but other relevant applications are briefly considered. Cold spray splats are excluded because of their distinct bonding and stress generation mechanisms. Finally, promising future research directions are outlined to advance the understanding and control of the mechanical properties in single splats, ultimately supporting the development of more robust and reliable coating technologies. Full article

Rigid polyurethane foams (RPUFs) are essential polymeric materials, prized for their low density, high mechanical strength, and superior thermal insulation, making them indispensable in construction, refrigeration, and transportation. Despite these advantages, their highly porous, carbon-rich structure renders them intrinsically flammable, promoting rapid flame spread, intense heat release, and the generation of toxic smoke. Traditional strategies to reduce flammability have primarily focused on incorporating additive or reactive flame retardants into the foam matrix, which can effectively suppress combustion but often compromise mechanical integrity, suffer from migration or compatibility issues, and involve complex synthesis routes. Despite recent progress, the long-term stability, scalability, and durability of surface flame-retardant coatings for RPUFs remain underexplored, limiting their practical application in industrial environments. Recent advances have emphasized the development of surface-engineered flame-retardant coatings, including intumescent systems, inorganic–organic hybrids, bio-inspired materials, and nanostructured composites. These coatings form protective interfaces that inhibit ignition, restrict heat and mass transfer, promote char formation, and suppress smoke without altering the intrinsic properties of RPUFs. Emerging deposition methods, such as layer-by-layer assembly, spray coating, ultraviolet (UV) curing, and brush application, enable precise control over thickness, uniformity, and adhesion, enhancing durability and multifunctionality. Integrating bio-based and hybrid approaches further offers environmentally friendly and sustainable solutions. Collectively, these developments demonstrate the potential of surface-engineered coatings to achieve high-efficiency flame retardancy while preserving thermal and mechanical performance, providing a pathway for safe, multifunctional, and industrially viable RPUFs. Full article

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 review presents a comprehensive overview of metallic abradable coatings and the advanced testing methodologies used to evaluate their performance in gas turbine engines. Abradable materials are engineered to act as sacrificial coatings, enabling minimal blade tip wear while maintaining tight clearances between rotating blades and stationary components. Such functionality is critical in aerospace applications, where engines operate at high rotational speeds and across wide temperature ranges. The review examines the principal factors governing the design and selection of metallic-based abradable coatings, including material composition, thermal stability, and microstructural tailoring through the addition of phase modifiers, porosity formers, and solid lubricants. The performance of various metallic matrix materials is also discussed concerning their operational temperature ranges and wear characteristics. Particular attention is given to abradability evaluation methods, emphasizing the need to replicate engine-representative conditions to capture blade–coating interactions, frictional behavior, and wear mechanisms. This review consolidates advances in material compositions, microstructural engineering, and experimental testing, integrating perspectives from materials science, tribology, and methodology to guide the development of next-generation turbine coatings. It specifically addresses the lack of a unified review linking material design, thermal spray processes, and performance evaluation by summarizing key compositions, microstructures, and testing methods. Full article

Micro-arc oxidation (MAO) technology demonstrates remarkable advantages in fabricating ceramic coatings on lightweight alloys. For aluminum alloys, MAO rapidly forms dense, pore-free ceramic layers within minutes, significantly enhancing corrosion and wear resistance at low processing costs. In magnesium alloys, optimized electrolyte compositions and process parameters enable composite coatings with a combination of high hardness and self-lubrication properties, while post-treatments like laser melting or corrosion inhibitors extend salt spray corrosion resistance. Titanium alloys benefit from MAO coatings with exceptional interfacial bonding strength and mechanical performance, making them ideal for biomedical implants and aerospace components. Notably, dense ceramic oxide films grown in situ via MAO on high-entropy alloys (HEAs) triple surface hardness and enhance wear/corrosion resistance. However, MAO applications on steel require pretreatments like aluminizing, thermal spraying, or ion plating. Current challenges include coating uniformity control, efficiency for complex geometries, and long-term stability. Future research focuses on multifunctional coatings (self-healing, antibacterial) and eco-friendly electrolyte systems to expand engineering applications. Full article

Spent coffee grounds represent an abundant waste resource with potential for sustainable material applications. This study investigates the use of carbonized spent coffee grounds (CSCG) as fillers in polyurethane (PU) coatings for carbon fiber-reinforced polymer (CFRP) substrates to enhance mechanical durability and anti-icing performance. SCGs were dried, sieved (<100 µm), and oxidatively carbonized in air at 100–300 °C for 60–120 min, then incorporated into PU at 1 or 5 wt.% and applied by spray-coating. A full-factorial design was employed to evaluate the effects of carbonization temperature, particle size, and filler loading. The optimized formulation (300 °C, 100 µm, 5 wt.%) showed the highest water contact angle (103.5°), lowest work of adhesion (55.8 mJ/m²), and improved thermal stability with 60% char yield. Mechanical testing revealed increased tensile modulus with reduced strain, and differential scanning calorimetry indicated an upward shift in glass-transition temperature, suggesting restricted chain mobility. Ice formation at 0 °C was sparse and discontinuous, attributed to lowered polar surface energy, rough surface texture, and porous carbon morphology. These results demonstrate that CSCGs are effective sustainable fillers for PU coatings, offering combined improvements in mechanical, thermal, and anti-icing properties suitable for aerospace, wind power, and other icing-prone applications. Full article