Search Results (380)

Difficult, extreme operating conditions of parabolic antennas under precipitation and sub-zero temperatures require the creation of effective heating systems. The purpose of the research is to develop a multilayer coating containing two metal-ceramic layers, epoxy composite layers, carbon fabric, and an outer layer of basalt fabric, which allows for effective heating of the antenna, and to study the properties of this coating. The multilayer coating was formed on an aluminum base that was subjected to abrasive jet processing. The first and second metal-ceramic layers, Al₂O₃ + 5% Al, which were applied by high-speed multi-chamber cumulative detonation spraying (CDS), respectively, provide maximum adhesion strength to the aluminum base and high adhesion strength to the third layer of the epoxy composite containing Al₂O₃. On this not-yet-polymerized layer of epoxy composite containing Al₂O₃, a layer of carbon fabric (impregnated with epoxy resin) was formed, which serves as a resistive heating element. On top of this carbon fabric, a layer of epoxy composite containing Cr₂O₃ and SiO₂ was applied. Next, basalt fabric was applied to this still-not-yet-polymerized layer. Then, the resulting layered coating was compacted and dried. To study this multilayer coating, X-ray analysis, light and raster scanning microscopy, and transmission electron microscopy were used. The thickness of the coating layers and microhardness were measured on transverse microsections. The adhesion strength of the metal-ceramic coating layers to the aluminum base was determined by both bending testing and peeling using the adhesive method. It was established that CDS provides the formation of metal-ceramic layers with a maximum fraction of lamellae and a microhardness of 7900–10,520 MPa. In these metal-ceramic layers, a dispersed subgrain structure, a uniform distribution of nanoparticles, and a gradient-free level of dislocation density are observed. Such a structure prevents the formation of local concentrators of internal stresses, thereby increasing the level of dispersion and substructural strengthening of the metal-ceramic layers’ material. The formation of materials with a nanostructure increases their strength and crack resistance. The effectiveness of using aluminum, chromium, and silicon oxides as nanofillers in epoxy composite layers was demonstrated. The presence of structures near the surface of these nanofillers, which differ from the properties of the epoxy matrix in the coating, was established. Such zones, specifically the outer surface layers (OSL), significantly affect the properties of the epoxy composite. The results of industrial tests showed the high performance of the multilayer coating during antenna heating. Full article

Multilayer thin films composed of cobalt (Co), carbon (C), and chromium (Cr) possess promising electromagnetic properties, yet the combined Co–C–Cr system remains underexplored, particularly regarding its performance as a microwave absorber. Existing research has primarily focused on binary Co–C or Co–Cr compositions, leaving a critical knowledge gap in understanding how ternary multilayer architectures influence electromagnetic behavior. This study addresses this gap by investigating the structure, phase composition, and microwave absorption performance of Co–C–Cr multilayer coatings fabricated via magnetron sputtering onto porous silicon substrates. This study compares four-layer and eight-layer configurations to assess how multilayer architecture affects impedance matching, reflection coefficients, and absorption characteristics within the 8.2–12.4 GHz frequency range. Structural analyses using X-ray diffraction and transmission electron microscopy confirm the coexistence of amorphous and nanocrystalline phases, which enhance absorption through dielectric and magnetic loss mechanisms. Both experimental and simulated results show that increasing the number of layers improves impedance gradients and broadens the operational bandwidth. The eight-layer coatings demonstrate a more uniform absorption response, while four-layer structures exhibit sharper resonant minima. These findings advance the understanding of ternary multilayer systems and contribute to the development of frequency-selective surfaces and broadband microwave shielding materials. Full article

Ceramic dental prosthetics with internal metal structures are made from a cobalt–chromium alloy that is coated with ceramic. This study aims to validate surface treatments for the metal that enhance the adhesion of the ceramic coating under masticatory forces. Surface conditioning is performed using mechanical methods, like sandblasting (SB), and thermal methods, such as oxidation (O). The ceramic coating is applied to the metal component following the conditioning process, which can be conducted using either a single method or a combination of methods. Each conditioned sample undergoes characterization through various techniques, including drop shape analysis (DSA), scanning electron microscopy (SEM), X-ray diffraction (EDX), and atomic force microscopy (AFM). After the ceramic coating is applied and subjected to thermal sintering, the metal–ceramic samples are mechanically tested to assess the adhesion of the ceramic layer. The research findings, illustrated by scanning electron microscopy (SEM) images of the metal structures’ surfaces, indicate that alloy powder particles ranging from 10 to 50 µm were either adhered to the surfaces or present as discrete dots. Particles that exceed the initial design specifications of the structure can be smoothed out using sandblasting or mechanical finishing techniques. The energy-dispersive spectroscopy (EDS) results show that, after sandblasting, fragments of aluminum oxide remain trapped on the surface of the metal structures. These remnants are considered impurities, which can negatively impact the adhesion of the ceramic to the metal substrate. The analysis focuses on the exfoliation of the ceramic material from the deformed metal surfaces. The results emphasize the significant role of the sandblasting method and the micro-topography it creates, as well as the importance of the oxidation temperature in the treatment process. Drawing on 25 years of experience in dental prosthetics and the findings from this study, this publication aims to serve as a guide for applying the ceramic bonding layer to metal surfaces and for conditioning methods. These practices are essential for enhancing the adhesion of ceramic materials to metal substrates. Full article

To enhance the high-temperature oxidation resistance of chromium carbide metal ceramic coatings, micro/nanoparticle modification was applied to the alloy binder phase of the typical Cr₃C₂-NiCr coating. This led to the development of Cr₃C₂-NiCrCoMo and Cr₃C₂-NiCrCoMo/nano-CeO₂ coatings with superior high-temperature oxidation performance. This study compares the high-temperature oxidation behavior of these coating samples and explores their respective oxidation mechanisms. The results indicate that the addition of CoCrMo improves the compatibility between the oxide film and the coating, enhancing the microstructure and integrity of the oxide film. Compared to Cr₃C₂-NiCrCoMo coatings, the incorporation of nano-CeO₂ promotes the reaction between oxides in the Cr₃C₂-NiCrCoMo/nano-CeO₂ coating, increasing the content of binary spinel phases, reducing thermal stress at the oxide–coating interface, and improving the adhesion strength of the oxide film. As a result, the oxidation rate of the coating is reduced, and its oxidation resistance is improved. Full article

The development of power engineering requires the introduction of new materials and technologies to improve the quality and durability of products. One promising direction is the creation of heat-protective coatings for the protection of working surfaces of turbine blades of gas turbine engines operating at temperatures up to 1000–1200 °C. Intermetallic coatings based on iron aluminides (Fe₃Al, FeAl) have high resistance to oxidation due to the formation of an oxide layer: Al₂O₃. However, their application is limited by brittleness due to the so-called third element effect, which can be reduced through alloying with chromium. In this study the processes of formation of Fe–Al–Cr intermetallic coatings produced by air plasma spraying and the mechanisms affecting their stability at high temperatures were investigated. Experimental studies included the analysis of the microhardness, wear resistance, and corrosion resistance of coatings, as well as their phase composition and microstructure. The results showed that the optimization of sputtering parameters, especially in the FrCrAl (30_33) mode, promotes the formation of a coating with improved tribological and anticorrosion characteristics, which is associated with its dense and uniform structure. These data have an important practical significance for the creation of wear-resistant and corrosion-resistant coatings applicable in power engineering. Full article

Thermally sprayed carbide cermet coatings, particularly those based on tungsten carbide (WC) and chromium carbide (Cr₃C₂) and produced with the high velocity oxygen fuel (HVOF) process, are used in tribological applications as environmentally friendly alternatives to electroplated hard chrome coatings. These functional coatings are especially prevalent in the automotive industry, offering excellent wear resistance. However, their mechanical and tribological performances are highly dependent on factors such as feedstock powders, spray parameters, and service conditions. This review aims to gain deeper insights into the above elements. It also outlines emerging advancements in HVOF technology—including in situ powder mixing, laser treatment, artificial intelligence integration, and the use of novel materials such as rare earth elements or transition metals—which can further enhance coating performance and broaden their applications to sectors such as the aerospace and hydro-machinery industries. Finally, this literature review focuses on process optimization and sustainability, including environmental and health impacts, critical material use, and operational limitations. It uses a life cycle assessment (LCA) as a tool for evaluating ecological performance and addresses current challenges such as exposure risks, process control constraints, and the push toward safer, more sustainable alternatives to traditional WC and Cr₃C₂ cermet coatings. Full article

We explored anodic aluminum oxide (AAO) stealth materials combining low infrared emissivity and visible structural coloration through multi-parameter modulation. Using DC ion gold sputtering and UHV magnetron chromium sputtering, we successfully prepared an AAO stealth material with high-saturation visible structural coloration and low infrared emissivity (ε < 0.17). Quantitative evaluation based on the CIE Lab color difference model indicated that the gold-coated samples had high matching accuracy with PANTONE standard colors ($\mathsf{\Delta }{E}_{ab}^{*}$ < 1.6). The chromium-coated samples had slightly lower matching accuracy ($\mathsf{\Delta }{E}_{ab}^{*}$ < 3.0), but still displayed rich coloration, with color difference within human-perceptible tolerance limits. Full article

This study proposes the development of a dual-wavelength optical fiber sensor (DWOFS) that integrates two optical fiber structures in a multimode transmission line to measure the refractive index and temperature of a liquid concurrently. One structure is based on a refractive index sensor that utilizes surface plasmon resonance, comprising a 5 mm long single-mode fiber (SMF) section coated with chromium/gold (Cr/Au) films. The secondary structure employs a multimode interferometer with a 29 mm long no-core fiber (NCF) section covered with a thick layer of polydimethylsiloxane (PDMS) to measure temperature. The measurements obtained reveal two distinct drops in the transmission spectrum at approximately 600 nm and 1550 nm, respectively, enabling precise measurement of the two parameters. The sensor demonstrates a high degree of sensitivity to both refractive index and temperature, spanning the visible ($2770.30\mathrm{n}\mathrm{m}/\mathrm{R}\mathrm{I}\mathrm{U}$) and infrared $(-0.178\mathrm{n}\mathrm{m}/°\mathrm{C}$) regions of the spectra, respectively. Furthermore, the thermo-optical coefficient for water $({-0.9928\times 10}^{-4}\mathrm{R}\mathrm{I}\mathrm{U}/°\mathrm{C})$ was estimated. The proposed sensor offers a compact solution for the simultaneous measurement of refractive index and temperature in liquid samples for a variety of applications, including biological, environmental, and healthcare research. Full article

In the design of L-DED (laser-directed energy deposition) cladding processes, the chemical composition of the metallic powders is typically assumed to match that of the intended coating. However, during the deposition of the first layer, dilution with the substrate alters the weld metal composition, deviating from the nominal powder chemistry. Although the application of multiple layers can gradually reduce this dilution effect, it introduces additional complexity and processing time. This study proposes an alternative strategy to counteract substrate dilution from the very first deposited layer, eliminating the need for multilayer coatings. Specifically, to achieve a corrosion-resistant monolayer of AISI 316L stainless steel on a high-strength, quenched-and-tempered AISI 4140 steel substrate, a dilution-compensating alloy powder is added to the standard AISI 316L feedstock. Single-layer coatings, both with and without compensation, were evaluated in terms of chemical composition, microstructure, and corrosion resistance. The results show that unmodified coatings suffered a chromium depletion of approximately 2 wt.%, leading to a reduced pitting potential of Ep = 725 ± 6 mV in synthetic seawater. In contrast, the use of the compensation alloy preserved chromium content and significantly improved corrosion resistance, achieving a pitting potential of Ep = 890 ± 9 mV. Full article

Aluminium is an attractive material for proton-exchange-membrane fuel cell bipolar plates as it has a much lower density than steel and is easier to form than both steel and graphite. This work focused on the development of amorphous carbon films deposited using closed-field unbalanced magnetron sputtering (CFUBMS) in order to improve the corrosion resistance of aluminium bipolar plates and to enhance fuel cell performance and durability. Chromium and tungsten adhesion layers were used for the coatings. It was possible to achieve good electrical conductivity and high electrochemical corrosion resistance up to 70 °C on polished Aluminium alloy 6082 by tuning the deposition parameters. Coatings with a tungsten adhesion layer showed better corrosion resistance than those with a chromium adhesion layer. In situ, accelerated stress testing of single cells was performed using uncoated and coated Al6082 bipolar plates. Both coatings resulted in improved fuel cell performance compared to uncoated aluminium when used on the cathode side of the fuel cell. Full article

Background/Objectives: In this paper, we report the development of the first chrome-doped hydroxyapatite in a poly (vinyl alcohol) (PVA) matrix enriched with amoxicillin for biomedical applications. The development of chromium-doped hydroxyapatite coatings in a PVA matrix enriched with amoxicillin aims to provide new biomaterials with improved physico-chemical and biological properties, making them promising candidates for biomedical applications. Methods: Through ultrasound studies, we obtained valuable information on the stability of the samples. X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM), Fourier-transform infrared (FTIR) spectroscopy, metallographic microscopy (MM), and atomic force microscopy (AFM) were employed for the characterization of the samples. The biocompatibility of the CrHApAPV and CrHApAPV-Ax coatings was assessed using the MG63 human osteoblast-like cell line. To evaluate the cytotoxic potential of these coatings, the cell viability was quantified using the MTT assay after 24 h of incubation. The antibacterial activity of the coatings was evaluated with the aid of the reference strain Pseudomonas aeruginosa ATCC 27853 (P. aeruginosa). Results: The XRD patterns of CrHApAPV and CrHApAPV-Ax samples were examined to evaluate the effects of PVA and amoxicillin on the lattice parameters, unit cell volume, and average crystallite sizes. The results of the in vitro antibacterial assay demonstrated that both the CrHApAPV and CrHApAPV-Ax coatings exhibited very good antibacterial properties for all the tested time intervals. Conclusions: Our results underline the stability of the analyzed samples. Moreover, our physico-chemical and biological studies highlight that CrHApAPV and CrHApAPV-Ax coatings could be considered promising materials for biomedical uses. Full article

Enhancing the durability and tribological performance of babbitt alloys is critical for high-stress applications in automotive, marine, and industrial machinery. The present study explores the electrodeposition of chromium coatings on SnSb11Cu6 alloys to improve their microstructural, mechanical, and tribological properties. The coatings were applied through an electrolytic process and systematically characterized using scanning electron microscopy and energy-dispersive X-ray spectroscopy to evaluate their morphology, composition, and wear performance. The chromium coating exhibited a uniform thickness of 20.2 µm and significantly improved the surface hardness to 715.2 HV, far surpassing the matrix and intermetallic phases of the uncoated alloy. Tribological testing under dry sliding conditions demonstrated a 44% reduction in the coefficient of friction (COF) and a 54% decrease in mass wear for the coated alloy, highlighting the protective role of the chromium layer against abrasive and adhesive wear. To further analyze the frictional behavior, a deep learning model based on a one-dimensional convolutional neural network was employed to predict COF trends over time, achieving excellent accuracy with R² values of 0.9971 for validation and 0.9968 for testing. Feature importance analysis identified coating hardness as the most critical factor influencing COF and wear resistance, followed by matrix hardness near the coating. These findings underscore the effectiveness of chromium coatings in mitigating wear damage and improving the operational lifespan of SnSb11Cu6 alloys in high-stress applications. This study not only advances the understanding of chromium coatings for babbitt materials but also demonstrates the potential of machine learning in optimizing tribological performance. Full article

This work is part of a current and essential issue aiming to find a solution for the replacement of chromium(VI) and cadmium in the surface treatment process applied to electrical connectors. The application of a protective coating obtained by the sol–gel route proves to be an interesting alternative method and numerous studies describe efficient anticorrosion coatings to protect various metallic alloys. The issue of electrical connectors made of 6061 alloy is to combine anticorrosion protection and electrical conduction, which are antagonistic properties, so multifunctional sol–gel coatings and/or architectures have to be synthesized and shaped on connectors. In this work, several experimental parameters, such as the type of carbon filler, the hydrolysis ratio, the precursors’ introduction order are studied and evaluated to achieve industrial requirements. Thus, aqueous suspensions of carbon fillers have been introduced into sol–gel formulations to give rise to conductive coatings (200–500 mΩ_□) with high anticorrosion properties (500 h NSS resistance), in which thickness is less than 10 microns. The incorporation of organic additives poly(2-ethyl-2-oxazoline) or hydroxypropylmethylcellulose positively impacts the flash point of the sol (>60 °C) making the sol–gel process compatible with the HSE recommendation and the ATEX standard. Full article

Friction and wear reduction in internal combustion engines are crucial for improving efficiency and durability. This study investigates the effect of microtextured surfaces on friction power loss in an engine’s piston ring-cylinder system. A numerical analysis was conducted on piston rings equipped with dimple-shaped microtextures using AVL Excite Piston & Rings, modelling a hard chromium-coated piston ring and a cast iron cylinder. The goal was to determine the optimal surface texture parameters that minimize friction power loss under typical urban driving conditions with SAE 0W-30 oil. A two-step Design of Experiments (DoE) approach was employed, where the first step involved mapping the effects of texture parameters, i.e., dimple depth (A = 0.5, 1, 1.5 µm), dimple distance (B = 120, 160, 240 µm), and dimple diameter (C = 50, 60, 70 µm), to identify influential factors. The second step aimed at locating a parameter configuration with minimal friction power loss. The results demonstrated that the optimized texture parameters can significantly reduce friction power loss. The lowest friction power loss of 8.96 W was achieved with a dimple depth of 2 µm, distance of 80 µm, and diameter of 60 µm, which contributed to an 8.3% improvement over the reference surface. The model built to describe the investigated texturing approach exhibited a strong correlation with an R² value of 0.93, and the deviation between predicted and measured values was below 1%. Future work will involve tribometer tests to experimentally validate the optimized parameters and confirm the simulation results. Full article

In this study, NiCrBSi composite coatings reinforced with 5–15 wt.% TiC particles were prepared using laser cladding to investigate the influence of the TiC content and laser beam power on the coatings’ quality, structure, and properties. Penetrant tests revealed the presence of cracks in the composite coatings, which were reduced with the higher laser power due to a decrease in cooling rate. A macroscopic analysis showed that pure NiCrBSi coatings exhibited a high quality and were free of defects, while the addition of TiC particles led to the formation of large pores, particularly in coatings produced with a lower laser power. Microstructural characterization was conducted using Scanning Electron Microscopy (SEM), Energy-Dispersive Spectroscopy (EDS), and X-ray Diffraction (XRD). The microstructure of the pure NiCrBSi coatings consisted of an austenitic matrix with chromium-based precipitates (carbides and borides). Variations in structural morphology across different regions of the coatings and under varying laser powers were described. When TiC particles were added, partial dissolution occurred in the molten pool, enriching it with titanium and carbon, which subsequently led to the precipitation of titanium carbides. The average microhardness of the composite coatings increased by 28%–40% compared to the pure NiCrBSi coating, while the erosion resistance remained comparable. Solid particle erosion tests in accordance with the ASTM G76-18 standard resulted in average erosion values of the pure NiCrBSi coating of 0.0056 and 0.0025 mm³/g for the 30° and 90° impingement angles, respectively. Full article