Search Results (156)

A Ti-Al-Si composite coating was prepared on Ti65 titanium alloy using a two-step hot-dipping + pre-oxidation method to improve its tribological performance and high-temperature oxidation resistance. The second-step dipping time strongly affected the coating microstructure and wear behavior. The optimal coating, prepared with a dipping time of 5 min in each step, exhibited negligible wear after oxidation at 800 °C for 1000 h and 2500 h, with slight adhesive wear and oxidative wear as the dominant mechanisms. Longer dipping times led to mixed wear modes and reduced wear resistance. Under high-temperature corrosion conditions, the coating showed good long-term stability in water vapor, with its mass gain following a sub-parabolic law, Δm = 0.39·t^0.47, because the internal multilayered structure effectively blocked inward oxygen diffusion. However, in environments containing NaCl or 75 wt.% Na₂SO₄ + 25 wt.% NaCl, catastrophic hot corrosion occurred, regardless of the presence of water vapor, through a chlorine-driven oxidation–chlorination–reoxidation autocatalytic cycle. In the mixed salt environment, Na₂SO₄ decomposition supplied additional oxygen and alkaline species, accelerating the degradation and spallation of the Al₂O₃ and TiO₂ scales. Water vapor further intensified this cycle by generating HCl, which promoted rapid consumption of Al and Ti in the coating. This study reveals the wear behavior and hot corrosion failure mechanisms of Ti-Al-Si coatings under complex conditions, providing guidance for process optimization and applications in marine atmospheres. Full article

Hot-press forming (HPF) steel is a promising lightweight material for automotive applications but suffers from oxidation and reduced corrosion due to high-temperature processing. Aluminized coatings, particularly Al-10Si, are widely used to mitigate this issue. However, HPF heat treatment can create brittle alloy layers with cracks, compromising retention and increasing corrosion risk. This study investigated the effects of Sr addition on the microstructure and corrosion resistance of Al-Si-coated HPF steel. Al-Si and Al-Si-Sr coatings were applied to steel substrates and subjected to heat treatment to produce heat-treated (HT) Al-Si and HT Al-Si-Sr samples. Sr addition refined and spheroidized eutectic Si particles, improved coating homogeneity, and mitigated vertical crack formation in the Al-Fe-Si intermetallic layer. The resulting dense, crack-free alloy layer effectively shielded the Fe substrate from corrosion. After heat treatment, Sr facilitated the formation of a fine lamellar microstructure and a dense, continuous oxide film, enhancing coating retention and sustaining barrier protection. These improvements significantly delayed corrosion propagation into the Fe substrate. Corrosion resistance was evaluated using salt-spray tests (ASTM B117), potentiodynamic polarization, and electrochemical impedance spectroscopy in 3.5 wt.% NaCl solutions. Microstructural analyses revealed that even minimal Sr content (0.05%) considerably enhanced the performance of Al-Si coatings, demonstrating industrial applicability. This study highlights the potential of Sr-added Al-Si coatings in addressing the demand for lightweight and corrosion-resistant materials in the automotive industry, offering a viable solution for high-performance and environmentally sustainable applications. Full article

This study investigates the 55%Al-Zn-Si coating system. Using microstructural characterization and thermodynamic simulation, we systematically analyzed its microstructure formation, solidification behavior, and the regulatory effects of Cr, Nb, and V micro-alloying elements. The results show that the typical coating consists of a primary α-Al dendritic skeleton and an interdendritic Zn-rich eutectic phase, exhibiting a characteristic spangle morphology. The addition of Si is crucial. By participating in the formation of a Fe-Al-Si ternary compound layer, it effectively suppresses the intense reaction at the Fe/Al interface, providing essential conditions for the sufficient growth of the outer Al-rich dendrites and the formation of a continuous transition layer. Thermodynamic analysis further clarifies that the coating solidification follows three distinct stages: precipitation of the primary α-Al phase, an Al-Si binary eutectic reaction, and a final Al-Zn-Si ternary eutectic transformation. Regarding micro-alloying, this study reveals the specific roles of different elements: Cr significantly refines the transition layer structure, promoting its transformation from coarse lamellae into a fine and uniform morphology; V tends to combine with Al to form high-melting-point enriched regions, inhibiting the growth of Fe-Al intermetallics and reducing the thickness of the brittle transition layer by approximately 50%; conversely, the addition of Nb disrupts the normal solidification sequence, inducing abnormal segregation of Al-rich and Si-rich phases, which compromises the homogeneity and integrity of the coating structure. Through an in-depth analysis of the fundamental solidification mechanism and micro-alloying effects, this research provides an important theoretical basis for optimizing the microstructure of hot-dip Al-Zn sheets via precise composition design and micro-alloying strategies. Full article

A coupled modeling framework is developed to predict coating thickness after air knife wiping in hot-dip galvanizing. A 3D large eddy simulation (LES) using the WALE sub-grid scale (SGS) model is performed to resolve the jet impingement on the moving strip. Time-averaged wall static pressure $p_{\omega }\left(y\right)$ and wall shear stress ${\tau }_{\omega }\left(y\right)$ along the strip direction are extracted and used as driving inputs for a thin film model. Starting from the continuity and momentum equations, a lubrication-type formulation is derived, leading to a local cubic equation for film thickness $h\left(y\right)$ that accounts for both pressure gradient and gravity. A coupling workflow is established to preprocess the LES wall signals and compute the final coating thickness $h_{final}$. Parametric sweeps of inlet total pressure $P_0$ and the knife-to-strip distance $H$ are employed to construct operating window maps. The predicted trends show that increasing $P_0$ or decreasing $H$ intensifies wall loading and reduces $h_{final}$, while the operating window boundary is governed by the balance between the gas-induced shears. Representative results, including peak wall loading and thickness ranges, are reported for industrially relevant operating conditions. Full article

This review provides a comprehensive overview of high-wear-resistant metal–ceramic surface engineering technologies based on Directed Energy Deposition (DED) for high-temperature industrial applications. In high-temperature processes such as continuous hot-dip coating, critical components (e.g., rollers and sleeves) are exposed to severe wear and chemical reactions, leading to rapid degradation and frequent replacement, which results in significant economic losses. This review focuses on the fundamental characteristics of DED processes and their advantages over conventional surface modification techniques such as HVOF, PVD/CVD, and arc-based methods. Particular attention is given to the process–structure–property relationships governing coating performance, including coating thickness, bonding characteristics, and high-temperature stability. Representative material systems, particularly WC-based metal–ceramic composites (e.g., Co–WC), are systematically discussed in terms of their wear resistance and applicability under severe operating conditions. Quantitative tribological performance metrics, including wear rate and friction coefficient, are also reviewed to provide a more rigorous understanding of coating performance. The analysis highlights that DED offers unique advantages in achieving thick coatings with strong metallurgical bonding and high applicability to repair and remanufacturing of large-scale components. In addition, recent advances in DED technologies, such as closed-loop control, self-regulating effects, and data-driven process optimization, are examined to highlight emerging trends in the field. The review also identifies current technical limitations and outlines future research directions, emphasizing the need for improved process control, defect mitigation, and integration of advanced monitoring techniques. Full article

Objective: This work aims to reduce the surface tension of an aluminum–silicon alloy melt by adding different amounts of the Zn element, thus improving the coatability and coating quality of hot-dip aluminum plating on steel plates. Method: Wetting experiments were conducted at 1023 K using a modified sessile drop method. Conclusions: The addition of the Zn element can reduce the surface tension of the Al-Si alloy, thus decreasing the wettability of the Al-Si alloy. Zn vapor can break down the surface oxide film to expose the fresh melt. The wettability of the Al-10Si alloy on interstitial-free (IF) steel and surface tension were investigated using the modified sessile drop method at 1023 K. Axisymmetric Drop Shape Analysis software was utilized to calculate the contact angles of the Al-10Si-xZn/Al₂O₃ and Al-10Si-xZn/IF steel systems (x ranges from 0 wt.% to 5 wt.%). Moreover, the microtopography and microstructure of surfaces and cross-sections were analyzed by means of an energy-dispersive spectrometer and scanning electron microscope. The results indicated that the surface tension of the alloy melt gradually decreases with an increase in Zn content, ranging from 874 to 760 mN/m. The contact angle of the Al-10Si-xZn alloy melt on IF steel also progressively decreases with increasing Zn content, which is attributed to the lower surface tension of Zn. This study also discovered that the Zn element can disrupt the oxide film of the Al-10Si alloy, exposing the fresh melt and thereby reducing the surface tension of the alloy liquid, thus enhancing wettability. The addition of Zn might be capable of improving the hot-dip aluminizing coatability of steel plates and the quality of the coating. Full article

Corrosion resistance of steel wires can be achieved through several approaches, one of the most established being hot-dip galvanizing. The effectiveness of anticorrosive protection of a galvanized wire is considered to depend not only on the galvanizing process itself, namely bath composition, temperature, and immersion duration—but also on the post-galvanizing wiping method, which ultimately determines the final thickness and uniformity of the zinc coating. This study describes and quantifies the resulting parameters of the Zn layer, systematically comparing two technical variants. Four parameters were analyzed to characterize the coating: the effective thickness of the constituent layers, their morphology (examined by SEM), their compositional profile (EDX mapping), and their microhardness. To comprehensively assess the influence of the wiping method on the anticorrosion performance of the galvanized wire, the final corrosion tests, fifth in the sequence, will be conducted in a salt fog environment using an Erichsen chamber, in accordance with standardized procedures. Full article

This study investigates the technological and chemical causes of early zinc-coating degradation on cold-formed steel sections produced from DX51D+Z140 galvanized coils. Commercially manufactured products exhibiting early corrosion symptoms were used in this study. The entire processing route, which included strip preparation, cold rolling, hot-dip galvanizing, passivation, multi-roll forming, storage, and transportation to customers, was analyzed with respect to the residual surface chemistry and process-related deviations that affect the coating integrity. Thirty-three specimens were examined using electromagnetic measurements of coating thickness. Statistical analysis based on the Cochran’s and Fisher’s criteria confirmed that the increased variability in zinc coating thickness is associated with a higher susceptibility to localized corrosion. Surface and chemical analysis revealed chloride contamination on the outer surface, absence of detectable Cr(VI) residues indicative of insufficient passivation, iron oxide inclusions beneath the zinc coating originating from the strip preparation, traces of organic emulsion residues impairing wetting and adhesion, and micro-defects related to deformation during roll forming. Early zinc coating degradation was shown to result from the cumulative action of multiple technological (surface damage during rolling, variation in the coating thickness) and environmental (moisture during storage and transportation) parameters. On the basis of the obtained results, a methodology was proposed to prevent steel product corrosion in industrial conditions. Full article

Soil corrosion is a critical durability and cost factor for metallic foundations in photovoltaic (PV) power plants, yet it is still addressed with fragmented criteria compared with atmospheric corrosion. This paper reviews the main soil corrosivity drivers relevant to PV installations—moisture and aeration dynamics, electrical resistivity, pH and buffer capacity, dissolved ions (notably chlorides and sulfates), microbiological activity, hydro-climatic variability and geological heterogeneity—highlighting their coupled and non-linear effects, such as differential aeration, macrocell formation and corrosion localization. Building on this mechanistic basis, an engineering-oriented methodological roadmap is proposed to translate soil characterization into durability decisions. The approach combines soil corrosivity classification according to DIN 50929-3 and DVGW GW 9, tiered estimation of hot-dip galvanized coating consumption using AASHTO screening, resistivity–pH correlations and ionic penalty factors, and verification against conservative NBS envelopes. When coating life is insufficient, a traceable steel thickness allowance based on DIN bare-steel corrosion rates is introduced to meet the target service life. The framework provides a practical and auditable basis for durability design and risk control of PV foundations in heterogeneous soils. The proposed framework shows that, for soils exceeding AASHTO mild criteria, zinc corrosion rates may increase by a factor of 1.3–1.7 when chloride and sulfate penalties are considered, potentially reducing coating service life by more than 40%. The methodology proposed enables designers to estimate the penalty factors for sulfates ($f_p\left({SO}_4^{2-}\right)$) and chlorides ($f_p\left({Cl}^{-}\right)$) in each specific project, calculating the appropriate values of $K_{{SO}_4^{2-}}$ and $K_{{Cl}^{-}}$ using electrochemical techniques—ER/LPR and EIS—to estimate the effect of the soluble salts content in the ${Zn}_{Corr Rate}$, not properly catch by the proxy indicator $V_{corr}\left(ER, pH\right)$ when sulfate and chloride content are over AAHSTO limits for mildly corrosive soils. Full article

ZnAl and ZnAlCe layered double hydroxide (LDH) conversion layers modified with picolinoyl N4-phenylthiosemicarbazide (HL) are fabricated on hot-dip galvanized steel (HDG) to improve corrosion protection. X-ray diffraction (XRD) confirms that HL molecules are not intercalated within the LDH interlayers, whereas Fourier transform infrared spectroscopy (FT-IR), X-ray photoelectron spectroscopy (XPS), and energy-dispersive X-ray spectroscopy (EDS) analyses reveal their surface adsorption. Moreover, scanning electron microscopy (FE-SEM) observations reveal that HL modification induces changes in surface morphology. After 168 h in 0.1 M NaCl, the LDH structure remains intact, and N and S signals are still detected, confirming the persistence of both the LDH layer and adsorbed HL molecules under corrosive conditions. During 168 h immersion in NaCl, electrochemical measurements indicate that the modified LDH layers exhibit higher corrosion resistance than the unmodified ones, with the ZnAlCe LDH/HL coating providing the most effective protection. Full article

AISI 1045 steel often undergoes premature failure under combined corrosive-wear conditions due to its insufficient surface durability. To address this, a hot-dip aluminum (HDA) coating was deposited on the steel substrate. The microstructure, corrosion behavior, and tribological properties of the coating were systematically characterized using scanning electron microscopy (SEM), electrochemical techniques, and tribometry. The results reveal that the coating exhibits a continuous triple-layer structure, consisting of the steel substrate, an intermediate Fe-Al intermetallic compound layer, and an outer aluminum-rich layer. In a 3.5 wt.% NaCl solution, the coating formed a protective Al₂O₃ film, demonstrating clear passivation behavior. It significantly enhanced the substrate’s performance, achieving an approximately 90% reduction in wear rate and a substantial increase in charge transfer resistance. The coated sample showed a lower friction coefficient (0.24) compared to the bare substrate (0.34). Herein, this work demonstrates that a straightforward and industrially viable hot-dip aluminizing process can effectively improve the corrosion and wear resistance of medium-carbon steel. The findings provide a practical surface-hardening strategy for such steels operating in aggressive environments. Full article

The stability of the Fe/Zn interface during the hot-dip galvanizing process critically influences the coating’s quality and service performance. In this investigation, the impact of silicon atom positioning on the stability, bonding strength, and electronic structure of the Fe/Zn interface was systematically examined through first-principles calculations grounded in density functional theory, employing the CASTEP software and the GGA-PBE functional. By constructing the FeSi and ZnSi disordered solid solution models, low-energy stable configurations were selected, and 24 ZnSi/FeSi interface models (misfit < 5%) were further established. The interfacial adhesion work, interfacial energy, and electronic structure parameters were systematically calculated. The findings indicate that the position of Si atoms significantly affects interface stability, with Si atoms located on the Zn side exerting a more pronounced influence than those on the Fe side. The interfacial stability is optimal when the Si on the Fe side is far away from the interface and the Si on the Zn side is located at the interface. Notably, the S11Z32 model exhibited the highest adhesion work (4.763 J/m²) and the lowest interface energy (0.022 J/m²). This study elucidates the regulatory role of Si atoms in stabilizing the Fe/Zn interface and provides a theoretical foundation for optimizing the hot-dip galvanizing process and guiding the design of novel materials. Full article

The silicon content in steel is the key to the quality control of hot-dip galvanizing. Its fluctuation will directly restrict the application of galvanized steel by altering the interface reaction and structural stability. This study systematically explored the comprehensive effects of high silicon content in the steel substrate on the microstructure, interface reactions, defect distribution, and mechanical properties of the hot-dip galvanized coating through both experimental and theoretical calculations. Results indicate significant Si segregation at the coating/interface, with co-enrichment of P, leading to uncontrolled Fe-Zn reactions, destabilization of the δ-phase, and abnormal thickening of the ζ-phase (FeZn₁₃), manifesting as the typical “Sandelin Effect.” CT analysis shows defect volumes distributed within 10⁻⁶–10⁻⁵ mm³, predominantly concentrated at the interface, which serve as primary channels for corrosion initiation and spalling failure. Mechanical tests demonstrate that high Si content weakens coating/substrate adhesion, reduces ductility, and accelerates the transition from ductile to brittle fracture under elevated temperatures. This study reveals that high Si content significantly degrades coating reliability through the coupled effects of “abnormal phase growth–element segregation–defect enrichment.” These findings provide theoretical and practical insights into interfacial instability mechanisms and coating optimization strategies for high-Si steel hot-dip galvanizing. Full article

The adoption of advanced high-strength steels (AHSS) in the automotive industry has significantly increased in recent years driven by weight reduction and enhanced crashworthiness. Hot dip galvanised sacrificial coatings are regularly applied to these steels for corrosion protection. In this investigation, the scanning vibrating electrode technique (SVET) demonstrated that hydrogen evolution on the steel substrate is taking place when these sacrificial coatings are damaged during service, increasing the risk of hydrogen embrittlement. The hydrogen embrittlement susceptibility of a new generation of nano-precipitate ferritic, FNP, AHSS have been studied and compared against conventional dual phase ferritic-martensitic, FM, AHSS at equivalent strength levels. Hydrogen permeation tests have shown that FNP AHSS have lower effective diffusion coefficients, D_eff, than FM AHSS at equivalent strength levels. At 800 MPa strength levels D_eff were 1.68 × 10⁻⁷ cm²/s and 1.87 × 10⁻⁷ cm²/s for FNP800 and FM800, respectively. At higher strength levels, 1000 MPa, D_eff were 7.45 × 10⁻⁸ cm²/s and 1.45 × 10⁻⁷ cm²/s for the FNP1000 and FM1000, respectively. Slow strain-rate tests (SSRT) showed that FNP AHSS displayed over 35% higher resistance to hydrogen embrittlement than conventional FM AHSS. Quantitative fractographic analyses confirmed that the new ferritic nano-precipitate microstructure retains much more ductile behaviour than conventional martensitic-ferritic even under the most severe hydrogen charging conditions tested. Full article

Understanding contact mechanics is essential for optimizing electrical and mechanical interfaces, particularly in systems where surface structuring influences performance. This study investigates the mechanical contact behavior of hot-dip tinned copper surfaces modified via Direct Laser Interference Patterning (DLIP). Asymmetric, line-like microstructures with varying periodicities (2–10 µm) and tilt angles (0°, 15°, 30°) were fabricated on both as-received and aged hot-dip tinned copper substrates. The resulting surfaces were characterized using confocal laser scanning microscopy and subjected to indentation testing under controlled loads. Contact mechanical calculations and finite element simulations were employed to determine critical values for plastic deformation onset and to access the real contact area. Results show that structural periodicity, tilt angle, and material condition significantly affect load-bearing capacity and deformation behavior. Notably, intermediate periodicities (e.g., 7.5 µm) on as-received material at 0° tilt exhibited the highest susceptibility to plastic deformation, while aged samples demonstrated improved mechanical stability due to the harder Cu₆Sn₅ surface layer, which forms directly after coating and grows during aging until it reaches the surface and no residual tin is left. These findings provide valuable insights into the design of structured contact surfaces for electrical applications, highlighting the importance of tailored surface morphology and material selection. Full article