Search Results (136)

TiAl alloy offers advantages including low density, high specific strength and stiffness, and excellent high-temperature creep resistance. It is widely used in the aerospace, automotive, and chemical sectors, as well as in other fields. However, at temperatures of 800 °C and above, it forms a porous oxide film predominantly composed of TiO₂, which fails to provide adequate protection. Applying high-temperature protective coatings is therefore essential. Oxides demonstrating protective efficacy at elevated temperatures include Al₂O₃, Cr₂O₃, and SiO₂. The Pilling–Bedworth Ratio (PBR)—defined as the ratio of the volume of the oxide formed to the volume of the metal consumed—serves as a critical criterion for assessing oxide film integrity. A PBR value greater than 1 but less than 2 indicates superior film integrity and enhanced oxidation resistance. Among common oxides, Al₂O₃ exhibits a PBR value within this optimal range (1−2), rendering aluminum-based compound coatings the most extensively utilized. Aluminum coatings can be applied via methods such as pack cementation, thermal spraying, and hot-dip aluminizing. Pack cementation, being the simplest to operate, is widely employed. In this study, a powder mixture with the composition Al:Al₂O₃:NH₄Cl:CeO₂ = 30:66:3:1 was used to aluminize γ-TiAl intermetallic compound specimens via pack cementation at 600 °C for 5 h. Subsequent isothermal oxidation at 900 °C for 20 h yielded an oxidation kinetic curve adhering to the parabolic rate law. This treatment significantly enhanced the high-temperature oxidation resistance of the γ-TiAl intermetallic compound, thereby broadening its potential application scenarios. Full article

Postharvest losses and limited physiological knowledge restrict the conservation and year-round availability of underutilized crops such as Dioscorea trifida. This study characterized the postharvest behavior of Colombian purple D. trifida tubers and evaluated low-cost, GRAS-status technologies to improve storage performance in smallholder production systems. Tubers were stored for 34 days at ambient conditions (20 °C, 90% RH) and compared with treatments including cold storage, calcium pretreatments combined with Aloe vera-based coatings, and short-duration hot water immersion. Over storage, total carbohydrates increased, while potassium remained at substantial levels until the final day. Weight loss and respiration declined steadily, and sprouting was absent, suggesting extended endodormancy in this genotype. Major deterioration causes observed upon reception included fragmentation, insect damage, and surface molds, highlighting the importance of improved sanitation and mechanical protection during harvest, early postharvest stages, and transportation. Edible coatings enhanced antioxidant activity and increased malic and succinic acid concentrations. Cold storage at 3 °C reduced weight loss more effectively than storage at 12 or 20 °C, although citric acid accumulation was greater at the latter temperature. Among all treatments, immersion at 55 °C for 5 min was the most promising, offering a scalable, low-input option to extend shelf life in neglected yam species. Full article

Hot stamping is a promising method to manufacture ultra-high-strength automotive steel components with high dimension accuracy. In this work, two actual industrial production flows (with and without Al-Si hot dipping) were investigated to reveal their microstructural evolution and hydrogen content at different production steps. Meanwhile, the variations in composition and phase structures of the Al-Si coating layer were studied in terms of energy-dispersive spectrometry and electron backscattering diffraction techniques. The results showed that the microstructure at the steel substrate changed from the pancake-shaped pearlite and ferrite, degenerated pearlite and annealed ferrite, lath martensite, and then tempered martensite with the progress of the production steps, which was not affected by the Al-Si hot dipping. The final coating layer exhibited a multi-sublayer structure with the alternative distribution of FeAl and Fe₂Al₅, which contained many microcracks on the brittle phase Fe₂Al₅. The Al-Si-coated specimens always had higher hydrogen content than the bare steel specimens because of the hydrogen generation at the hot stamping stage and hydrogen absorption during the hot-dip aluminizing stage. Full article

The traditional hot-dip tinning processes face challenges in controlling excessive copper dissolution and interfacial instability. This study involved designing a dissolution experiment using the hot-dip tin plating process. Through microscopic characterization and dissolution kinetics analysis, it systematically revealed the regulatory mechanism of trace Ni addition (0–0.5 wt.%) on the dissolution behavior and interfacial reaction of copper wire in a tin alloy melt. The experiment showed that Ni atoms formed a (Cu_1−x,Ni_x)₆Sn₅ ternary phase by replacing Cu in the Cu₆Sn₅ lattice, resulting in a transformation of the grain morphology of the IMC layer from equiaxed to fibrous. At the same time, the addition of Ni changed the kinetics of the interfacial reaction, effectively increasing the activation energy from 40.84 kJ/mol in the pure Sn system to 54.21 kJ/mol in the Sn-0.5Ni system, which extended the complete dissolution time of the copper wire at 573 K by three times. Full article

Structural batteries, also known as “massless batteries”, integrate energy storage directly into load-bearing materials, offering a transformative alternative to traditional Li-ion batteries. Unlike conventional systems that serve only as energy storage devices, structural batteries replace passive structural components, reducing overall weight while providing mechanical reinforcement. However, achieving uniform and efficient coatings of active materials on carbon fibers remains a major challenge, limiting their scalability and electrochemical performance. This study investigates ultrasonic spray coating as a precise and scalable technique for fabricating composite cathodes in structural batteries. Using a computer-controlled ultrasonic nozzle, this method ensures uniform deposition with minimal material waste while maintaining the mechanical integrity of carbon fibers. Compared to traditional techniques such as electrophoretic deposition, vacuum bag hot plate processing, and dip-coating, ultrasonic spray coating achieved superior coating consistency and reproducibility. Electrochemical testing revealed a specific capacity of 100 mAh/g_LFP with 80% retention for more than 350 cycles at 0.5 C, demonstrating its potential as a viable coating solution. While structural batteries are not yet commercially viable, these findings represent a step toward their practical implementation. Further research and optimization will be essential in advancing this technology for next-generation aerospace and transportation applications. Full article

This study evaluates the effects of three mechanical pre-treatment methods on S235JRG2 steel sheets: blasting with a synthetic corundum (F40), blasting with steel shot (S170), and grinding with synthetic corundum (P40). Untreated samples served as a reference. The analysis of mechanical pre-treatments focused on surface integrity, including measurements of surface roughness parameters Ra and Rz (ISO 21920-2) and subsurface microhardness (ISO 6507-1). Zinc coatings were assessed through mechanical testing (cupping test, ISO 1520) and corrosion testing in a neutral salt spray environment (ISO 9227), with results evaluated using digital image analysis. Experimental findings indicate that electroplated zinc deposition rates are influenced by surface roughness, while subsurface microhardness has no significant effect. In contrast, for hot-dip galvanizing, both parameters impact the process. The mechanical properties of electroplated zinc coatings are further affected by steel surface integrity, whereas hot-dip zinc coatings are primarily governed by intermetallic phase formation, making the influence of steel surface integrity statistically negligible. Corrosion testing revealed that blasting with a synthetic corundum is particularly unsuitable, as it leads to numerous inhomogeneities in both coating types, accelerating corrosion degradation. Full article

This paper presents a novel and effective approach for the rational selection of zinc coatings in industrial applications. The corrosion behaviors of three types of zinc coatings were investigated through salt spray testing in the laboratory. Corrosion failure characteristics of the coatings were analyzed using corrosion morphology observation, electrochemical analysis, corrosion product identification, and weight loss measurements. Additionally, the environmental impacts of the production processes for the three coatings were evaluated. Among the three coatings, the thermally sprayed zinc–aluminum coating exhibited the best corrosion resistance in the salt spray test, while the hot-dip zinc coating showed the poorest performance. The electrochemical characteristics of the coatings at various stages of corrosion were examined using polarization curves, revealing the changes in corrosion current and corrosion potential that corresponded to the failure progression of the coatings. The corrosion products of the thermally sprayed zinc–aluminum coating primarily included ZnO, Al₂O₃, Zn(OH)₂, and ZnAl₂O₄ phases. In contrast, the corrosion products of the thermally sprayed zinc coating and the hot-dip zinc coating predominantly consisted of ZnO and Zn(OH)₂ phases. Finally, the environmental impact indicators of the three coatings were assessed using the IMPACT2002+ method. Full article

Inorganic/organic composite passivation film can significantly improve the corrosion resistance performance of hot-dip Al-Zn-coated steel. However, yellowing of the passivation film always leads to obvious performance degradation in corrosion resistance. Investigating the yellowing mechanism of the passivation film and its impact on corrosion resistance would provide a foundation for enhancing its yellowing resistance property. This study primarily focuses on the yellowing mechanism of the passivation film based on the copolymer of N-vinylpyrrolidone and N-vinylcaprolactam. It is found that the oxidation and semi-carbonization of butyramide and valeroamide generated by C–N bond cleavage in the copolymer at high temperatures are responsible for the yellowing of the passivation film. The cracking of the passivation film caused by yellowing degree exposes more of the bare Al-Zn coating, further accelerating the degradation in the corrosion resistance. Additionally, it is observed that the impact of yellowing on the corrosion resistance is negligible when the color difference (ΔE*) caused by yellowing is less than 3.0, whereas ΔE* values above 3.0 result in rapid degradation in the corrosion resistance of the passivation film. The formula y = 0.77 − 0.07x + 0.023x² + 0.0039x³ effectively expresses the relationship between corrosion area (y) and ΔE* (x) (R² = 0.995). Full article

The article compares the properties of coatings (cataphoretic, hot-dip zinc, and thermo-diffusion zinc) applied to steel components used in the automotive industry. The research focused on the analysis of corrosion resistance, hardness measurements, and tribological properties conducted on steel guides used in trailer and truck body structures as well as fasteners (M12 × 40 bolts). The base surfaces were cleaned chemically. Corrosion resistance was tested in a salt chamber, while coating thickness was measured using the magnetic induction method. Coating hardness (HV 0.02) was assessed with a microhardness tester, and tribological properties were tested under dry friction conditions. The results showed that the zinc coatings demonstrated corrosion resistance far superior to paint coatings. Full article

Mg-Cu bimetallic materials have been widely studied because of their low density, good electrical conductivity, and excellent hydrogen storage properties. However, the interface bonding strength of Mg/Cu is low. In this study, we examined the effect of hot-dip tin coating (HDTC) with copper (Cu) on the interfacial metallurgical bonds between AZ91D Magnesium (Mg) alloy and Cu composite casting. A transition layer composed of Mg₂Cu and MgCu₂ intermetallic compounds (IMCs) formed at the interface of the AZ91D/HDTC-Cu composite casting. However, the transition layer was about 1 μm at the AZ91D/Cu interface, mainly comprising Mg(Al, Cu)₂ IMC. Both the AZ91D/Cu and AZ91D/HDTC-Cu interfaces exhibited many labyrinthine Mg(Al, Cu)₂ IMCs and layer-like Mg₂(Al, Cu) IMCs. Moreover, the interfacial shear strength of the AZ91D/Cu was changed from 12.6 MPa to 52.4 MPa due to the solid solution of Sn atom and the precipitation of Mg₂Sn IMC at the interface after HDTC treatment. Meanwhile, the shear fracture surfaces are characterized by brittle fractures. Full article

In the Czochralski single-crystal silicon manufacturing industry, single-crystal furnaces often experience corrosion from silicon vapor, which reduces their operational lifespan. However, the preparation of metal coatings on the surface of C/C composites is challenging due to their low coefficient of thermal expansion and the intricate structure of carbon fibers. To address this issue and achieve high-quality alloy coatings, Ni-Al and Ni-Al/Si composite coatings are successfully prepared on the surface of C/C composites through a combination of electroplating and hot-dip plating, and their oxidation behavior at elevated temperatures is thoroughly investigated. The experimental results indicate that the Ni-Al composite coatings exhibit superior antioxidant properties compared to Ni coatings following thermal shock experiments, thereby significantly enhancing the antioxidant performance of C/C composites. This improvement is attributed to the preferential oxidation of surface aluminum, which forms a dense Al₂O₃ layer in aerobic and high-temperature environments, effectively preventing oxygen from reaching the underlying matrix. During the oxidation process, coating elements migrate outward along the concentration gradient, while oxygen molecules diffuse inward. Simultaneously, aluminum atoms diffuse inward, and Ni atoms diffuse outward, where they partially dissolve with oxygen. The inner coating’s Ni enhances the bonding of the coating by connecting the substrate to the outer layer. Meanwhile, the added Si in the Ni-Al/Si composite coating further improves the antioxidant properties of the coating. Full article

In this paper, the results of a study of the structure and phase composition of the hot-dip aluminizing coatings formed on the commercially pure titanium surface in AW-6063 aluminum alloy melt after heat treatment at 700 and 850 °C are presented. It is shown that as a result of aluminizing on the titanium surface, a homogeneous coating 30–40 µm thick without defects is formed. The hot-dip aluminizing coating consists of aluminum and the intermetallic compound TiAl₃, located at the boundary with the substrate. Heat treatment results in the formation of a heterogeneous coating structure: its outer layer has a frame-type structure consisting of TiAl₃ particles surrounded by an Al₂O₃ + TiO₂ grid, and the inner continuous layer adjacent to the titanium consists of TiAl₂, TiAl, and Ti₃Al intermetallic layers. Increasing in the heat treatment temperature and/or holding time results in an increase in the thickness of both the outer and boundary layers of the coating. A mechanism for the formation of the coating structure via heat treatment is proposed. The scratch test method was used to evaluate the cohesive and adhesive strength of the coatings, and their scratch hardness was determined, which averaged 200 MPa. It was shown that the coating structure formed during heat treatment at 850 °C ensures higher resistance to cohesive failure. Full article

This paper presents the results of studies on the growth kinetics, microstructure (SEM/EDS) and corrosion behavior of coatings obtained by hot-dip galvanizing process in baths containing Bi additive. The coatings for testing were produced on low-silicon steel in a Zn bath containing 0.04, 0.12 and 0.4 wt.% Bi. The corrosion resistance of the coatings was determined comparatively in standard Neutral Salt Spray Tests (NSST) (ISO 9227) and sulfur dioxide test (SDT) in a humid atmosphere (ISO 22479). Potentiodynamic tests and electrochemical impedance spectroscopy measurements were conducted. It was found that the addition of 0.04 and 0.12 wt.% Bi reduces the total thickness of the coatings and the thickness of intermetallic layers, while the content of 0.4 wt.% Bi in the bath increases the thickness of the layers forming the coating. Direct corrosion tests (NSST and SDT) and electrochemical tests showed that the addition of Bi to the zinc bath reduces the corrosion resistance of the coatings. The corrosion resistance of the coatings decreases with increasing Bi concentration in the zinc bath. In the microstructure of the coatings, it was found that Bi precipitates mainly on the surface of the coating, but also on the cross-section of the outer layer and ζ intermetallic layer. Bi precipitates, due to their cathodic nature, affect the reduction of the corrosion resistance of the coatings with the increase of their content in the bath. Full article

Metallization, a process for applying anti-corrosion coatings, has advantages over hot-dip galvanizing, such as reduced thermal stress and the ability to work “in situ”. This process consists of the projection of a protective metal as coating from a wire as application material, and this wire is obtained by multi-stage wiredrawing. For the metallization process, a zinc–aluminum alloy wire obtained by this process is used. This industrial process requires multiple stages/dies of diameter reduction, and determining the optimal sequence is complex. Thus, this work focuses on developing models with the aim of designing and optimizing the wiredrawing process of zinc–aluminum (ZnAl) alloys, specifically ZnAl15%, used for anti-corrosion applications. Both analytical models and numerical models based on the finite element method (FEM) and implemented by computer-aided engineering (CAE) software Deform 2D/3D v.12, enabled the prediction of the drawing stress and drawing force in each drawing stage, producing values consistent with experimental measurements. Key findings include the modeling of the material behavior when ZnAl15% wires were subjected to the tensile test at different speeds, with strain rate sensitivity coefficient m = 0.0128, demonstrating that this type of alloy is especially sensitive to the strain rate. In addition, the optimal friction coefficient (µ) for the drawing process of this material was experimentally identified as µ = 0.28, the ideal drawing die angle was determined to be 2α = 10°, and the alloy’s deformability limit has been established by a reduction ratio r ≤ 22.5%, which indicates good plastic deformation capacity. The experimental results confirmed that the development of the proposed models can be feasible to facilitate the design and optimization of industrial processes, improving the efficiency and quality of ZnAl15% alloy wire production. Full article

Several prestressing reinforced structures have recently collapsed due to chloride-induced steel corrosion. This study investigates the effect of the corrosion of hot-dip galvanized conventional prestressing steel reinforcement under hydrogen evolution on bond strength in normal-strength concrete. The impact of hydrogen evolution on the porosity of cement paste at the interfacial transition zone (ITZ) is verified through image analysis. The whole surface of prestressing strands is hot-dip galvanized, and their corrosion behavior when embedded in the cement paste is investigated by measuring the time dependence of the open-circuit potential. Concerning the uniformity of the hot-dip galvanized coating and its composition, it is advisable to coat the individual wires of the prestressing reinforcement and subsequently form a strand. It is demonstrated that the corrosion of the coating under the evolution of hydrogen in the cement paste reduces the bond strength of hot-dip galvanized reinforcement in normal-strength concrete. Image analysis after 28 days of cement paste aging indicates insignificant filling of hydrogen-generated pores by zinc corrosion products. Applying an additional surface treatment (topcoat) stable in an alkaline environment is necessary to avoid corrosion of the coating under hydrogen evolution and limit the risk of bond strength reduction. Full article