Search Results (41)

Tribological processes in extreme environments pose serious material challenges, requiring coatings that resist both wear and corrosion. This review summarizes recent advances in protective coatings engineered for extreme environments such as high temperatures, chemically aggressive media, and high-pressure and abrasive domains, as well as cryogenic and space applications. A comprehensive overview of promising coating materials is provided, including ceramic-based coatings, metallic and alloy coatings, and polymer and composite systems, as well as nanostructured and multilayered architectures. These materials are deployed using advanced coating technologies such as thermal spraying (plasma spray, high-velocity oxygen fuel (HVOF), and cold spray), chemical and physical vapor deposition (CVD and PVD), electrochemical methods (electrodeposition), additive manufacturing, and in situ coating approaches. Key degradation mechanisms such as adhesive and abrasive wear, oxidation, hot corrosion, stress corrosion cracking, and tribocorrosion are examined with coating performance. The review also explores application-specific needs in aerospace, marine, energy, biomedical, and mining sectors operating in aggressive physiological environments. Emerging trends in the field are highlighted, including self-healing and smart coatings, environmentally friendly coating technologies, functionally graded and nanostructured coatings, and the integration of machine learning in coating design and optimization. Finally, the review addresses broader considerations such as scalability, cost-effectiveness, long-term durability, maintenance requirements, and environmental regulations. This comprehensive analysis aims to synthesize current knowledge while identifying future directions for innovation in protective coatings for extreme environments. Full article

This paper presents the results of a comprehensive study of the structure, phase composition, thermal corrosion, and tribological properties of multilayer gradient coatings based on YSZ/NiCrAlY obtained using detonation spraying. X-ray phase analysis showed that the coatings consist entirely of metastable tetragonal zirconium dioxide (t’-ZrO₂) phase stabilized by high temperature and rapid cooling during spraying. SEM analysis confirmed the multilayer gradient phase distribution and high density of the structure. Wear resistance, optical profilometry, wear quantification, and coefficient of friction measurements were used to evaluate the operational stability. The results confirm that the structural parameters of the coating, such as porosity and phase gradient, play a key role in improving its resistance to thermal corrosion and CMAS melt, which makes such coatings promising for use in high-temperature applications. It is shown that a dense and thick coating effectively prevents the penetration of aggressive media, providing a high barrier effect and minimal structural damage. Tribological tests in the temperature range from 21 °C to 650 °C revealed that the best characteristics are observed at 550 °C: minimum coefficient of friction (0.63) and high stability in the stage of stable wear. At room temperature and at 650 °C, there is an increase in wear due to the absence or destabilization of the protective layer. Full article

Developing resource-efficient technologies for producing ceramic materials with specific properties and performance characteristics is one of the most important tasks in modern materials science. As natural resources face depletion, the use of anthropogenic wastes, including fly ash from coal combustion, for the development of new compositions and the production of ceramics with an improved microstructure is of particular significance. The use of PM₁₀ fly ash microspheres in ceramic production will help to reduce particulate matter emissions. In this study, fine narrow fractions of PM₁₀ microspheres were successfully separated from coal fly ash using aerodynamic and magnetic separation. Glass–ceramic materials with a homogeneous microstructure, an open porosity of 0.4–37%, a compressive strength of 5–159 MPa, and acid resistance of up to 99.9% were obtained using narrow fractions. The materials obtained are promising for application as highly porous ceramics, effective microfiltration membranes, and fine-structured technical ceramics, which can be used in installations operating in aggressive media and/or at high temperatures. The ceramic membranes were characterised by high liquid permeability values up to 1194 L·m⁻²·h⁻¹·bar⁻¹. Filtration tests showed that the retention coefficient for dispersed microsilica particles with d_av = 1.9 μm is 0.99. Full article

Additive manufacturing (AM), particularly fused deposition modeling (FDM) 3D printing, has emerged as a versatile and accessible technology for prototyping and functional part production across a wide range of industrial applications. One of the critical performance-limiting factors in AM is the chemical resistance of thermoplastic materials, which directly influences their structural integrity, durability, and suitability in chemically aggressive environments. This study systematically investigates the chemical resistance of eight different widely utilized FDM filaments—acrylonitrile butadiene styrene (ABS), acrylonitrile styrene acrylate (ASA), polyamide (PA, Nylon), polycarbonate (PC), polyethylene terephthalate glycol (PETG), polylactic acid (PLA), polypropylene (PP), and polyvinyl butyral (PVB)—by examining their tensile strength and impact resistance after immersion in representative chemical agents: distilled water, ethanol (99.5%), isopropyl alcohol (75% and 99%), acetic acid (8%), hydrochloric acid (37%), hydrogen peroxide (30%), and acetone (99.5%). Quantitative mechanical testing was conducted in accordance with ASTM D638 and ASTM D256 standards, and statistical variability was accounted for using triplicate measurements with standard deviation analysis. The results reveal that PP exhibits the highest chemical resilience, retaining over 97% of its mechanical properties even after 7 days of immersion in aggressive solvents like acetone. PETG and ASA also demonstrated quite successful stability (>90% retention) in mildly corrosive environments such as alcohols and weak acids. In contrast, PLA, due to its low crystallinity and polar ester backbone, and PVB, due to its high amorphous content, showed substantial degradation: tensile strength losses exceeding 70% and impact resistance dropping below 20% in acetone. Moderate resistance was observed in ABS and PC, which maintained structural properties in neutral or weakly reactive conditions but suffered mechanical deterioration (>50% loss) in solvent-rich media. A strong correlation (r > 0.95) between tensile and impact strength reduction was found for most materials, indicating that chemical attack affects both static and dynamic mechanical performance uniformly. The findings of this study provide a robust framework for selecting appropriate 3D printing materials in applications exposed to solvents, acids, or oxidizing agents. PP is recommended for harsh chemical environments; PETG and ASA are suitable for moderate exposure scenarios, whereas PLA and PVB should be limited to low-risk, esthetic, or disposable applications. Full article

The aim of this research was to examine the effect of water-based hydrophobic impregnations on concrete in order to improve its durability, chemical resistance, and physical–mechanical parameters. The purpose of this research was to prevent as much water evaporation as possible during concrete hydration, which resulted in the improvement in concrete properties including strength, durability, resistance of concrete in high-pressure water, water tightness, etc. Water-based hydrophobic impregnations based on silane and siloxane, epoxy resin, and oil were chosen to achieve improvements in concrete parameters. The comparison of water-based hydrophobic impregnations with solvent-based hydrophobic impregnations was also performed using the determination of absorbency, water pressure penetration depth, watertightness, concrete penetration depth, and resistance to aggressive environment. The concrete microstructure was observed using a digital microscope and a scanning electron microscope (SEM). Samples with hydrophobic agents exhibited a higher contact angle, lower absorbency, and higher resistance to aggressive environment, when compared to the untreated surfaces, confirming the water repellency of the water-soluble hydrophobic impregnations. The positive effect of hydrophobic agents in the compressive strength was also recorded. Furthermore, the benefit of the addition of 0.1 wt.% of nanocellulose into the hydrophobic impregnations was observed. Based on the obtained results, it was found that the addition of nanocellulose to water-soluble hydrophobic impregnations reduced the depth of pressurized water seepage and increased the compressive strength of the concrete after 28 days by 2 MPa. Full article

In this work, the effect of an acidic environment on the structure of composite samples based on ultra-high molecular weight polyethylene (UHMWPE) modified with mineral filler in the form of diabase (DB) is studied. The stability of samples was investigated in solutions of sulfuric (H₂SO₄) and hydrochloric (HCl) acids with concentrations of 10 vol% and 20 vol% at room temperature for 16 weeks. It was found that the introduction of 10 wt% DB into the UHMWPE matrix significantly increases the resistance of the composite sample to aggressive media, which is confirmed by the minimum degree of swelling compared to pure UHMWPE and composites with higher filler content. Scanning electron microscopy (SEM) demonstrated a uniform distribution of DB in the sample structure and the absence of defects such as agglomeration and cracks. The methods of infrared spectroscopy (IRS) and X-ray structural analysis (XRD) revealed a decrease in the degree of crystallinity of the samples after acid exposure, but no significant changes in the chemical structure of the materials were recorded, which confirms their resistance to chemical degradation. The best chemical resistance was demonstrated by composites containing 10 wt% DB, which is associated with the formation of a barrier structure preventing the diffusion of acids. The obtained results indicate the promising application of UHMWPE with DB filler to create samples resistant to aggressive media. Full article

This paper aims to verify the effect of water-soluble hydrophobisations on cementitious composites such as concrete (S1) and cement-bonded particle boards (S2). The research was focused on the water-soluble hydrophobisations based on methylsilanolate (MS), a mixture of silanes and siloxanes (SS) and alcohol with the addition of nano-silica (N). The results provide a comprehensive overview of the benefits and effectiveness of water-soluble hydrophobisations in the context of building materials, outlining a direction towards the development of new, more environmentally friendly solutions in the construction industry. For this reason, alternative raw materials (brick recyclate and brick dust) were used for S1 substrate preparations. How the water-soluble hydrophobisations, including hydrophobisations with the addition of nano-silica (N), affect the process of water evaporation during hydration and the resulting water repellence of the S1 and S2 substrates were experimentally verified through a series of tests, e.g., measurement of the contact angle and depth of water penetration under pressure. The evaluation of the effect of hydrophobisations on the resistance of substrate to aggressive gaseous and liquid environments was observed by the determination of the resistance to carbonation and sulphation processes and the resistance of the concrete to aggressive liquid media (10% H₂SO₄, 10% CH₃COOH). Although the hydrophobisations did not have a significant effect on some aspects of S1, such as the resistance to carbonation and sulphate attack, improvement was observed in other areas, such as the quadrupling increase in contact angle of the surface and 9 mm decrease in water pressure penetration into the concrete substrate. Full article

To date, composite materials, such as polymer concrete, have found wide application in various industries due to their unique properties combining high strength, resistance to aggressive media and durability. Improving the performance characteristics of polymer concrete is an important task aimed at expanding the areas of its application. One of the promising methods of increasing the strength of this material is the use of various fillers. In this paper, the effect of fillers, based on carbon and basalt fibres, on the mechanical properties of polymer concrete was investigated. The polymer concrete was made of the following components: rubble stone, sand, quartz flour and polyester resin. During the experimental work, the amount of carbon and basalt fibres in the polymer concrete mixture varied from 0 to 6%. Bending and compressive strength tests showed that the addition of carbon and basalt fibres increased these properties. The highest bending and compressive strengths were achieved when carbon fibre contents were up to 1.5%, while basalt fibres provided the highest strengths in the case of around 2%. These results confirmed that carbon fibres had a higher efficiency in strengthening polymer concrete compared to that of basalt fibres. This could be explained by the fact that carbon fibres had a higher tensile strength and modulus of elasticity, which allowed them to better redistribute loads within the composite material. The fibre length for carbon fibre, which gave the maximum increase in properties, was 10–15 mm. For basalt fibre, the maximum bending strength was reached at 20 mm and compressive strength at 10 mm. Increasing the content of carbon fibre above 2% and basalt fibre above 1.5% did not give further increase in mechanical properties. In conclusion, it could be stated that the use of carbon fibres as fillers offered significant advantages in strengthening polymer concrete, opening up opportunities for its use in more demanding conditions and in a wider range of industrial applications. Full article

Ti alloys have been widely used in biomedical applications due to their special properties. They have specific properties such as biocompatibility, biofunctionality and high corrosion resistance, which enable them to function inside the human body. Among them, Ti-6Al-4V is probably one of the most widely used alloys for implants. However, aluminum and vanadium ions have been reported to cause problems and adverse reactions in the human body over long periods. Thus, in the present study, Ti–15Zr–10Nb alloy synthesized by high vacuum melting was manufactured and characterized by different techniques. The phase composition was determined by XRD. This showed the presence of α and β phases in the alloy, consistent with the microstructural study. From a microstructural point of view, the alloy shows lamellar and acicular structures with α-grain boundaries. Vickers microhardness measurements showed an increased hardness compared to Ti-CP. Furthermore, the electrochemical behavior was evaluated using HCl as an electrolyte. The obtained results were compared to Ti-CP tested in the same electrochemical condition. The studies indicated that Ti-CP presents a nobler electrochemical behavior than Ti-15Zr-5Nb. Thus, despite the very good corrosion properties of Ti-15Zr-5Nb in a simulated oral environment and Ringer’s solutions, the present study reveals that the Ti-15Zr-5Nb alloy has lower corrosion resistance in aggressive media when compared to Ti-CP. Full article

Thin films of transition metal oxides and oxynitrides have proven highly effective in protecting stainless steels against corrosion in both chemically aggressive environments and biological fluids. In the present work, cerium zirconium oxynitride thin films were deposited to enhance the corrosion resistance of surgical-grade stainless steel to be used in osteosynthesis processes. Two techniques were employed: co-sputtering and radiofrequency (RF) sputtering, and the morphology and corrosion efficiency of the coatings deposited by each technique were evaluated. X-ray diffraction, X-ray photoelectron spectroscopy and field emission transmission electron microscopy were used to characterize the morphological and chemical structure, respectively. Additionally, the corrosion resistance of the oxynitride-coated surgical grade stainless steel system (ZrCeO_xN_y-AISI 316L) was assessed using Hank’s solution as the corrosive electrolyte, to determine its resistance to corrosion in biological media. The results show that ZrCeO_xN_y coatings increase the corrosion resistance of surgical grade stainless steel by two orders of magnitude and that the Ce(III)/Ce(IV) equilibrium decreases the corrosion rate, thereby increasing the durability of the steel in a biological environment. The results show that Ce coatings increase the corrosion resistance of surgical grade stainless steel by two orders of magnitude and that the Ce(III)/Ce(IV) equilibrium decreases the corrosion rate, thereby increasing the durability of the steel in a biological environment. Full article

The purpose of this study is to determine the material properties of CFRP composites in the form of a fabric for the construction of racing car bodywork. This work focused on the determination of the strength and tribological properties as well as investigating the effects of the operating environment on the developed material. Three material variants, differing in the number of layers used to produce the reinforcement, were used in this study. The tests were carried out on two-/three-/four-layer sheets produced by infusion. Due to the later use of the tested composites for the sheathing of a racing car, the results obtained were analysed in terms of the most favourable strength properties while keeping the weight as low as possible. In this study, the hardness, impact strength, and tensile and bending stresses of the developed composites were examined. In addition to the strength properties, the density, the effects of immersion in water, and the composite’s resistance to staining and friction in the presence of aggressive media were also checked. The structure and the breakthroughs resulting from the strength tests were observed using a stereoscopic microscope. The material’s resistance to sunlight and UVB was also tested. Full article

Microbiologically influenced corrosion (MIC) is a serious threat to the integrity of crude oil pipelines. Sulphate-reducing bacteria (SRB) are the primary microorganisms responsible for MIC, and their aggressiveness is dependent on the energy source available to them. Acetate, a common energy source, has been shown to accelerate the corrosion of carbon steel in the presence of SRB. This study investigated the effect of acetate on the growth of SRB and the corrosion of carbon steel plates in simulated anaerobic conditions. The corrosion kinetics were studied using linear polarization resistance (LPR) and weight loss immersion tests for 42 days. The samples were characterized using Scanning Electron Microscopy (SEM) and Energy-Dispersive X-ray Spectroscopy (EDX). The results show that the addition of acetate to cultured media significantly increased the corrosion rate of carbon steel plates in both formation water and Postgate Medium B (PMB). This was due to increased growth of SRB in the presence of acetate, which led to the production of more corrosive hydrogen sulphide (H₂S). The findings based on experimental data obtained from this study confirm that acetate can accelerate the corrosion of carbon steel in the presence of SRB. Full article

In this study, the suitability of waste from glass fibre production as a secondary filler for a polymeric durable hydrophobic coating, based on an innovative polyurethane organic–mineral base, was experimentally verified. The main aim of this work was to develop a basic formulation for a polymeric hydrophobic coating designed primarily for usage in aggressive environments. For this purpose, a total of four formulations were tested with different weight percentages of waste glass fibre, i.e., from 30 to 60%. The basic properties in the fresh state, such as the coating workability and kinematic and dynamic viscosity, were verified, and an application test was performed. The formulations were also verified after the polymerisation of the coating. Adhesion on a concrete substrate and the tensile properties and hardness of the coating were tested. Chemical resistance to liquid aggressive media and the microstructure of the coating after exposure to SO₂ were also tested, as these are critical properties. All the formulations showed better workability than the reference coating without a filler, and the formulation with the highest filling (60%) appeared to be optimal. The maximum adhesion on the concrete substrate (11.9 MPa) and tensile strength (21.6 MPa) were recorded for the formulation with 60% waste fibreglass. It can be concluded that with an increase in the waste glass content, there was a significant improvement in the properties of the coatings. Additionally, the waste fibreglass did not have a significant negative impact on chemical resistance. Full article

Traditional butyl rubber halogenation technology involves the halogenation of IIR using molecular chlorine or bromine in a solution. However, this method is technologically complex. This study investigated a novel method for the halogenation of butyl rubber to enhance its stability and resistance to thermal oxidation and aggressive media. The butyl rubber was modified through mechanochemical modification, induced by solvent swelling in a polychlorinated n-alkane solution. During the modification, samples were obtained with chlorine content ranging from 3 to 15%. After extraction, the halogen content was quantitatively determined with the oxygen flask combustion method and X-ray photoelectron spectroscopy. It was shown that for samples with total chlorine content of up to 6%, there was almost no leaching of chlorine from the samples. The chemical structure of the extracted rubbers was ascertained using FT-IR and ¹H NMR spectroscopy, and it was demonstrated that all samples showed absorption peaks and signals typical for chlorobutyl rubbers. It was observed that modification with polychlorinated n-alkanes improved the thermal and oxidative stability (the oxygen absorption rate decreased by 40%) and chemical resistance, estimated by the degree of swelling, which decreased with the increase in the chlorine content. This technology allows the production of a chlorinated rubber solution that can be directly used by rubber goods manufacturers and suppliers. Full article

In case of using titanium alloys in equipment exposed to aggressive media (for example, sea water), it is necessary to take into account and, first of all, prevent the formation of a galvanic couple of titanium and another metal/alloy, which in most cases leads to the corrosion destruction of the latter. Another significant problem of using titanium is its low wear-resistance and poor tribological characteristics. To impart the necessary properties to titanium and its alloys, a composite coating was formed on the top of titanium. For the coating formation, a combination of the plasma electrolytic treatment and polymer spraying was used. The SEM, EDS and XRD analyses established morphological features, elemental and phase composition of the composite coatings. Contact angles and the wettability parameters of the composite coatings were investigated. An analysis of the data obtained showed that composite coatings have better protective properties than untreated material and base PEO coatings. Full article