Search Results (141)

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 study investigates the development of silver (Ag)-doped zirconia (ZrO₂) coatings deposited on 316LVM stainless steel via the unbalanced magnetron sputtering technique. The oxygen content in the Ar/O₂ gas mixture was systematically varied (12.5%, 25%, 37.5%, and 50%) to assess its influence on the resulting coating properties. In response to the growing demand for biomedical implants with improved durability and biocompatibility, the objective was to develop coatings that enhance both wear and corrosion resistance in physiological environments. The effects of silver incorporation and oxygen concentration on the structural, tribological, and electrochemical behavior of the coatings were systematically analyzed. X-ray diffraction (XRD) was employed to identify crystalline phases, while atomic force microscopy (AFM) was used to characterize surface topography prior to wear testing. Wear resistance was evaluated using a ball-on-plane tribometer under simulated prosthetic motion, applying a 5 N load with a bone pin as the counter body. Corrosion resistance was assessed through electrochemical impedance spectroscopy (EIS) in a physiological solution. Additionally, tribocorrosive performance was investigated by coupling tribological and electrochemical tests in Ringer’s lactate solution, simulating dynamic in vivo contact conditions. The results demonstrate that Ag doping, combined with increased oxygen content in the sputtering atmosphere, significantly improves both wear and corrosion resistance. Notably, the ZrO₂-Ag coating deposited with 50% O₂ exhibited the lowest wear volume (0.086 mm³) and a minimum coefficient of friction (0.0043) under a 5 N load. This same coating also displayed superior electrochemical performance, with the highest charge transfer resistance (38.83 kΩ·cm²) and the lowest corrosion current density (3.32 × 10⁻⁸ A/cm²). These findings confirm the high structural integrity and outstanding tribocorrosive behavior of the coating, highlighting its potential for application in biomedical implant technology. Full article

Nickel aluminum bronze (NAB) and manganese aluminum bronze (MAB) are widely used in propulsion and seawater handling systems in naval platforms due to their attractive combination of mechanical strength, toughness, and very low susceptibility to marine corrosion. Nevertheless, it is well known that they can suffer from selective phase corrosion and erosion–corrosion, primarily caused by cavitation and sand erosion. Both alloys have a multiphase microstructure that governs their mechanical and chemical behavior. The tribocorrosion behavior of cast NAB and MAB alloys was studied in artificial seawater to analyze the effect on microstructure. The microstructure and nanohardness were evaluated and correlated with tribocorrosion test results conducted under two different loads (10 and 40 N) in a unidirectional sliding mode using a 1 M NaCl solution as the electrolyte. A significant increase in the corrosion rate due to the wear effect was observed in both alloys. MAB exhibited a slightly better tribocorrosion performance than NAB, which was attributed to significant differences in the shape, distribution, and size of the intermetallic kappa phases—rich in iron, aluminum, and nickel—within the microstructure. Pitting corrosion was observed in NAB, while selective corrosion of kappa phases occurred in MAB, highlighting the role of the protective layer in the tribocorrosion behavior of both alloys. These findings were supported by post-test solution analysis using ICP-AES and corrosion product characterization by EDX. A synergistic effect between wear and corrosion was confirmed for both alloys, as erosion removes the protective layer, exposing fresh material to continuous friction and favoring a progressive material loss over time. The practical impact of this study lies in improving the control and design of highly alloyed bronze microstructures under in-service corrosion–erosion conditions. Full article

This study investigates the tribo-corrosion behavior of Ti6Al4V biomedical alloy, when sliding against fused filament fabrication (FFF) 3D-printed polyether ether ketone (PEEK) pins in a phosphate-buffered saline (PBS) solution. This research aims to evaluate wear mechanisms and electrochemical responses under simulated physiological conditions, providing critical insights for enhancing the durability and performance of biomedical implants. Potentiodynamic polarization tests demonstrate that the Ti6Al4V alloy possesses excellent corrosion resistance, which is further enhanced under sliding conditions compared to the test without sliding. When tested against 3D-printed PEEK, the alloy exhibits a mixed wear mechanism characterized by both abrasive and adhesive wear. Open-circuit potential (OCP) measurement of Ti6Al4V demonstrates the alloy’s superior electrochemical stability, indicating high corrosion resistance and a favorable coefficient of friction. These findings highlight the potential of 3D-printed PEEK as a viable alternative for biomedical applications, offering rapid patient-specific prototyping, tunable mechanical properties, and improved surface adaptability compared to conventional materials. Full article

This study investigates the tribocorrosion behavior of 304 stainless steel (304SS), S31254 super austenitic stainless steel (S31254 SASS), and a medium-entropy austenitic stainless steel (MEASS) in 3.5 wt.% NaCl solution under sliding conditions. The objective is to clarify the performance differences among these alloys when exposed to simultaneous mechanical wear and corrosion. Electrochemical techniques, including potentiodynamic polarization and potentiostatic sliding tests, were used to evaluate corrosion resistance and repassivation behavior. Quantitative analysis based on ASTM G119 revealed that MEASS showed a 68% lower total material loss compared to 304SS and a 55% lower loss compared to S31254. MEASS also exhibited the lowest corrosion current density (1.46 μA/cm²) under tribocorrosion conditions, representing an 83% reduction compared to 304SS. These improvements are attributed to the higher chromium and nickel contents of MEASS, which enhance passive film stability and reduce susceptibility to localized corrosion. The results demonstrate that MEASS offers superior resistance to combined mechanical and corrosive degradation in chloride-containing environments. Full article

Food security is one of the main problems in several countries. In food processing the cutting operation is very important as the operation is basic to food preparation. Due to cutting tools being exposed to a high-demand environment that includes high contact pressure, a corrosive atmosphere, and a high-speed process, they are subject to high mechanical and corrosive wear that reduces their lifetime and efficiency. Tribocorrosion is one of the main phenomena that reduces the lifetime and efficiency of cutting tools. This work presents electrochemical and tribocorrosion studies of D2 steel surfaces coated with TiN, TiCN, and TiCrN films. The samples were coated by a commercial source, using the PVD-cathodic arc technique. The crystalline structure of TiN and TiCN films presented a TiN and Ti phase, while the crystalline structure of TiCrN showed CrN and Cr phases. The films exhibited good adhesion, but the surfaces coated with TiN and TiCN films presented lower hardness. Although the TiN, TiCN, and TiCrN films showed better wear and corrosion resistance than the D2 steel surfaces, the inclusion of C and Cr in the TiN films decreased the TiN wear and electrochemical resistance in 3.5% (w/w) of NaCl solution. Full article

The increasing demand for lightweight, high-performance materials in marine and offshore engineering has driven the development of hybrid solutions combining metals and composites. This study investigates the stress corrosion cracking (SCC) and tribocorrosion behaviour of a novel hybrid wire consisting of a superaustenitic stainless steel (6Mo) outer shell and a carbon fibre-reinforced polymer (CFRP) core. Microstructural analysis, residual stress measurement, and corrosion testing were performed to assess the integrity of the welded structure under harsh conditions. The results revealed that residual stresses and interdendritic segregation in the weld zone significantly contribute to SCC susceptibility, while the 6Mo steel showed improved corrosion resistance over 316L under tribocorrosion conditions but was more sensitive to the sliding frequency. These findings provide critical insights into the degradation mechanisms of metal composite hybrid wires and support the future design of corrosion-resistant components for offshore and structural applications. Full article

The manufacturing of integrated circuits involves multiple steps of chemical mechanical planarization (CMP) involving different materials. Mitigating CMP-induced defects is a main requirement of all CMP schemes. In this context, controlling galvanic corrosion is a particularly challenging task for planarizing device structures involving contact regions of different metals with dissimilar levels of corrosivity. Since galvanic corrosion occurs in the reactive environment of CMP slurries, an essential aspect of slurry engineering for metal CMP is to control the surface chemistries responsible for these bimetallic effects. Using a CMP system based on copper and cobalt (used in interconnects for wiring and blocking copper diffusion, respectively), the present work explores certain theoretical and experimental aspects of evaluating and controlling galvanic corrosion in barrier CMP. The limitations of conventional electrochemical tests for studying CMP-related galvanic corrosion are examined, and a tribo-electrochemical method for investigating these systems is demonstrated. Alkaline CMP slurries based on sodium percarbonate are used to planarize both Co and Cu samples. Galvanic corrosion of Co is controlled by using the metal-selective complex forming functions of malonic acid at the Co and Cu sample surfaces. A commonly used corrosion inhibitor, benzotriazole, is employed to further reduce the galvanic effects. Full article

Titanium (Ti) alloys are widely used in biomedical applications but face challenges like poor biological activity and corrosion at modular interfaces. Strontium (Sr)-doped micro-arc oxidation (MAO) surfaces are proposed to improve biocompatibility and tribocorrosion resistance. This study examines the electrochemical behaviour of Ti surfaces treated with 0.0013 M and 0.13 M Sr-doped MAO via open circuit potential, potentiodynamic polarisation, and electrochemical impedance spectroscopy in a basic physiological solution at 37 °C. The results indicate that higher Sr concentrations led to lower passivation current densities (more than two times lower than at the lowest Sr concentration) and reduced barrier layer capacitance (more than one and a half times lower than at the lowest Sr concentration), suggesting improved corrosion resistance for Sr-enriched MAO treatments on Ti implants. Full article

Although extensive studies have examined the tribocorrosion behavior of stainless steels, the performance of medium-entropy austenitic super stainless steels (MEASS) under severe combined corrosion and mechanical wear conditions has not been fully established. This study systematically compares the tribocorrosion behavior of a newly developed MEASS with conventional S31254 super austenitic stainless steel (SASS) in a 1 M H₂SO₄ solution, aiming to explore innovative material designs for enhanced performance under these demanding conditions. Electrochemical tests were conducted under both open-circuit potential (OCP) and cathodic potential, with and without sliding wear, to assess the corrosion, wear, and synergistic effects influencing the tribocorrosion performance. Worn surface morphologies and hardness were analyzed using scanning electron microscopy (SEM), transmission electron microscopy (TEM), and hardness measurements, respectively. The experimental results revealed that MEASS exhibits a superior repassivation capability compared to S31254, with a 34.3% lower total material loss after 24 h of tribocorrosion test, primarily attributed to enhanced strain hardening and improved wear resistance. These findings emphasize the strong potential of MEASS for use in corrosive environments, particularly in chemical processing industries, where high resistance to wear and corrosion is critically required. Full article

Background/Objectives: Peri-implantitis often necessitates surgical intervention, with implantoplasty being proposed as a decontamination method in resective surgeries. This mechanical cleaning technique aims to halt disease progression by removing bacterial colonies. However, implantoplasty may compromise mechanical properties, reduce corrosion resistance, and lead to cytotoxic effects due to titanium particle release. This study aimed to evaluate the corrosion and mechanical resistance of implantoplasty-treated dental implants, with and without bacterial contamination. Methods: Twenty dental implants were divided into three groups: control (C), implantoplasty (IP), and implantoplasty with bacterial contamination (IPC) using Streptococcus aureus and Porphyromonas gingivalis. Scanning electron microscopy was used to assess surface morphology. Fatigue life curves were obtained using a Bionix servohydraulic machine, and electrochemical corrosion tests were conducted to measure corrosion potentials and intensities. Results: The IPC group demonstrated significantly lower fatigue resistance and higher susceptibility to corrosion compared to the control and IP groups. Fatigue life decreased by 21.7%, and corrosion current density (ICORR) increased from 0.025 μA/cm² (control) to 0.089 μA/cm² (IP) and 0.122 μA/cm² (IPC). Corrosion potential (ECORR) shifted from −380 mV (control) to −450 mV (IP) and −495 mV (IPC). Surface defects caused by bacterial colonization facilitated stress concentration and crack initiation during fatigue testing. Conclusions: Dental implants treated with implantoplasty and exposed to bacterial contamination exhibit significantly reduced mechanical and corrosion resistance. Bacterial activity exacerbates surface vulnerability, leading to titanium loss and pitting corrosion. These findings highlight the clinical implications of bacterial colonization on implantoplasty-treated surfaces. Full article

This study aims to achieve in situ-formed pure Ti and Ti6Al4V coatings on 316L stainless steel through hot pressing and examine their wear and corrosion properties thoroughly in two simulated body fluids: physiological serum (0.9% NaCl) and Hanks’ solution. The sintering and diffusion bonding process was conducted at 1050 °C under a uniaxial pressure of 40 MPa for 30 min in a vacuum environment of 10⁻⁴ mbar. Following sintering, in situ-formed pure Ti and Ti6Al4V coatings, approximately 1000 µm thick, were produced on 316L substrates approximately 3000 µm in thickness. The mean hardness of 316L substrates, pure Ti, and Ti6Al4V coatings are around 165 HV, 170 HV, and 420 HV, respectively. The interface of the stainless steel substrate and the pure Ti and Ti6Al4V coatings exhibited no microstructural defects, while the interface exhibited significantly higher hardness values (ranging from 600 to 700 HV). The coatings improved corrosion resistance in both electrolytes compared to the 316L substrate. Wet wear tests revealed reduced friction coefficients in 0.9% NaCl relative to Hanks’ solution, highlighting the chemical interactions between the material surface and the electrolyte type and the significance of tribocorrosion in biocoatings. Full article

The study examined the corrosion and wear characteristics of hot-dip galvanized steel in complex soil environments. The results showed that hot-dip galvanized steel exhibited improved corrosion resistance characteristics. Additionally, the sliding speed was observed to influence both the coefficient of friction (COF) and the state of the worn surface. Moreover, the corrosion resistance of hot-dip galvanized steel declined as the immersion period increased. Following the incorporation of friction behavior, the galvanized layer is prone to accelerated degradation. The wear of the galvanized layer resulted in the failure of its electrochemical protection, creating a pathway for corrosion to occur on the substrate as a result of the coupling effect of corrosion and wear. The use of hot-dip galvanized steel presents challenges when exposed to a tribocorrosion environment for a prolonged period. This study lays the groundwork for future research on the maintenance cycle of industrial structures constructed primarily with hot-dip galvanized steel. Full article

Chemical mechanical planarization (CMP) is a technique used to efficiently prepare defect-free, flat surfaces of stainless steel (SS) foils and sheets that are implemented in various modern devices. CMP uses (electro)chemical reactions to structurally weaken the surface layers of a workpiece for easy removal by low-pressure mechanical abrasion. Using a model CMP system of 316/316L stainless steel (SS) in an acidic (pH = 3.63) slurry with alumina abrasives, citrate buffer (CB), and H₂O₂, we examine the tribo-electrochemical mechanisms of SS CMP that dictate the designs of functionally efficient and cost-effective CMP slurries. The use of CB as a pH-controlled complexing agent prevents defect-causing dissolution of SS and eliminates the need for using separate (often toxic) corrosion inhibitors in the slurry. A material removal rate of 8.6 nm min⁻¹ is obtained at a moderate down pressure of 0.014 MPa with a platen rotation speed of 95 RPM. Electrochemical techniques are strategically combined with mechanical abrasion of SS test samples to probe complex CMP mechanisms that are not readily accessible with electrochemical experiments alone. Corrosion-like reactions of salt-film formation at the SS surface act to enable the CMP process, where corrosion-induced wear plays a major role in material removal. Full article

High-entropy alloy (HEA) coatings have attracted wide scientific attention in academic research and industrial innovation. In the present paper, the NiCoCrAlY HEA coatings are successfully synthesized on the surface of M50 steel to improve the corrosion resistance and tribocorrosion resistance of M50 steel in salt-contaminated lubricating oil. The corrosion and tribocorrosion behaviors of M50 steel and NiCoCrAlY coatings are studied systemically under the same conditions. The experimental results show that NiCoCrAlY coatings have good, densified microstructures and improve effectively the corrosion resistance and tribocorrosion resistance of M50 steel because the protective passivation films and oxide films are formed on the surface of NiCoCrAlY coatings. NiCoCrAlY coatings have high corrosion potential, a low corrosion current density, and a corrosion rate that is comparable with M50 steel. The corrosion potential of M50 steel decreases and the corrosion current density increases with the increase in load due to wear-induced corrosion. The corrosion and tribocorrosion mechanisms of M50 steel and coatings are discussed in light of the experimental results. The wear mechanism of M50 steel is abrasive wear. It is accompanied by corrosion wear for M50 steel and oxidative wear for NiCoCrAlY coatings. Full article