CRUCIBLE CPM 420V

Borides are promising materials with good wear and corrosion resistance properties. Boride coatings are expected to perform better where wear and corrosion resistances are simultaneously required. Zirconium diboride is an important emerging material for such applications, due to its high hardness, high melting point, good wear resistance and corrosion as well as high temperature oxidation resistance. Special properties of laser beam like beam directionality, high intensity and spatial resolution makes laser alloying a fast and efficient technique for producing improved wear resistance coatings. In the present work, mild steel was laser alloyed with ZrB2, using "two-stage" technique of laser alloying. These coatings after characterization by optical microscopy, SEM, EDAX and XRD techniques were tested on a "Pin-on-Disk" machine for determining their wear resistance.

With the aim to produce a coating having good corrosion and wear resistance alongside hardness but lesser friction coefficient, Ni-P-PTFE-Al2O3 (NiPPA) dispersion coating was developed. This was achieved by introducing nanosized polytetrafluoroethylene (PTFE) and alumina (Al2O3) in the Ni-P matrix deposited on mild steel substrate. The coating was characterized using scanning electron microscopy, energy dispersive analysis of x-ray, and x-ray diffractrometry. Microhardness and wear resistance of the coating was measured using Vicker’s hardness tester and Pin-on-Disc method, respectively. The corrosion behavior was measured using electrochemical polarization and immersion tests with and without exposure in 3.5% NaCl solution. It is observed that codeposition of Al2O3 and PTFE particles with Ni-P coating results in comparatively smooth surface with nodular grains. The NiPPA coating was observed to have moderate hardness between electroless Ni-P-PTFE and Ni-P-Al2O3 coating and good wear resistance with lubricating effect. Addition of both PTFE and Al2O3 is observed to enhance corrosion resistance of the Ni-P coating. However, improvement in corrosion resistance is more due to addition of Al2O3 than PTFE. Continuous exposure for 10-20 days in corrosive solution is found to deteriorate corrosion protection properties of the coating.

Effect of boronizing on microstructure, high-temperature wear and corrosion behavior of additive manufactured Inconel 718

Chromium oxide coatings are chemically inert, have high mechanical strength, hardness and good optical characteristics; therefore, they have been widely used in many applications including corrosion protection, wear resistance, electronics, and optics. Cr2O3 is well suited for wear resistance applications, as it is one of the hardest oxides with 29.5 GPa hardness. Several deposition techniques have been tried for making these coatings. Cr2O3 coating hardness can vary substantially due to compositional and microstructural variations, depending on the deposition method. Hardness of a plasma-sprayed Cr2O3 coating, 50 lm thick was about 14.7 GPa, while a 200 nm thick RF-sputtered chromium oxide coating, stoichiometrically close to Cr2O3, exhibited 30 GPa hardness combined with good scratch resistance. Even for the bulk Cr2O3, hardness values reported were from 9 GPa to 29.5 GPa. Hones et al. investigated a correlation between the hardness and the sputtering deposition parameters, i.e. oxygen partial pressure and substrate temperature, and found favorable deposition conditions with an oxygen partial pressure of about 15–20 % of the total sputtering gas pressure at substrate temperatures exceeding 500 K. Good coating adhesion is required for wear and corrosion resistance applications. Premature failure can occur for many reasons including coating delamination, cracking and plastic deformation. In addition to this, thin ceramic PVD coatings usually have columnar grain structure with micro cracks, pinholes, transient grain boundaries and often high throughcoating porosity, which all lead to accelerated pitting corrosion and failure at the coating/substrate interface, especially in hostile environments. On the other hand, several studies showed that coating thickness plays an important role in enhancing both PVD-coated tool cutting performance and resistance to abrasive and erosive wear. Graded systems have been employed to obtain thicker coatings without losing performance in terms of coating adhesion and toughness. It is likely that thicker coatings will improve corrosion resistance in aqueous environments by eliminating through-thickness pin-hole defects. Coating mechanical, adhesion and wear properties are strongly affected by microstructure. Interfaces with high adhesion are known to ensure prolonged coating life and good wear resistance. Sputtered coating microstructure and physical characteristics depend on the deposition parameters. Also, substrate surface conditions prior to deposition, characterized by surface roughness, stress and oxidation state, play an important role in controlling coating properties. In this paper SEM and TEM techniques were used to characterize thicker chromium oxide coating interfacial microstructure as a step towards developing a unique method for depositing thicker coatings with small grains, smooth surface and low residual stress.

Effect of shot peening and treatment temperature on wear and corrosion resistance of sequentially plasma treated AISI 316L steel

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.

In the present work, a low-carbon steel substrate was coated with Al2O3 and TiC using self-propagating high temperature synthesis. The synthesized coatings were annealed at 450 °C for 2–6 h. The characteristics of the substrate, coated, and annealed samples were examined, including microhardness, wear resistance, and corrosion resistance. A pin-on-disc tribometer was employed to conduct the wear test by varying the load, sliding velocity, and distance. The impact of these factors on the wear rate and worn surface morphology was then examined. Further, corrosion resistance was evaluated using electrochemical corrosion testing with 3.5 wt% NaCl as electrolyte. Results showed that Al2O3 and TiC specimens annealed at 450 °C for 5 h and 4 h improved the microhardness by 1.3 and 1.06 times than that of as-coated specimens respectively. The synthesized Al2O3 and TiC coatings showed an abrasive wear mechanism at higher loads and tribolayer formation was observed at higher sliding velocity and distances. The corrosion and wear resistances of the samples were found as follows: substrate< Al2O3 coated < TiC coated < Al2O3 annealed < TiC annealed. The Al2O3 and TiC ceramic coatings were found to improve wear and corrosion resistance having potential applications in cement, petrochemical, and marine industries.

High wear resistance of metallocene polyethylene with long-chain branch for artificial joints

A robust superhydrophobic PPS-PTFE/SiO2 composite coating on AZ31 Mg alloy with excellent wear and corrosion resistance properties

The effect of high-velocity oxy-fuel spraying parameters on microstructure, corrosion and wear resistance of Fe-based metallic glass coatings

Micro arc oxidation (MAO), also known as plasma electrolytic oxidation (PEO), which is applied to obtain hard oxide coatings on aluminum alloys. The coatings formed during the MAO process are superior to anodic oxide coatings on plenty of properties, such as strong coating-substrate adhesion, adequate thickness, high hardness, excellent corrosion and wear resistance. There are several parameters affecting the properties of MAO coating, including composition of the substrate and electrolyte, process time, applied voltage and current density, but few works study the influence of cathodic current on MAO coating. This study investigated the effect of cathodic current density on the structures and properties of the coatings. The MAO coatings on 7075 Al alloys were obtained in aluminate-based electrolyte by using a bipolar pulsed power supply. The morphology, microstructure and compositions of the MAO coatings were characterized by using scanning electron microscope (SEM), X-ray diffraction (XRD), electron probe micro-analyzer (EPMA). The measurements of surface roughness, thickness, and microhardness were also conducted. Furthermore, the ball-on-disk tribometer and potentiodynamic polarization were used to evaluate the wear and corrosion resistance, respectively. Experimental results showed that the ceramic coatings are mainly composed of α-Al2O3 and γ-Al2O3. The microstructural observations of the MAO coatings revealed that with increasing cathodic current, the presence of pancake-like structure and the size of micro-pores are significantly reduced, meaning the coatings became smoother and more compact. Moreover, due to the low porosity and the phase composition, the microhardness of the ceramic coatings can reach ~1400 HV. With increasing cathodic current, the MAO coatings are nearly pore-free and crack-free. Therefore, the coatings exhibit an obvious improvement in corrosion and wear resistance.

Advancements in understanding the microstructure and properties of additive manufacturing Ti-6Al-4V alloy: A comprehensive review

In general, silicide-based materials offer efficient improvement of turbines and offshore systems due to their exceptional oxidation, corrosion, and wear resistance. The standard requirement of materials used in these systems is the ability to withstand high temperatures. Nickel silicide (NiSi) is commonly known to possess these abilities, however, its inherent brittleness makes large scale production difficult using standard metal forming techniques. Laser Metal Deposition (LMD) is an Additive Manufacturing (AM) technique similar to cladding that allows pore-free microstructure formation of the metal with refined grains, enabling excellent mechanical properties. In the present study, NiSi16 is deposited on structural steel and nickel substrates, and microstructural development is observed in both cases. The deposited beads are characterised using conventional analytical techniques, i.e., LVFESEM, EDX and XRD, and the results are discussed in the context of changes in chemical composition.

CrC and NbC carbide coatings both have good mechanical properties, wear resistance, and corrosion resistance. The present study seeks to combine the two coating systems in order to further enhance their properties. NbCrCx and NbCrCxNy coatings (where x and y denote the atomic percentages of carbon and nitrogen, respectively) were deposited on SKH51 substrates using a radio-frequency unbalanced magnetron sputtering system. The mechanical, tribological, and corrosive properties of the coatings were investigated and compared. Among the NbCrCx coatings, the NbCrC61 coating showed high levels of hardness, excellent adhesion strength, and good wear resistance. Among the NbCrCxNy coatings, the NbCrC55N5 coating showed high adhesion strength and hardness and excellent tribological properties. However, for nitrogen contents greater than 16 at%, the adhesion strength was dramatically reduced, resulting in poor tribological performance. Among all of the coatings, the NbCrC49 coating showed the best corrosion resistance due to its enhanced crystallinity, high adhesion strength, moderate surface roughness, and high sp3 C-C bonding ratio.

Aluminum-Nickel (AlNi) alloys are of great interest due to their exceptional high-temperature wear and corrosion resistance, making them valuable in transport, energy, and materials processing applications. However, challenges in the production and shaping of these alloys, particularly as thick coatings, remain significant. This study introduces an innovative method for the high-throughput synthesis of AlNi coatings, utilizing a two-step process: low-pressure cold spray deposition followed by laser surface alloying. The combination of these two techniques not only improves the synthesis process but also opens avenues for exploring new material compositions with specific application requirements. This approach holds significant potential for accelerating the development and optimization of advanced coatings and multiphase compounds in applications such as repair and additive manufacturing.Aluminum and nickel powders were co-sprayed to create coatings with controlled compositions ranging from 50Al50Ni to 10Al90Ni (wt%). Subsequent laser treatment induced in-situ alloying and homogenization, resulting in dense, uniform AlNi coatings. The microstructure and chemical composition were characterized using Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS), while X-ray Diffraction (XRD) identified the formation of various phases, including Al3Ni and AlNi3 phases. The process demonstrated effective alloying and microstructural homogeneity, with residual alumina present at the surface. Despite the presence of some microstructural defects, such as cracking, this method provides a robust foundation for further refinement and opens new possibilities for tailoring alloy properties through combinatorial cold spray and laser alloying techniques.