Electrodeposition, characterization and long term stability of NiW and NiWZn coatings on copper substrate in alkaline solution

This paper describes the electrodeposition of Ni, NiW and NiWZn coatings onto copper surfaces from electrolyte solutions containing Na₃C₆H₅O₇, Na₂WO₄, NiSO₄ and ZnSO₄. The electrocatalytic effects of electrodeposited coatings were investigated for hydrogen evolution reactions in 1 M NaOH solution. Surface characterization studies were carried out by energy dispersive X-ray spectroscopy, scanning electron microscopy, atomic force microscopy and cross-section analysis. The effect of operating conditions on the chemical composition, microstructure and electrocatalytic properties of Ni-W coatings was studied. The Zn ions were used to improve the active surface area and catalytic activity of the electrodeposited surface. The electrocatalytic activity of NiW and NiWZn coated electrodes for the hydrogen evolution reaction in alkaline solution was compared with that of an electrodeposited Ni electrode and copper substrate by using cathodic polarization curves and electrochemical impedance spectroscopy techniques over 96 h of electrolysis. The results proved that the NiWZn coated electrode showed better electrocatalytic activity and durability than bare Cu, Ni and NiW coatings.     

Structural and Mechanical Properties of Zr-Si-N Coatings Deposited by Arc Evaporation at Different Substrate Bias Voltages

ZrN and Zr-Si-N coatings were formed using vacuum-arc plasma fluxes deposition system at the substrate bias voltage (U_B) ranged from ??50 to ??220 V on HS6-5-2 steel substrates. The structural, mechanical and tribological properties were characterized using x-ray diffraction, atomic force microscopy, scanning electron microscopy, optical microscopy, nanoindentation and ball-on-disk test. The surface roughness parameter Ra of ZrN coatings is lower than Zr-Si-N coatings. Both roughness Ra of Zr-Si-N coatings and the number of surface defects with mainly small dimensions to 1 µm decrease with increasing negative substrate bias voltage. The addition of silicon to ZrN significantly reduces the crystallite size, from about 18.3 nm for ZrN coating to 6.4 nm for Zr-Si-N coating both deposited at the same U_B?=???100 V and 7.8 nm for U_B?=???150 V. The hardness of Zr-Si-N coatings increases to about 30 GPa with the increase in negative substrate bias voltage (U_B?=???220 V). Adhesion of the coatings tested is high, and critical load is above 80 N and reduces with U_B increase. Coefficient of friction determined using AFM shows similar trend as surface roughness in microscale.     

Influence of Al Contents on the Microstructure, Mechanical, and Wear properties of Magnetron Sputtered CrAlN Coatings

CrAlN (0 < x < 0.1) coatings were deposited on SA304 substrate by a reactive magnetron sputtering. The microstructure and composition of the as-deposited coatings were systematically characterized by field emission scanning electron microscopy/EDS and atomic force microscopy, and the phase formation by x-ray diffraction (XRD). The hardness of the coatings was investigated using nanoindentation, while wear properties were investigated using pin-on-disk tribometer. XRD study reveals that the deposited CrAlN coatings crystallized in the cubic B1 NaCl structure. The minimum and maximum hardness of the coatings are found to be 15.28 and 18.81 GPa, respectively. The COF and wear rate are found to be 0.48 and 2.25 × 10^?5 mm³/N · m, which is lower than the CrN coatings deposited and characterized under the same environment (0.63 and 2.25 × 10^?5 mm³/Nm).     

Electrocatalytic behaviour of NiBi coatings for hydrogen evolution reaction in alkaline medium

The nickel-bismuth binary coatings with various chemical compositions were galvanostatically deposited on the copper electrode in view of their possible applications as electrocatalytic materials for the hydrogen evolution reaction (HER) in alkaline solution. The HER activity of coatings was tested with the help of potentiodynamic measurements and electrochemical impedance spectroscopy (EIS) technique. The electrochemical characterization was achieved by the means of cyclic voltammetry (CV). The surface morphology and surface composition of coatings were determined with scanning electron microscopy (SEM), and energy dispersive X-ray (EDX). The potentiodynamic measurements show that, the binary coatings decrease the hydrogen over potential and increase the current density values for HER. The EIS analysis confirms, the charge transfer resistances decrease and the double layer capacitance values increase for binary coatings. The EDX results in sign that the composition of binary coating changes by using coating bath. The Cu/NiBi-2 coating (Ni²⁺/Bi³⁺ is 99.71:0.29 molar ratio) is the best suitable cathode composition for the HER in alkaline media under these experimental conditions.     

Properties of Detonation Nanostructured Titanium-Based Coatings

Titanium-based coatings were deposited on aluminum samples using cumulative-detonation equipment. The gas mixture consumption (propane-oxygen-air) was up to 5 m³ per 1 kg of powder. The titanium-based coatings were examined by scanning electron microscopy (SEM), transmission electron microscopy (TEM) with diffraction, x-ray phase analysis, hardness measurements, and plasticity adhesion/cohesion resistance scratch tests. It was shown that the detonation titanium-based coatings are characterized by the presence of nanodispersed ceramic compounds and exhibit high values of plasticity, hardness, and adhesion strength. The titanium-based coatings had an amorphous structure, high hardness of up to 16 GPa, and a tensile bonding strength ranging from 52.5 to 53.0 MPa. A failure mode occurring in the tested samples was cohesive within the inter and intralamellar structure of coating.     

Characterization of Graphite Coatings Produced by CoBlast™ Technology

In this article, the surface characterization of graphite-based coatings deposited on metallic substrates at ambient temperature via a modified micro-blasting process technique named CoBlast? is reported. The coated metals were characterized using scanning electron microscopy, energy-dispersive x-ray spectroscopy, x-ray diffractometer, and x-ray photoelectron spectroscopy. Surface roughness and contact angles were also evaluated. The results showed that the coated layer irrespective of the substrate type was hydrophobic and consisted of graphite, the grit material, and surface oxides, while surface roughness values varied from one substrate to the other. Implications of the resulting surface properties in relation to wear and corrosion applications are highlighted.     

Influence of Type of Bath Agitation (Magnetic Stirring and Rotating Disk Cathode) on Tribological Properties of Nickel Electrodeposits

In this study, nickel coatings were electrodeposited by magnet stirrer process and rotating disk cathode with a pulse power source. The surface morphology and cross-section observations were made using scanning electron microscopy and optical microscopy. The results showed that there was cauliflower morphology for all samples that were electrodeposited from a bath agitated with a magnet stirrer. On the other hand, only the nickel coating that was deposited on a rotating disk cathode at 4 A/dm² had the cauliflower morphology. By using the rotating disk cathode process the current efficiency was decreased. Also, with increasing the current density for all samples the surface roughness was decreased. The loss of mass diagram, worn surface micrograph and friction-distance profile indicated that the wear resistance of the nickel coatings that were produced by magnet stirrer process at 2 A/dm² and rotating disk cathode process at 4 A/dm² were lower than the other coatings.     

Plasma-Sprayed Photocatalytic Zinc Oxide Coatings

Fabrication of semiconductor coatings with photocatalytic action for photodegradation of organic pollutants is highly desirable. In this research, pure zinc oxide, which is well known for its promising photocatalytic activity, was deposited on stainless-steel plates by plasma spraying. The phase composition and microstructure of the deposited films were studied by x-ray diffraction analysis and scanning electron microscopy, respectively. Despite the low-energy conditions of the plasma spraying process, the zinc oxide coatings showed good mechanical integrity on the substrate. Their photocatalytic activity was evaluated using aqueous solution of methylene blue at concentration of 5 mg L^?1. The results showed the potential of the plasma spraying technique to deposit zinc oxide coatings with photocatalytic action under ultraviolet illumination. Ultraviolet–visible (UV–Vis) diffuse reflectance spectroscopy confirmed that the plasma spraying method could deposit zinc oxide films with higher photoabsorption ability relative to the initial powder.     

Poly(3‐octylthiophene) thermally treated as coating for corrosion protection of SS304 in sulfuric acid media

Poly(3‐octylthiophene) (P3OT) was synthesized by direct oxidation of the 3‐octylthiophene monomer using ferric chloride (FeCl₃) as an oxidant. Using the drop‐casting technique, P3OT coatings were deposited onto 304 type stainless steel electrodes. For the purpose of determining the effect of thermal annealing on the corrosion protection of stainless steel with P3OT coatings, the coated electrodes were thermally annealed for 30 h at two different temperatures, 55 and 100 °C. The corrosion behavior of P3OT coated stainless steel was investigated in 0.5 M sulfuric acid (H₂SO₄) at room temperature using potentiodynamic polarization curves (PPC), linear polarization resistance (LPR), and electrochemical impedance spectroscopy (EIS). The results indicated that the thermally treated P3OT coatings improved the corrosion resistance of the stainless steel in 0.5 M H₂SO₄. The best corrosion protection was obtained by the P3OT coating annealed at 100 °C. In order to study the temperature effect on the morphology of the coatings before and after the corrosive environment and compare it with corrosion protection, atomic force microscopy (AFM) and scanning electronic microscopy (SEM) were used.     

Resistance to Corrosion of Zirconia Coatings Deposited by Spray Pyrolysis in Nitrided Steel

Coatings of zirconium oxide were deposited onto three types of stainless steel, AISI 316L, 2205, and tool steel AISI D2, using the ultrasonic spray pyrolysis method. The effect of the flux ratio on the process and its influence on the structure and morphology of the coatings were investigated. The coatings obtained, 600 nm thick, were characterized using x-ray diffraction, scanning electron microscopy, confocal microscopy, and atomic force microscopy. The resistance to corrosion of the coatings deposited over steel (not nitrided) and stainless steel nitrided (for 2 h at 823 K) in an ammonia atmosphere was evaluated. The zirconia coating enhances the stainless steel’s resistance to corrosion, with the greatest increase in corrosion resistance being observed for tool steel. When the deposition is performed on previously nitrided stainless steel, the morphology of the surface improves and the coating is more homogeneous, which leads to an improved corrosion resistance.     

Suspension Plasma-Sprayed ZnFe<Subscript>2</Subscript>O<Subscript>4</Subscript> Nanostructured Coatings for ppm-Level Acetone Detection

Zinc ferrite (ZnFe₂O₄) sensitive coatings have been deposited by suspension plasma spraying. The phase constitution of the coatings was characterized by x-ray diffraction while the top surface and cross-sectional morphology of the coatings were inspected by scanning electron microscopy. The response to acetone was tested with the concentration in the range of 25-500 ppm at the working temperature from 175 to 275 °C. The sensors that were deposited at an arc current of 400 A showed better performance than those at 600 A owing to small grain size and high porosity. The sensor response increased with acetone concentration. The optimized sensors showed excellent response/recovery time and selectivity to acetone at 200 °C.     

Tribological behavior of W-DLC coated rubber seals

Tungsten-containing diamond-like carbon (W-DLC) coatings have been deposited on FKM (fluorocarbon) and HNBR (hydrogenated nitrile butadiene) rubbers via unbalanced magnetron reactive sputtering from a WC target in a C₂H₂/Ar plasma. The surface morphology and fracture cross sections of uncoated and coated rubbers have been characterized with high resolution scanning electron microscopy (SEM). The tribological behavior of uncoated and coated rubbers has been investigated with ball-on-disc tribotest under dry sliding condition against a 100Cr6 ball. The coefficient of friction (CoF) of uncoated rubbers is very high (> 1). Equally a relatively high CoF of W-DLC coated FKM (about 0.6) is observed due to the gradual failure and delamination of the coatings. On the contrary, W-DLC coated HNBR rubber exhibits a superior tribological performance with a very low CoF of 0.2-0.25. The latter is comparable to that of Me-DLC coatings deposited on steel substrates. After 10,000 sliding laps almost no damage of the coatings is observed on the wear tracks. In fact the network of micro-cracks as deposited facilitates the flexibility of the coatings. The different surface roughness and mechanical properties of the rubber substrates explain the differences in the tribological performances of the coated rubbers.     

TiB_2-ZrB_2/Ni涂层电极点焊镀锌钢板失效过程分析

目的了解TiB_2-ZrB_2/Ni涂层电极点焊镀锌钢板时的失效机理。方法通过扫描电镜(SEM)、X射线衍射仪(XRD)、显微硬度测试等表征方法,研究TiB_2-ZrB_2/Ni涂层点焊电极点焊镀锌钢板时表面结构、物相及性能的变化。结果 TiB_2-ZrB_2/Ni涂层电极对提高点焊电极寿命有很大帮助,点焊电极寿命可提高5倍左右。涂层使点焊电极表面的硬度得以明显提高,减缓了点焊电极端部塑性变形的进程。ZrB_2-TiB_2/Ni涂层在一定程度上减缓了钢板镀层与点焊电极产生合金化反应的进程。结论 ZrB_2-TiB_2/Ni涂层电极由于具有一定的塑性,点焊过程中涂层不会出现完全脱落现象。涂层作用一直持续至电极失效,电极失效的形式主要表现为塑性变形。     

Oxidation of double glow plasma discharge coatings of iridium on molybdenum for liquid fuelled rocket motor casings

Abstract

Dense and uniform coatings of iridium (Ir), 5–7 μm in thickness, were deposited onto molybdenum (Mo) substrates by double glow plasma discharge in the temperature range of 800–850°C at 35 Pa. During deposition, the Mo substrate was biased at a voltage of ?300 V while the 99·9% Ir target was at a bias voltage of ?800 V. After deposition, the Ir coating was ablated using an oxyacetylene torch with a flame temperature of ～2000°C to determine the high temperature stability of the coated substrate. The morphology and microstructure of the Ir coating were observed using scanning electron microscopy while the composition and structure were measured using X-ray diffraction and energy dispersive spectroscopy. The thickness of the as deposited Ir coating was uniform and the interface between the coating and the substrate exhibited excellent adhesion with no evidence of delamination and cracks. After exposure to the flame, the surface of the as ablated coating presented imperfections including pores, bulges and cracks; however, the Ir coating retained sufficient adhesion to limit the weight loss of the Ir coated Mo substrate to 10 mg cm^?2 s^?1.     

High-Performance Molybdenum Coating by Wire–HVOF Thermal Spray Process

Coating deposition on many industrial components with good microstructural, mechanical properties, and better wear resistance is always a challenge for the thermal spray community. A number of thermal spray methods are used to develop such promising coatings for many industrial applications, viz. arc spray, flame spray, plasma, and HVOF. All these processes have their own limitations to achieve porous free, very dense, high-performance wear-resistant coatings. In this work, an attempt has been made to overcome this limitation. Molybdenum coatings were deposited on low-carbon steel substrates using wire–high-velocity oxy-fuel (W-HVOF; WH) thermal spray system (trade name HIJET 9610^®). For a comparison, Mo coatings were also fabricated by arc spray, flame spray, plasma spray, and powder-HVOF processes. As-sprayed coatings were analyzed using x-ray diffraction, scanning electron microscopy for phase, and microstructural analysis, respectively. Coating microhardness, surface roughness, and porosity were also measured. Adhesion strength and wear tests were conducted to determine the mechanical and wear properties of the as-sprayed coatings. Results show that the coatings deposited by W-HVOF have better performance in terms of microstructural, mechanical, and wear resistance properties, in comparison with available thermal spray process (flame spray and plasma spray).     

Improvement of the Electrochemical Behavior of Steel Surfaces Using a [Ti-Al/Ti-Al-N] n Multilayer System

The aim of this work is to improve the corrosion resistance of AISI D3 steel surfaces using a [Ti-Al/Ti-Al-N] _n multilayer system deposited with different periods (Λ) and bilayer numbers (n), via magnetron co-sputtering pulsed d.c. procedure, from a metallic (Ti-Al) binary target. The multilayer coatings were characterized by cross-sectional scanning electron microscopy that showed the modulation and microstructure of the [Ti-Al/Ti-Al-N] _n multilayer system. The composition of the single Ti-Al and Ti-Al-N layer films was studied via x-ray photoelectron spectroscopy, where typical signals for Ti_2p1/2, Ti_2p, N_1s, and Al_2p3/2 were detected. The electrochemical properties were evaluated by electrochemical impedance spectroscopy and Tafel polarization curves. The optimal electrochemical behavior was obtained for the [Ti-Al/Ti-Al-N] _n multilayered period of Λ = 25 nm (100 bilayers). At these conditions, the maximum polarization resistance (1719.32 kΩ cm²) and corrosion rate (0.7 μmy) were 300 and 35 times higher than that of uncoated AISI D3 steel substrate (5.61 kΩ cm² and 25 μmy, respectively). Finally, scanning electron microscopy was used to analyze the [Ti-Al/Ti-Al-N] _n multilayered surface after the corrosive attack. The improvement effects in the electrochemical behavior of the AISI D3 coated with the [Ti-Al/Ti-Al-N] _n multilayered coatings could be attributed to the number of interfaces that act as obstacles for the inward and outward diffusions of Cl^? ions, generating an increment in the energy or potential required for translating the corrosive ions across the coating/substrate interface.     

New generation hopeite coating on Ti6Al4V (TC4) by radio frequency magnetron sputtering for prosthetic-orthopaedic implant applications: synthesis and characterisation

ABSTRACT

Bioceramic coatings with multifunctionality have emerged as an effective alternative to conventional coatings, owing to their combination of various properties that are essential for bio-implants, such as osseointegration and antibacterial character. In the present study, thin hopeite coatings were synthesised by radio frequency magnetron sputtering on TC4 substrates. The obtained hopeite coatings were thermally treated at 500°C in ambient air and characterised in terms of surface morphology, phase composition, surface roughness, adhesion strength, antibacterial efficacy, apatite forming ability, surface wettability and corrosion resistance by Scanning Electron Microscopy (SEM), X-ray diffraction (XRD), Atomic Force Microscopy(AFM), Tensometer, Fluorescence-Activated Cell Sorting (FACS), Simulated Body Fluid (SBF) immersion, Contact Angle Goniometer and potentiostatic polarisation respectively. It was observed that the post-deposition annealing increases the crystallinity of the synthesised hopeite coatings. SEM analysis showed deposited particles are spherical in shape and small in dimensions (<1?μm in diameter). XRD results confirm the deposited coating is crystalline in nature. AFM analysis reveals deposited hopeite coating has an average surface roughness value of 8.66?nm. Tensile pullout experiments indicated that the adhesive strength of the hopeite coating is 21.75?±?2.1?MPa. FACS study confirms the deposited hopeite coating possesses antibacterial character. SBF immersion experiments clearly demonstrate apatite growth on the surface of the deposited hopeite coating. The surface wettability test showed that the deposited coatings are hydrophobic in character having an average contact angle value of 136.65°. Potentiodynamic polarisation experiments in SBF showed a significant improvement in corrosion resistance (R_p?=?7945.87?Ω?cm²) of hopeite coated samples. In summary, it can be concluded that the new generation multifunctional hopeite coating synthesised by an alternative new process route of radio frequency magnetron sputtering on TC4 substrates is an effective alternative to conventional coatings. This is largely attributed to the strong osseointegration and antibacterial character of deposited hopeite coating ensuring the overall stability of metallic orthopaedic implants.     

Supersonic Plasma Spray Deposition of CoNiCrAlY Coatings on Ti-6Al-4V Alloy

Plasma spray is a versatile technology used for production of environmental and thermal barrier coatings, mainly in the aerospace, gas turbine, and automotive industries, with potential application in the renewable energy industry. New plasma spray technologies have been developed recently to produce high-quality coatings as an alternative to the costly low-pressure plasma-spray process. In this work, we studied the properties of as-sprayed CoNiCrAlY coatings deposited on Ti-6Al-4V substrate with smooth surface (R _a = 0.8 μm) by means of a plasma torch operating in supersonic regime at atmospheric pressure. The CoNiCrAlY coatings were evaluated in terms of their surface roughness, microstructure, instrumented indentation, and phase content. Static and dynamic depositions were investigated to examine their effect on coating characteristics. Results show that the substrate surface velocity has a major influence on the coating properties. The sprayed CoNiCrAlY coatings exhibit low roughness (R _a of 5.7 μm), low porosity (0.8%), excellent mechanical properties (H _it = 6.1 GPa, E _it = 155 GPa), and elevated interface toughness (2.4 MPa m^1/2).     

Electrodeposition and Corrosion Resistance of Ni-Graphene Composite Coatings

The research on the graphene application for the electrodeposition of nickel composite coatings was conducted. The study assessed an important role of graphene in an increased corrosion resistance of these coatings. Watts-type nickel plating bath with low concentration of nickel ions, organic addition agents, and graphene as dispersed particles were used for deposition of the composite coatings nickel-graphene. The results of investigations of composite coatings nickel-graphene deposited from the bath containing 0.33, 0.5, and 1 g/dm³ graphene and one surface-active substance were shown. The contents of particles in coatings, the surface morphology, the cross-sectional structures of the coated samples, and their thickness and the internal stresses were studied. Voltammetric method was used for examination of the corrosion resistance of samples of composite coatings in 0.5 M NaCl. The obtained results suggest that the content of incorporated graphene particles increases with an increasing amount of graphene in plating bath. The application of organic compounds was advantageous because it caused compressive stresses in the deposited coatings. All of the nickel-graphene composite layers had better corrosion resistance than the nickel coating.     

Development and Application of HVOF Sprayed Spinel Protective Coating for SOFC Interconnects

Protective coatings are needed for metallic interconnects used in solid oxide fuel cell (SOFC) stacks to prevent excessive high-temperature oxidation and evaporation of chromium species. These phenomena affect the lifetime of the stacks by increasing the area-specific resistance (ASR) and poisoning of the cathode. Protective MnCo₂O₄ and MnCo_1.8Fe_0.2O₄ coatings were applied on ferritic steel interconnect material (Crofer 22 APU) by high velocity oxy fuel spraying. The substrate-coating systems were tested in long-term exposure tests to investigate their high-temperature oxidation behavior. Additionally, the ASRs were measured at 700 °C for 1000 h. Finally, a real coated interconnect was used in a SOFC single-cell stack for 6000 h. Post-mortem analysis was carried out with scanning electron microscopy. The deposited coatings reduced significantly the oxidation of the metal, exhibited low and stable ASR and reduced effectively the migration of chromium.