Effects of Mo addition on tribological performance of plasma-sprayed Ti–Si–C coatings

Ti–Si–C–Mo composite coatings were fabricated by plasma spraying using Ti, Si, graphite and Mo powders. The effect of Mo on microstructure and tribological performance of the Ti–Si–C coatings were investigated. The results showed that the Ti–Si–C coating consisted of TiC, Ti₃SiC₂, Ti₅Si₃, and residual graphite. The Ti–Si–C–Mo coatings consisted of TiC, Ti₃SiC₂, Ti₅Si₃, residual graphite, Mo and Mo₅Si₃ phases. With increasing Mo contents, the fractions of Mo and Mo₅Si₃ phases increased, and the fractions of Ti₃SiC₂ and Ti₅Si₃ phases decreased. All the coatings existed a typical lamellar structure. The addition of Mo enhanced the hardness and fracture toughness of Ti–Si–C coating by 16% and 52%, respectively. The coating porosity decreased by 57.6%. The wear resistance of the Ti–Si–C coating was also improved and the mass loss decreased by 83%. The wear mechanism of the Ti–Si–C–Mo coatings was the combination of abrasive wear, adhesive wear, and tribo-oxidation wear.     

Friction behavior of TiN–MoS2/PTFE composite coatings in dry sliding against SiC

To improve the dry friction behavior of traditional hard coatings, MoS₂/PTFE lubricating coatings were prepared on the PVD TiN-coated cemented carbide using spray method. The influences of MoS₂/PTFE lubricating coatings on the primary characteristics of TiN coatings were investigated. Reciprocating sliding tests were carried out with the TiN–MoS₂/PTFE coated specimen (T-M-P) under dry sliding conditions, and the tribological behaviors were compared to those of the TiN-coated one (T-N). The test results indicated that the adhesion force of coatings with substrate for T-M-P specimen increased, the surface micro-hardness, roughness and friction coefficient significantly decreased. Meanwhile, the surface adhesions and abrasion grooves of T-M-P specimen were reduced, and the main wear forms of T-M-P were abrasion wear and coating delamination. The MoS₂/PTFE lubricating coatings can be considered effective to improve the friction properties of traditional hard coatings.     

Bifunctional Ti3C2Tx–CNT/PANI composite with excellent electromagnetic shielding and supercapacitive performance

Ti₃C₂T_x exhibits excellent electromagnetic (EM) shielding and electrochemical properties. However, the inherent re-stacking tendency and easy oxidation of Ti₃C₂T_x limit its further application. In this study, a multi-walled carbon nanotube/polyaniline composite (CNT/PANI, denoted as C–P) was introduced into Ti₃C₂T_x nanosheets to obtain a Ti₃C₂T_x–CNT/PANI composite (T@CP). Owing to the integrated effects of Ti₃C₂T_x and C–P, the contribution of absorption was significantly improved, which finally enhanced the EM shielding performance of T@CP. The highest total EM shielding effectiveness (SE_T) was close to 50 dB (49.8 dB), which was substantially higher than that of pure Ti₃C₂T_x (45.3 dB). Moreover, T@CP demonstrated outstanding supercapacitive performance. The specific capacitance of T@CP (2134.5 mF/cm² at 2 mV/s) was considerably higher than that of pure Ti₃C₂T_x (414.3 mF/cm² at 2 mV/s). These findings provide a new route for the development of high-efficiency Ti₃C₂T_x-based bifunctional EM shielding and electrochemical materials.     

Effect of Si content on the microstructure and properties of Ti–Si–C composite coatings prepared by reactive plasma spraying

In this study, Ti–Si–C composite coatings were synthesized via plasma spraying of agglomerated powders prepared by a spray drying/precursor pyrolysis technology using Ti, Si, and sucrose powders. The influence of Si content, ranging from 0 wt% to 24 wt%, on the microstructure, mechanical properties, and oxidation resistance of the composite coatings was investigated. Results show that the phase composition of the Ti–Si–C composite coatings changes with the increasing Si content. The coatings without Si addition consist of TiC and Ti₃O; the coatings with 6–18 wt% Si are composed of TiC, Ti₅Si₃, and Ti₃O; the coatings with Si content of 24 wt% form only TiC and Ti₅Si₃ phases. As the Si content increases, the hardness of the Ti–Si–C composite coatings increases first and then decreases, depending on the intrinsic hardness of the ceramic phases, the brittleness of Ti₅Si₃, and the defects such as pores and cracks. The Ti–Si–C composite coatings have high wear resistance due to the in-situ synthesized high-hardness TiC and Ti₅Si₃. Owing to the high brittleness of Ti₅Si₃, the increasing Si content leads to higher wear volume loss at room temperature, which can be partially improved in high-temperature wear tests. The oxidation resistance of Ti–Si–C composite coatings increases with the increase of Si content, and the higher the oxidation temperature, the more obvious the influence of the Si addition on oxidation resistance.     

Structure and properties of electrodeposited Ni–Co–YZA composite coatings

The aim is to develop an economical composite coating with high thermal stability. Ni–Co alloys are found to possess better thermal, physical and mechanical properties compared to Ni. Also, oxide particles as distributed phase can impart better thermal stability. Hence, particulates of composite Yttria stabilised zirconia, a commonly used high temperature material and alumina (YZA) were reinforced in various Ni–Co alloy matrices through electrodeposition. The influence of YZA on the microhardness, tribology and corrosion behaviour of Ni–Co alloys with Co contents of 0 wt.%, 17 wt.%, 38 wt.% and 85 wt.% was evaluated. Optical and Scanning Electron Microscopy (SEM) confirmed the presence of YZA particles and Energy Dispersive X-ray Analysis (EDX) revealed the composition. Tribology testing showed that composite containing 38 wt.% Co displayed better wear resistance. It was found from the immersion corrosion studies that Ni–17Co–YZA coating displayed improved corrosion resistance. Thermal stability studies showed that Ni–85Co–YZA coating retained its microhardness at temperatures of 600 °C. Thus, these coatings can be tailored for various applications by varying the cobalt content.     

Deposition and structural analyses of molybdenum-disulfide (MoS2)–amorphous hydrogenated carbon (a-C:H) composite coatings

In this study we developed composite coatings consisting of amorphous hydrogenated carbon (a-C:H) and molybdenum-disulfide (MoS₂), and clarified their microstructure. In addition, we interpreted the tribological properties of the composite coatings in the viewpoint of a deposition-induced microstructural modification. The coatings were produced by the hybrid deposition technique of RF-generated methane and argon plasma and DC magnetron co-sputtering of MoS₂ target. The deposition parameter investigated in this study was methane flow rate. Structural analyses were performed using a transmission electron microscope (TEM) and an atomic force microscope (AFM). Friction tests were conducted using a ball-on-disk type tribometer. From an electron micrograph, it was confirmed that nano-clusters were embedded into an amorphous carbon host matrix. Surface roughness of the composite coating was ～ 0.25 nm in R_a compared to 5.0 nm in R_a of sputtered MoS₂. The concentration measurements were performed, and the results show that the sulfur and molybdenum concentration ratio, [S]/[Mo], is ～ 0.9, which indicates that the amount of sulfur was reduced due to the discharged plasma. In friction tests, composite coatings showed high friction in a vacuum condition. It was considered that lubricant MoS₂ lamellar structures showing super-low friction in a vacuum condition during friction could not be formed between ball and coating during friction because of the lack of sulfur in embedded clusters.     

Porous structure formation and physicomechanical properties of SiC–C carbon-ceramic composite materials. Part 2

A study has been made of the effects of adding nanocrystalline zirconium dioxide powder stabilized by yttrium oxide on the production and properties of a composite material based on zircon. It is found that the particles of zirconium dioxide are located at the zircon grain boundaries and delay the consolidation of the zircon matrix during sintering and zircon grain growth.     

Thermoset–thermoplastic hybrid nanoparticles and composite coatings

Structured thermoset–thermoplastic hybrid nanoparticles and composite coatings were successfully synthesized through a novel one-pot approach. Both the polyaddition of epoxy curing and the free radical polymerization of various vinyl monomers were performed in sequence in miniemulsion droplets. Benefiting from the precise control of the compatibility between thermoset phase (epoxy monomer/amine curing agent) and vinyl phase (vinyl monomers/polymers), colloidally stable, core–shell structured thermoset–thermoplastic hybrid nanoparticles between 100 and 200 nm were obtained through chemically induced phase separation. The influence of the compositions on the colloidal stability and morphology of the final hybrid latexes and films was studied in detail. Meanwhile, the mechanical properties of thermoset–thermoplastic coatings and corresponding thermoplastic coatings were investigated. It is found that the thermoset–thermoplastic composite coatings showed significantly improved film properties in terms of hardness compared to the analogous thermoplastic coatings. Furthermore the thermoset–thermoplastic hybrid films were highly transparent even with 33 wt% of epoxy thermoset domains embedded.     

Microstructures and tribological properties of vacuum plasma sprayed B4C–Ni composite coatings

A promising wear resistant coating has been fabricated via vacuum plasma spray (VPS) technique by using electroless plating composite powders comprised of B₄C and different amounts of Ni (10 and 20 vol.%). Tribological evaluation from the ball-on-disk test showed that the wear resistance of the composite coatings was superior to that of the pure B₄C coating, and the composite deposit containing 10 vol.% Ni demonstrated the optimum tribological properties. This mainly attributed to the more uniform microstructures of the composite coatings, and the higher thermal conductivity of the composite coating also contributed to its distinguished wear behaviors. For the coatings investigated, the dominant wear mechanism was determined to be oxidation and the formation of a transfer layer on the worn surface.     

Influence of Al content and post-annealing on synthesis and mechanical properties of plasma sprayed Cr–Al–C composite coatings

Due to ultra-high temperature and short reaction time, it was very challenging to produce high purity MAX phase by plasma spraying. In this study, Cr–Al-graphite agglomerated powders with different Al additions (x = 0.2–1.5) was used to prepare Cr–Al–C composite coatings by atmospheric plasma spraying followed with annealing. Results showed that the as-sprayed coatings displayed typical lamellar structure, mainly composed of Cr–C binary carbides (Cr₇C₃ and Cr₂₃C₆) and residual Al. After annealing at 700 °C, the newly formed Cr₂AlC phase increased significantly in the coatings. The higher addition of Al, the more Cr₂AlC phase formed after annealing. The enhanced atomic diffusion, sufficient Al source and existence of (Cr, Al)C_x contributed to the formation of Cr₂AlC under annealing. Annealing treatment improved the hardness of the coating, but with the increase of Cr₂AlC phase content, the hardness decreased slightly. The Al content and post-annealing had a synergistic effect on the formation of Cr₂AlC phase in the sprayed coatings. This provided an effective route to control the Cr₂AlC content in sprayed Cr–Al–C composite coatings.     

Improving hardness and toughness of plasma sprayed Ti–Si–C nano-composite coatings by post Ar-annealing

Ti–Si–C (TSC) composite coatings were fabricated by plasma spraying using Ti/Si/graphite agglomerates as feedstock. Ar-annealing was carried out to reduce the intrinsic defects and increase the performance of the as-sprayed TSC coating. The effects of the annealing temperature (500–900 °C) on the microstructures and mechanical performances of the TSC coatings were investigated. All TSC coatings consisted of TiC, Ti₅Si₃ and MAX phase Ti₃SiC₂. With the increase in temperature (>700 °C), TiC became predominant, while the Ti₃SiC₂ phase content increased, which was accompanied by a decrease in Ti₅Si₃ content. The high -temperature annealing (>700 °C) led to a homogenous microstructure with a relatively low porosity and increased number of micro-cracks. Notably, the hardness and fracture toughness of the TSC coating were simultaneously increased after the annealing, from 1164 HV to 1.96 MPa m^1/2 to 1560 HV and 3.45 MPa m^1/2, respectively. The formation of nanoscale TiC and Ti₅Si₃ with a network distribution, uniform and dense microstructure, and toughening effects of Ti₃SiC₂ and micro-cracks provided the high mechanical performances of the TSC composite coatings.     

Microstructure and mechanical properties of Ti–C–TiN-reinforced Ni204-based laser-cladding composite coating

In situ Ti(C, N), ring phase, and multi-phase enhanced Ni204-based alloy coating were prepared by adding various Ti/C/TiN ratios particles. The effects of the reinforcement phase on the microstructure, microhardness, tribological property, and microstructure characteristics at the interface between the coating and substrate were investigated. The results show that the coatings with a 5:1 mass fraction ratio of TiN/C exhibits the highest microhardness, which is 3.78 times higher than that of the original Ni204 coating. While, the coating with 21:7:2 mass fraction ratio of TiN/Ti/C exhibits the lowest friction coefficient, which is 4.44 times smaller than that of the original Ni204 coating. The addition of Ti and C particles promotes the precipitation of ring phase and carbides, reduces ceramic agglomeration, alleviates the floating of ceramic particles, and improves the bonding strength of reinforcement phases. Owing to the good mutual solubility among Fe, Ni, and, Cr elements, the diffusion happened at the interface between the coating and substrate.     

Electro-deposition and characterizations of nickel coatings on the carbon–polythene composite

Nickel coating on the carbon–polythene composite plate was prepared by electrodeposition in a nickel sulfate solution in this work. The morphology and cross-sectional microstructure of the nickel coating were examined by scanning electron microscope (SEM) and optical microscope (OM), respectively. The influence of bath temperature on the nickel deposition rate was investigated experimentally. The adhesion between the coating and the substrate was evaluated by the pull-off test. The corrosion behavior of the coating in an aqueous solution of NaCl was studied by electrochemical methods. The results showed that the nickel electrodeposition rate could reach up to 0.68 μm min⁻¹ on average under conditions of cathodic current density of 20 mA cm⁻² and bath temperature of 60 °C. It was confirmed that increasing the bath temperature up to 50 °C had a positive effect on the nickel deposit rate, while an adverse effect was observed beyond 60 °C. The adhesion strength between the nickel coating and the substrate can be more than 2.3 MPa. The corrosion potential of the bright coating in the NaCl solution was more positive than that of the dull coating, and the anodic dissolution rate of the bright coating was also far lower at the same polarization potential compared with the dull coating.     

Effects of pigmentation on siloxane–polyurethane coatings and their performance as fouling-release marine coatings

Siloxane–polyurethane paints were formulated and characterized for coating properties and performance as fouling-release (FR) marine coatings. Paints were formulated at 20 and 30 pigment volume concentrations with titanium dioxide, and aminopropyl-terminated poly(dimethylsiloxane) (APT-PDMS) loadings were varied from 0 to 30% based on binder mass. The coatings were characterized for water contact angle, surface energy (SE), gloss, and pseudobarnacle (PB) adhesion. The assessment of the FR performance compared with polyurethane (PU) and silicone standards through the use of laboratory biological assays was also performed. Biofilm retention and adhesion were conducted with the marine bacterium Cellulophaga lytica, and the microalgae diatom Navicula incerta. Live adult barnacle reattachment using Amphibalanus amphitrite was also performed. The pigmented coatings were found to have properties and FR performance similar to those prepared without pigment. However, a higher loading of PDMS was required, in some cases, to obtain the same properties as coatings prepared without pigment. These coatings rely on a self-stratification mechanism to bring the PDMS to the coating surface. The slight reduction in water contact angle (WCA) and increase in pseudobarnacle release force with pigmentation suggests that pigmentation slowed or interfered with the self-stratification mechanism. However, increasing the PDMS loading is an apparent method for overcoming this issue, allowing for coatings having similar properties as those of clear coatings and FR performance similar to those of silicone standard coatings.     

The effect of formulation variables on fouling-release performance of stratified siloxane–polyurethane coatings

The effects of formulation variables, such as type of polyol, solvent type and solvent content, and coating application method, on the surface properties of siloxane–polyurethane fouling-release coatings were explored. Fouling-release coatings allow the easy removal of marine organisms from a ship’s hull via the application of a shear force to the surface. Self-stratified siloxane–polyurethane coatings are a new approach to a tough fouling-release coating system. Combinatorial High Throughput Experimentation was employed to formulate and characterize 24 different siloxane–polyurethane coatings applied using drawdown and drop-casting methods. The resulting coatings were tested for surface energy using contact angle measurements. The fouling-release performance of the coatings was tested using a number of diverse marine organisms including bacteria (Halomonas pacifica and Cytophaga lytica), sporelings (young plants) of the green macroalga (Ulva linza), diatom ((microalga) Navicula incerta), and barnacle (Amphibalanus amphitrite). The performance of the majority of the coatings was found to be better than the silicone standards, Intersleek^® and Silastic^® T2. An increase in solvent content in the formulations increased the surface roughness of the coatings. Coatings made with polycaprolactone polyol appeared to be somewhat rougher compared to coatings made with the acrylic polyol. The adhesion strength of sporelings of Ulva increased with an increase in solvent content and increase in surface roughness. The adhesion strengths of Ulva sporelings, C. lytica, and N. incerta were independent of application method (cast or drawdown) in contrast to H. pacifica adhesion, which was dependent on the application method.     

Synthesis and anticorrosion performance of poly(2,3-dimethylaniline)–TiO2 composite

Poly(2,3-dimethylaniline)–TiO₂ composite (PTC) was prepared by oxidative polymerization of 2,3-dimethylaniline in phosphoric acid medium with ammonium persulphate as oxidant. The composite was characterized by Fourier transformation infrared (FTIR) spectroscopy, X-ray diffraction (XRD) and scanning electron microscopy (SEM). TiO₂ particles, rather being simply blended or mixed up, are encapsulated or entrapped into the polymer core, resulting in some significant improvement in its anticorrosion properties. Suitable coating with PTC was formed on steel using epoxy resin, and its corrosion resistance behavior was studied by open circuit potential (OCP) and electrochemical impendence spectroscopy (EIS) in 3.5% NaCl solution and also compared with that of PANI and poly(2,3-dimethylaniline) (P(2,3-DMA)). It has been found out that the coating containing PTC has got higher corrosion resistance than that of PANI and P(2,3-DMA).     

Enhanced performance of ultra-low carbon MgO–C bricks by the addition of special C/MgAl2O4 composite powders

Argon oxygen decarburization (AOD) refining as one type of secondary refining plays an important role in the steel industry. MgO–CaO and MgO–C bricks are widely used in AOD refining, and MgO–CaO bricks are easily hydrated. MgO–C bricks containing carbon easily pollute molten steel and have lower mechanical strength. In this study, ultra-low carbon MgO–C bricks containing C/MgAl₂O₄ composite powders used in AOD refining were explored. MgAlON as the strength phase was in situ generated in the composites (M3) containing 2 wt% C/MgAl₂O₄ composite powders. The samples were further compared with commercial MgO–CaO bricks (M1), which are currently used in the slag line of the AOD furnace, and the sample (M2) without the addition of C/MgAl₂O₄ composite powders. The hot modulus of rupture (HMOR) of M3 was the highest at 27.3 MPa, which increased 44% compared with that of M2 and increased 158% compared with that of M1. The number of thermal shock test cycles of M3 was 1.6 times that of M2. HMOR and cold crush strength (CCS) of samples after thermal shock resistance test were measured. The HMOR of M3 after 3 cycles of the thermal shock test was 2.1 times greater than that of M1. After 20 thermal shock cycles, the residual CCS ratio of M3 was highest, up to 94.6%. Improvement in the thermal shock resistance of the composites can be achieved by the addition of C/MgAl₂O₄ composite powders, which promote the generation of MgAlON. It was also found that the slag corrosion depth of M3 was the lowest at 64.7% of that of M2 and was 13% of that of M1. The internal micromorphologies researched by XRD and SEM and the corrosion mechanism revealed by thermodynamic calculations show that MgAlON was formed in situ after the corrosion test and endowed the composites with excellent properties.     

The effect of EEMAO processing on surface mechanical properties of the TiO2–ZrO2 nanostructured composite coatings

We report fabrication of TiO₂–ZrO₂ nanostructured composite coatings by EPD-Enhanced MAO (EEMAO) technique on titanium substrates where especial emphasis was placed on improving the surface hardness of the substrates and establishing a microstructure-property correlation. Based on the XRD and the EDX results, the layers consisted of anatase, rutile, monoclinic zirconia, and tetragonal zirconia. It was observed that the anatase/rutile and tetragonal/monoclinic zirconia rations increased with the processing time and the electrolyte concentration. The zirconia content also increased with the processing time and the electrolyte concentration. XPS technique was also employed to further confirm the surface chemical composition and stoichiometry of the layers. A uniform distribution of zirconia across the titania matrix was evident in the SEM images. The surface hardness of the TiO₂-ZrO₂ composite layers was observed to increase with the zirconia concentration. Employing EEMAO technique, the surface harness of the titanium substrates was successfully improved from ∼190 Hv to ∼700 Hv.     

Effect of MoS2 content on friction and wear properties of Mo and S co-doped CrN coatings at 25–600 °C

With increasingly harsh working environments for mechanical systems and the rapid development of various high-tech industries, requirements for the stable operation of mechanical systems are increasing in a wide temperature range. Mo and S co-doped CrN coatings with different MoS₂ contents were prepared via unbalanced magnetron sputtering to provide better friction properties to the coatings at high temperatures. Scanning electron microscopy and nanoindentation were adopted to analyze the microstructure and mechanical performance. The mechanical performance of the coatings was enhanced by increasing the MoS₂ content, however, excessive MoS₂ reduced the mechanical properties of the coatings. Besides, the adhesion of the coatings first increased and then decreased rapidly with the increase of the MoS₂ content. In addition, the residual stress of the coating first decreased and then increased upon increasing the MoS₂ content. The high-temperature tribological behavior of the coatings was measured from room temperature (25 °C) to 600 °C. The CrN/MoS₂-0.6A coating was found to exhibit low friction and wear coefficient at room temperature and relatively good comprehensive properties at high temperature. This study provides a feasible design for engineering applications and lays the foundations for the preparation of coatings with superior high-temperature friction properties.     

The influence of mechanical activation on the structure and phase formation of an electro-thermal explosion in the Ti–Zr–C system

The Ti_xZr_1-xC solid solutions were synthesized by electro-thermal explosion under pressure in the (Ti + Zr + C) blends mechanically activated in hexane (MA-ETE). The effect of mechanical activation (MA) duration on reaction blend characteristics, ETE parameters, phase composition, and microstructure formation in solid solutions was investigated. At MA, the Ti + Zr blend deforms metal crystal lattices for 20 min, complete amorphization occurs for 40 min, and the carbide grains form a cubic structure for 90 min. The single-phase Zr_0.50Ti_0.50C solid solution with a grain size of 3–5 μm and a submicron composite with a grain size of 0.1–0.2 μm containing the Ti_0.86Zr_0.14C and Zr_0.74Ti_0.26C solid solutions were synthesized in a one-stage process for the first time without any additional thermotreatment. The influence of mechanical activation on diffusional mass transfer of reactants, structure, and phase formation is discussed.