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Friction, Corrosion and Protection of Material Surfaces

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Thin Films and Interfaces".

Deadline for manuscript submissions: 20 March 2025 | Viewed by 18679

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Special Issue Editors

Prof. Dr. Xiaowei Li

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Guest Editor

School of Materials and Physics, China University of Mining and Technology, Xuzhou 221116, China
Interests: surface modification; carbon-based film; diamond-like carbon; friction; wear; tribocorrosion; mechanical property; residual stress; solid–liquid composite lubrication; biocompatibility; graphene; molecular dynamics simulation; ab initio calculation

Dr. Zhenyu Wang

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Guest Editor

Key Laboratory of Marine Materials and Related Technologies, Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo 315201, China
Interests: MAX phase coatings; corrosion/oxidation resistance; hard protective coatings; highly ionized PVD technique

Dr. Zhaolei Li

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Guest Editor

Department of Polymer Materials, School of Material Science and Engineering, Jiangsu University of Science and Technology, Zhenjiang 212100, China
Interests: metal corrosion; polymer coatings; inhibitors; solid polymer electrolytes

Dr. Cunao Feng

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Guest Editor

School of Materials and Physics, China University of Mining and Technology, Xuzhou 221116, China
Interests: friction transmission materials; wear-resistant materials; intelligent sensors; artificial intelligence monitoring

Special Issue Information

Dear Colleagues,

Friction and corrosion, which exist widely in engineering instruments, marine equipment, aerospace, artificial joints and other advanced manufacturing fields, are the key factors that cause damage to material (metallic and non-metallic materials, such as titanium alloys, stainless steels, alumina ceramics, fiber-reinforced composites, etc.) surfaces and the failure of equipment, which has attracted great attention. Therefore, it is crucial to study and understand the friction and corrosion behaviors of material surfaces to guide engineering applications and reduce safety hazards. Recently, the surface protection of traditional materials, such as laser cladding, nitriding treatments, high-performance films and coatings, etc., has gradually replaced the use of expensive high-performance materials, which has become a research focus.

This Special Issue (“Friction, Corrosion and Protection of Material Surfaces”) will include the friction and corrosion behaviors of new materials and advanced protective materials, new findings in friction and corrosion mechanisms, advanced protective technologies, and advances in the friction, corrosion and protection of material surfaces. It is my pleasure to invite you to submit original research papers (experiments or simulations), and state-of-the-art reviews for this Special Issue.

Prof. Dr. Xiaowei Li
Dr. Zhenyu wang
Dr. Zhaolei Li
Dr. Cunao Feng
Guest Editors

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Keywords

friction
corrosion
surface modification
coating
thin films
degradation mechanisms
advanced materials
surface and interface

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Published Papers (10 papers)

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Editorial

Jump to: Research, Review

2 pages, 162 KiB

Open AccessEditorial

Special Issue: Friction, Corrosion and Protection of Material Surfaces

by Cunao Feng, Zhenyu Wang, Zhaolei Li and Xiaowei Li

Materials 2023, 16(18), 6220; https://doi.org/10.3390/ma16186220 - 15 Sep 2023

Viewed by 950

Abstract

The current Special Issue, entitled “Friction, Corrosion and Protection of Material Surfaces”, aims to discuss the state-of-the-art research progress regarding the friction and corrosion behaviors of new materials and advanced protective materials or technologies, with a special focus on the understanding of underlying friction and corrosion mechanisms and modification approaches of material surfaces against friction and corrosion in order to guide the design and preparation of materials with high performance for practical applications [...] Full article

(This article belongs to the Special Issue Friction, Corrosion and Protection of Material Surfaces)

Research

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14 pages, 5499 KiB

Open AccessEditor’s ChoiceArticle

Comparison of Magnetron-Sputtered and Cathodic Arc-Deposited Ti and Cr Thin Films on Stainless Steel for Bipolar Plates

by Nils Fredebeul-Beverungen, Maximilian Steinhorst and Teja Roch

Materials 2024, 17(12), 2864; https://doi.org/10.3390/ma17122864 - 12 Jun 2024

Viewed by 758

Abstract

In this work, the potential of magnetron sputtering, as well as cathodic arc evaporation, is investigated with regard to its suitability as a bipolar plate coating of a PEM fuel cell. For this purpose, Cr and Ti thin films were deposited onto a 0.1 mm SS316L by varying the power and bias voltage. The surface structure and thickness of the coatings are examined via SEM and tactile profilometry. Moreover, the coating variants are compared with each other based on the electrical and electrochemical properties relevant to bipolar plates. The sputtered Cr thin films achieve the lowest contact resistance values and exhibit a columnar structure with a smooth surface. Regarding the electrochemical properties, titanium deposited via cathodic arc evaporation has a low current density in the passive region and high breakthrough potential. All in all, both deposition techniques have their individual advantages for the preparation of bipolar plates’ coatings. However, Ti thin films prepared via cathodic arc seem to be the most suitable option due to the combination of a high deposition rate, a low cost and good coating properties. Full article

(This article belongs to the Special Issue Friction, Corrosion and Protection of Material Surfaces)

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16 pages, 19168 KiB

Open AccessEditor’s ChoiceArticle

Enhanced Long-Term Corrosion Resistance of 316L Stainless Steel by Multilayer Amorphous Carbon Coatings

by Shuyu Li, Hao Li, Peng Guo, Xiaowei Li, Wei Yang, Guanshui Ma, Kazuhito Nishimura, Peiling Ke and Aiying Wang

Materials 2024, 17(9), 2129; https://doi.org/10.3390/ma17092129 - 1 May 2024

Cited by 1 | Viewed by 928

Abstract

Diamond-like carbon (DLC) coatings are effective in protecting the key components of marine equipment and can greatly improve their short-term performance (1.5~4.5 h). However, the lack of investigation into their long-term (more than 200 h) performance cannot meet the service life requirements of marine equipment. Here, three multilayered DLC coatings, namely Ti/DLC, TiC_x/DLC, and Ti-TiC_x/DLC, were prepared, and their long-term corrosion resistance was investigated. Results showed that the corrosion current density of all DLC coatings was reduced by 1–2 orders of magnitude compared with bare 316L stainless steel (316Lss). Moreover, under long-term (63 days) immersion in a 3.5 wt.% NaCl solution, all DLC coatings could provide excellent long-term corrosion protection for 316Lss, and Ti-TiC_x/DLC depicted the best corrosion resistance; the polarization resistances remained at ~3.0 × 10⁷ Ω·cm² after immersion for 63 days, with more interfaces to hinder the penetration of the corrosive media. Meanwhile, during neutral salt spray (3000 h), the corrosion resistance of Ti/DLC and TiC_x/DLC coatings showed a certain degree of improvement because the insoluble corrosion products at the defects blocked the subsequent corrosion. This study can provide a route to designing amorphous carbon protective coatings for long-term marine applications in different environments. Full article

(This article belongs to the Special Issue Friction, Corrosion and Protection of Material Surfaces)

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12 pages, 2611 KiB

Open AccessArticle

Structural Parameters and Behavior in Simulated Body Fluid of High Entropy Alloy Thin Films

by Doina Craciun, Edwin A. Laszlo, Julia C. Mirza-Rosca, Gabriela Dorcioman, Victor Geanta, Ionelia Voiculescu, Gabriel Craciun, Liviu Badea and Valentin Craciun

Materials 2024, 17(5), 1162; https://doi.org/10.3390/ma17051162 - 1 Mar 2024

Cited by 2 | Viewed by 1315

Abstract

The structure, composition and corrosion properties of thin films synthesized using the Pulsed Laser Deposition (PLD) technique starting from a three high entropy alloy (HEA) AlCoCrFeNix produced by vacuum arc remelting (VAR) method were investigated. The depositions were performed at room temperature on Si and mirror-like polished Ti substrates either under residual vacuum (low 10⁻⁷ mbar, films denoted HEA2, HEA6, and HEA10, which were grown from targets with Ni concentration molar ratio, x, equal to 0.4, 1.2, and 2.0, respectively) or under N₂ (10⁻⁴ mbar, films denoted HEN2, HEN6, and HEN10 for the same Ni concentration molar ratios). The deposited films’ structures, investigated using Grazing Incidence X-ray Diffraction, showed the presence of face-centered cubic and body-centered cubic phases, while their surface morphology, investigated using scanning electron microscopy, exhibited a smooth surface with micrometer size droplets. The mass density and thickness were obtained from simulations of acquired X-ray reflectivity curves. The films’ elemental composition, estimated using the energy dispersion X-ray spectroscopy, was quite close to that of the targets used. X-ray Photoelectron Spectroscopy investigation showed that films deposited under a N₂ atmosphere contained several percentages of N atoms in metallic nitride compounds. The electrochemical behavior of films under simulated body fluid (SBF) conditions was investigated by Open Circuit Potential (OCP) and Electrochemical Impedance Spectroscopy measurements. The measured OCP values increased over time, implying that a passive layer was formed on the surface of the films. It was observed that all films started to passivate in SBF solution, with the HEN6 film exhibiting the highest increase. The highest repassivation potential was exhibited by the same film, implying that it had the highest stability range of all analyzed films. Impedance measurements indicated high corrosion resistance values for HEA2, HEA6, and HEN6 samples. Much lower resistances were found for HEN10 and HEN2. Overall, HEN6 films exhibited the best corrosion behavior among the investigated films. It was noticed that for 24 h of immersion in SBF solution, this film was also a physical barrier to the corrosion process, not only a chemical one. Full article

(This article belongs to the Special Issue Friction, Corrosion and Protection of Material Surfaces)

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16 pages, 6661 KiB

Open AccessArticle

Comparative Study of Corrosion Performance of LVOF-Sprayed Ni-Based Composite Coatings Produced Using Standard and Reducing Flame Spray Stoichiometry

by Abdelhek Idir, Francesco Delloro, Rassim Younes, Mohand Amokrane Bradai, Abdelhamid Sadeddine and Gabriela Marginean

Materials 2024, 17(2), 458; https://doi.org/10.3390/ma17020458 - 18 Jan 2024

Viewed by 923

Abstract

Coating efficiency and quality can be significantly improved by carefully optimizing the coating parameters. Particularly in the flame spray method, the oxygen/fuel ratio, which is classified as oxidizing flame stoichiometry (excess oxygen) and reduces flame stoichiometry (excess acetylene), and spray distance are the most critical factors, as they correlate significantly with coating porosity and corrosion performance. Hence, understanding the effects of these parameters is essential to further minimize the porosity, improving the corrosion performance of thermally sprayed coatings. In this work, a NiWCrBSi alloy coating was deposited via the oxyacetylene flame spray/Flexicord-wire (FS/FC) method. The effect of the flame oxygen/fuel ratio and spray distance on the microstructure properties and corrosion behavior of the coatings was investigated. Afterwards, the microstructure, phases’ compositions, spray distance, and corrosion performance were studied. The equivalent circuit model was proposed, and the corrosion mechanism was discussed. The obtained results highlight that the oxygen-to-fuel ratio is a promising solution for the further application of flame spray/Flexicord-wire (FS/FC) cermet coatings in hostile environments. Depending on the flame’s oxygen/fuel ratio, careful selection of the flame stoichiometry provides low porosity and high corrosion performance. Full article

(This article belongs to the Special Issue Friction, Corrosion and Protection of Material Surfaces)

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20 pages, 44457 KiB

Open AccessArticle

Comprehensive Understanding of the Effect of TGO Growth Modes on Thermal Barrier Coating Failure Based on a Simulation

by Da Qiao, Jixin Man, Wengao Yan, Beirao Xue, Xiangde Bian and Wu Zeng

Materials 2024, 17(1), 180; https://doi.org/10.3390/ma17010180 - 28 Dec 2023

Cited by 1 | Viewed by 1075

Abstract

The growth stress induced by thermally grown oxide (TGO) is one of the main reasons for the failure of thermal barrier coatings (TBCs). In this study, the failure behavior of TBCs was examined based on different growth modes of TGO. A TBC thermo-mechanical model with a simplified sinusoidal interface morphology was established by the secondary development of a numerical simulation. The plasticity and creep behavior of materials were considered. Based on the subroutine development, the non-uniform growth of the TGO layer was realized. Cohesive elements were also applied to the TC/TGO interface. The stress distribution and evolution at the TC/TGO interface were investigated. Then, the cracking behavior near the interface was studied. The results show that lateral growth causes the off-valley site to replace the previous off-peak site as a vulnerable site. The non-uniform growth accelerates damage in the off-valley site, which leads to a change in the failure behavior. These results will provide significant guidance for understanding the TBC failure and the development of advanced TBCs. Full article

(This article belongs to the Special Issue Friction, Corrosion and Protection of Material Surfaces)

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10 pages, 2728 KiB

Open AccessArticle

Atomic-Scale Understanding on the Tribological Behavior of Amorphous Carbon Films under Different Contact Pressures and Surface Textured Shapes

by Zan Chen, Naizhou Du, Xiaowei Li, Xubing Wei, Jiaqing Ding, Shiqi Lu, Shuangjiang Du, Cunao Feng, Kai Chen, Dekun Zhang and Kwang-Ryeol Lee

Materials 2023, 16(18), 6108; https://doi.org/10.3390/ma16186108 - 7 Sep 2023

Cited by 4 | Viewed by 1181

Abstract

The textured design of amorphous carbon (a-C) film can significantly improve the tribological performance and service life of moving mechanical components. However, its friction dependence on different texture shapes, especially under different load conditions, remains unclear. In particular, due to the lack of information regarding the friction interface, the underlying friction mechanism has still not been unveiled. Therefore, the effects of contact pressure and textured shapes on the tribological behavior of a-C films under dry friction conditions were comparatively studied in this work by reactive molecular dynamics simulation. The results show that under low contact pressure, the tribological property of a-C film is sensitive to the textured shape, and the system with a circular textured surface exhibits a lower friction coefficient than that with a rectangular textured surface, which is attributed to the small fraction of unsaturated bonds. However, the increase of contact pressure results in the serious reconstruction and passivation of the friction interface. On the one hand, this induces a growth rate of friction force that is much smaller than that of the normal load, which is followed by a significant decrease in the friction coefficient with contact pressure. On the other hand, the destruction or even disappearance of the textured structure occurs, weakening the difference in the friction coefficient caused by different textured shapes of the a-C surface. These results reveal the friction mechanism of textured a-C film and provide a new way to functionalize the a-C as a protective film for applications in hard disks, MEMS, and NEMS. Full article

(This article belongs to the Special Issue Friction, Corrosion and Protection of Material Surfaces)

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13 pages, 5989 KiB

Open AccessFeature PaperArticle

In Situ Formation of MoS₂ on the Surface of CF to Improve the Tribological Properties of PUE

by Cunao Feng, Yu Guo, Xiaowei Li, Yang Cao, Qiuxue Kuang, Minghui Zhang and Dekun Zhang

Materials 2023, 16(17), 5773; https://doi.org/10.3390/ma16175773 - 23 Aug 2023

Viewed by 1072

Abstract

The roller is an important part of the belt conveyor used in coal transportation. Due to the harsh environment of coal mines, the rollers are in a state of high load and high friction for a long time, which causes wear failure and has a serious impact on the reliability and safety of the equipment. In order to prepare roller material with excellent bearing performance and friction performance, CF/PUE composites were prepared by pouring method with polyurethane as the matrix and carbon fiber as reinforcement. Due to the low surface activity of unmodified carbon fibers and poor bonding performance with the matrix, MoS₂ was generated on the surface of carbon fiber by the in situ generation method in this paper. It was found that the mechanical properties of MoS₂/CF/PUE composites were better when the CF content was 0.3 wt%. The Shore hardness reached 92.2 HA, which is 10% higher than pure polyurethane. The tensile strength was 38.44 MPa, which is 53% higher than pure polyurethane. The elongation at break was 850%, which is 16% higher than pure polyurethane. The maximum compressive stress was 2.32 MPa, which is 42% higher than pure polyurethane. The friction coefficient was much lower than that of pure PUE composites, the friction coefficient was 0.284, which is 59% lower than pure polyurethane. Full article

(This article belongs to the Special Issue Friction, Corrosion and Protection of Material Surfaces)

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21 pages, 5361 KiB

Open AccessArticle

Performance of Anticorrosive Paint Systems for Carbon Steel in the Antarctic Marine Environment

by Rosa Vera, Margarita Bagnara, Rodrigo Henríquez, Lisa Muñoz, Paula Rojas and Andrés Díaz-Gómez

Materials 2023, 16(16), 5713; https://doi.org/10.3390/ma16165713 - 21 Aug 2023

Cited by 3 | Viewed by 3729

Abstract

This study evaluated the behavior of three paint systems exposed to the Antarctic marine environment for 45 months compared to a control of uncoated carbon steel with a determined corrosion rate. At the study site, all environmental conditions, solar radiation, and the concentration [...] Read more.

{Cl}^{-}

and SO₂) were evaluated. The paint systems differed in terms of the primer and top coat. Coated samples were studied before and after exposure. They were evaluated visually and using SEM to determine adhesion, abrasion, and contact angle; using the Evans X-Cut Tape Test; using ATR-FTIR spectroscopy to analyze the state of aging of the top layer; and using electrochemical impedance spectroscopy (EIS) for coat protection characterization. The corrosion rate obtained for steel was 85.64 µm year⁻¹, which aligned with a C5 environmental corrosivity category. In general, the evaluation in the period studied showed the paint systems had good adhesion and resistance to delamination, without the presence of surface rust, and exhibited some loss of brightness, an increase in the abrasion index, and a decrease in the percentage of reflectance due to aging. EIS showed good protection capability of the three coating schemes. In general, this type of paint system has not previously been evaluated in an extreme environment after 45 months of exposure to the environment. The results showed that the best behavior was found for the system whose top layer was acrylic–aliphatic polyurethane. Full article

(This article belongs to the Special Issue Friction, Corrosion and Protection of Material Surfaces)

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Review

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21 pages, 1373 KiB

Open AccessReview

Nanocomposite Coatings for Anti-Corrosion Properties of Metallic Substrates

by Liana Maria Muresan

Materials 2023, 16(14), 5092; https://doi.org/10.3390/ma16145092 - 19 Jul 2023

Cited by 23 | Viewed by 5653

Abstract

Nanocomposites are high-performance materials with exceptional characteristics that possess properties that their individual constituents, by themselves, cannot provide. They have useful applications in many fields, ranging from membrane processes to fuel cells, biomedical devices, and anti-corrosion protection. Well-tailored nanocomposites are promising materials for anti-corrosion coatings on metals and alloys, exhibiting simple barrier protection or even smart auto-responsive and self-healing functionalities. Nanocomposite coatings can be prepared by using a large variety of matrices and reinforcement materials, often acting in synergy. In this context, recent advances in the preparation and characterization of corrosion-resistant nanocomposite coatings based on metallic, polymeric, and ceramic matrices, as well as the incorporation of various reinforcement materials, are reviewed. The review presents the most important materials used as matrices for nanocomposites (metals, polymers, and ceramics), the most popular fillers (nanoparticles, nanotubes, nanowires, nanorods, nanoplatelets, nanosheets, nanofilms, or nanocapsules), and their combinations. Some of the most important characteristics and applications of nanocomposite coatings, as well as the challenges for future research, are briefly discussed. Full article

(This article belongs to the Special Issue Friction, Corrosion and Protection of Material Surfaces)

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