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5.1
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Journals
Processes
Special Issues
Microstructure, Processing and Numerical Simulation of Coatings
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Microstructure, Processing and Numerical Simulation of Coatings

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Materials Processes".

Deadline for manuscript submissions: 20 March 2025 | Viewed by 4872

Special Issue Editors

Prof. Dr. Haibo Zhang

E-Mail Website
Guest Editor
School of Mechanical Engineering, Northeast Electric Power University, Jilin 132012, China
Interests: surface treatment of metal materials; metal 3D printing
Dr. Yu Liu

E-Mail Website
Guest Editor
School of Mechanical Engineering, Northeast Electric Power University, Jilin 132012, China
Interests: microstructure; wear and corrosions; lubricant design; surface coating technology
Special Issues, Collections and Topics in MDPI journals
Dr. Yali Gao

E-Mail Website
Guest Editor
School of Mechanical Engineering, Northeast Electric Power University, Jilin 132012, China
Interests: alloy; tribological behavior; surface treatment
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

It is well known that the coating is a layer on the substrate to protect and enhance the object and plays an important role in multiple fields. The properties of coatings depend strongly on the process parameters and different materials. Therefore, we would like to invite you to submit your original research to this Processes Special Issue entitled “Microstructure, Processing and Numerical Simulation of Coatings”. The topics of interest for this Special Issue, in particular, include (but are not restricted to):

  • Surface coating technology;
  • Coating microstructure characterization;
  • Coating material design;
  • Simulation and analysis of coatings;
  • Influence of processing parameters on coatings；
  • Topics such as magnesium, aluminium, titanium, shape memory alloys and XRD, SEM and TEM analysis;
  • Other aspects of coating material.

Prof. Dr. Haibo Zhang
Dr. Yu Liu
Dr. Yali Gao
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • surface coating technology
  • microstructure
  • coatings material design
  • simulation analysis
  • numerical simulation
  • different process parameters

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Further information on MDPI's Special Issue polices can be found here.

Published Papers (4 papers)

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Research

15 pages, 11362 KiB  
Article
Influence of Laser Scanning Speed on Wear and Corrosion Resistance of Aluminum–Nickel Coating on Magnesium Alloy
by Yali Gao, Shan Jiang, Pengyong Lu, Sicheng Bai, Dongdong Zhang and Meng Jie
Processes 2024, 12(8), 1689; https://doi.org/10.3390/pr12081689 - 13 Aug 2024
Viewed by 971
Abstract
To improve the wear and corrosion resistance, Al-Ni coating was prepared on Mg alloy by laser cladding, and the influence of the laser scanning speed on the microstructure, wear and corrosion resistance of the coatings was systematically analyzed. The results showed that the [...] Read more.
To improve the wear and corrosion resistance, Al-Ni coating was prepared on Mg alloy by laser cladding, and the influence of the laser scanning speed on the microstructure, wear and corrosion resistance of the coatings was systematically analyzed. The results showed that the coatings with different scanning speeds were composed of Al3Ni2, Mg17Al12 and Mg2Al3 phases. The coatings presented fine needle-like grains. Under different scanning speeds, the microhardness of the coatings was 3.3–4.8 times that of the substrate, and the wear volume of the coatings was decreased by 40.08–51.38%. The coating with a laser scanning speed of 600 mm/min had the highest hardness, the best wear and corrosion resistance. Full article
(This article belongs to the Special Issue Microstructure, Processing and Numerical Simulation of Coatings)
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19 pages, 15427 KiB  
Article
Research on the Process of Laser Cladding Ni60 Coating on High-Nickel Cast Iron Surfaces
by Shunhu Chen, Aixin Feng, Chunlun Chen and Xiangyu Song
Processes 2024, 12(4), 647; https://doi.org/10.3390/pr12040647 - 24 Mar 2024
Viewed by 1151
Abstract
In order to achieve high-performance coatings on the surface of electric submersible pump impellers, it is crucial to optimize the laser cladding process parameters. Using Ansys 2021 R1 commercial software, a numerical simulation of laser cladding Ni60 powder on high nickel cast iron [...] Read more.
In order to achieve high-performance coatings on the surface of electric submersible pump impellers, it is crucial to optimize the laser cladding process parameters. Using Ansys 2021 R1 commercial software, a numerical simulation of laser cladding Ni60 powder on high nickel cast iron was conducted. The simulation utilized a 3D Gaussian heat source, parametric language, and life–death unit technology to replicate the characteristics of synchronous powder delivery laser cladding. The study focused on analyzing the temperature field cloud map and molten pool size under different laser power and scanning speeds, narrowing down the process parameter window, selecting optimized laser power and scanning speed, and assessing the changes in surface morphology, melting height and width, dilution rate, microhardness, and microstructure of the laser cladding coating. Results indicate that the coating width and thickness increase with higher laser power and lower scanning speeds. The microstructure consists primarily of dendritic, block, short rod, and long strip formations, and exhibits a tightly distributed and uniform grain structure. Furthermore, the microhardness of the coating shows a negative correlation with laser power and scanning speed. The optimal process parameters were determined to be a laser power of 1100 W and a scanning speed of 6 mm/s. A comparison with the simulation confirmed the effectiveness of the simulation in effectively guiding actual production. Full article
(This article belongs to the Special Issue Microstructure, Processing and Numerical Simulation of Coatings)
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18 pages, 3865 KiB  
Article
Maximizing Corrosion Resistance of HA+Ce Coated Mg Implants Using Random Forest and Whale Optimization Algorithm
by Zeinab Rajabi, Faramarz Afshar Taromi, Saeed Pourmahdian and Hossein Eivaz Mohammadloo
Processes 2024, 12(3), 490; https://doi.org/10.3390/pr12030490 - 28 Feb 2024
Viewed by 930
Abstract
In this paper, a hybrid three-stage methodology based on in vitro experiments, simulations, and metaheuristic optimization is presented to enhance the corrosion resistance of hydroxyapatite (HA)-coated magnesium implants in biomedical applications. In the first stage, we add cerium (Ce) to HA and present [...] Read more.
In this paper, a hybrid three-stage methodology based on in vitro experiments, simulations, and metaheuristic optimization is presented to enhance the corrosion resistance of hydroxyapatite (HA)-coated magnesium implants in biomedical applications. In the first stage, we add cerium (Ce) to HA and present a new coating (named HA+Ce) to improve the resistance of the coating to corrosion. Then, various HA+Ce compounds with different factors (e.g., concentration, pH, immersion time, and temperature) are generated and their propensity for corrosion is examined in a physiological environment using EIS and DC polarization tests in a simulated body fluid solution. Eventually, a comprehensive dataset comprising 1024 HA+Ce coating samples is collected. In the second stage, machine learning using random forest (RF) is used to learn the relation between the input factors of the coating and its corrosion resistance. In the third stage, a metaheuristic algorithm based on the whale optimization algorithm (WOA) is utilized to find the best HA+Ce compound with the maximum corrosion resistance, while the objective function of WOA for a new unseen coating solution is estimated using the trained RF model. Finally, the morphology and composition of the best coating solution are inspected using FE-SEM. According to the obtained results, the HA+Ce coating with an immersion time of 60 min, concentrations of 0.9 for Ce and 1.2 for HA, pH of 4.1 for solution, and temperature of 70 °C demonstrated the highest level of corrosion resistance among all experiments and simulations. The final optimized HA+Ce coating solution has obtained a corrosion resistance of 14,050 Ω·cm2, which resulted in a gain of 14.9% compared to the HA-coated Mg implants. Full article
(This article belongs to the Special Issue Microstructure, Processing and Numerical Simulation of Coatings)
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18 pages, 14172 KiB  
Article
Coating Composites Based on Polyurea Elastomers with Increased Fire Resistance and Their Use as Roofing Systems
by Wojciech Dukarski, Iwona Rykowska, Piotr Krzyżanowski, Joanna Paciorek-Sadowska and Marek Isbrandt
Processes 2023, 11(8), 2421; https://doi.org/10.3390/pr11082421 - 11 Aug 2023
Cited by 1 | Viewed by 1286
Abstract
This paper presents the results of tests on elastomer coatings based on polyurea–polyurethane formulation with increased fire parameters. Coatings modified with flame retardants: bis(phenylphosphate) resorcinol (RDP), trischloropropyl phosphate (TCPP), and aluminum hydroxide (ATH) were tested. Fourier transform infrared spectroscopy (FTIR) and thermogravimetric analysis [...] Read more.
This paper presents the results of tests on elastomer coatings based on polyurea–polyurethane formulation with increased fire parameters. Coatings modified with flame retardants: bis(phenylphosphate) resorcinol (RDP), trischloropropyl phosphate (TCPP), and aluminum hydroxide (ATH) were tested. Fourier transform infrared spectroscopy (FTIR) and thermogravimetric analysis (TGA/DTG) were used to investigate the structure and thermal stability. The effectiveness of resorcinol bis(phenylphosphate) (RDP), tris chloropropyl phosphate (TCPP), and aluminum hydroxide (ATH) on heat release rate (HRR), smoke release rate (RSR), and oxygen consumption was evaluated using cone calorimetry. The cone calorimetry results were correlated with the mechanical properties of the coatings. The cone calorimetry analysis showed suitable organophosphorus flame retardant (FR) performance, significantly decreasing HRR and oxygen consumption. Additionally, 15% TCPP caused a reduction of HRR by over 50%, obtaining 211.4 kW/m2 and pHRR by over 55%, reaching 538.3 kW/m2. However, organophosphorus flame retardants caused a significant deterioration of mechanical properties simultaneously. Introducing a mixture of two FRs (RDP/TCPP) resulted in obtaining a coating with improved fire resistance and maintained good mechanical strength. The polyurea–polyurethane coating, modified with a mixture of two RDP/TCPP retardants (10:5), was simulated for the burning of roof systems. The result of the simulation was assessed positively. Thus, finally, it was confirmed that the proposed polyurea–polyurethane coating achieved the assumed flame retardant level. Full article
(This article belongs to the Special Issue Microstructure, Processing and Numerical Simulation of Coatings)
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