Corrosion-Resistant Hydrophobic Thermal Barrier Composite Coating on Metal Strip: A New Dimension to Steel Strips for Roofing Segment

This study demonstrates a cost-effective, thin, multifunctional composite coating system with outstanding thermal insulation for thermal management and heat shield applications, such as roofs, as well as outstanding resistance to corrosion. The hydrophobic multifunctional epoxy composite coating systems were designed with surface-modified fillers to impart both reduced heat conduction and high infrared reflectance in a thin coating with a 65-100 μm dry film thickness (DFT). With a judicial combination of hollow microspheres (HMS) activated and modified with silica (sHMS) and stearic acid-modified TiO2 (sMO), the developed composite coating attained the highest thermal insulation property with a temperature drop of 21-31 °C at different distances below the coated panel, which is superior to the values of temperature drop reported earlier. The high solar reflectance of the composite coating in the near-infrared (NIR) region exceeds 72% with a low thermal conductivity of 0.178 W m-1 K-1. After 720 h of exposure in a 3.5 wt % NaCl solution, the composite coating revealed a corrosion protection efficiency of 99%. The work demonstrates that high solar reflectivity and low thermal conductivity must be active simultaneously to achieve superior thermal shielding in a thin coating on a metal. A careful selection of fillers and appropriate surface modifications ensures hydrophobicity and proper distribution of the fillers in the coating for a high barrier effect to prevent environmental deterioration. With these superior performance parameters, the developed composite coatings make an essential contribution to energy sustainability and the protection against environmental degradation.

Advancements in Nickel-Phosphate/Boron Based Electroless Composite Coatings: A Comprehensive Review of Mechanical Properties and Recent Developments

Nickel-Phosphate/Boron (Ni-P/B) electroless coatings have been widely used to improve physical and mechanical properties in various industrial applications, including the automotive, aerospace, chemical processing, food, oil and gas, electronic, textile, and printing industries. Electroless nickel coatings are one of the most popular surface-coating methods due to their low cost and short processing time. The purpose of this review is to look at several coating materials and the existing processes for making electroless coatings on different materials. The improvement of Ni-P/B composite coatings by the incorporation of secondary particles into an alloy matrix at the macro, micro, and nano levels is explained in detail. Process parameters like type of surfactant, annealing temperature, size of the reinforcement material, and reducing-agent percentage on mechanical characteristics like hardness, high-temperature oxidation behaviour, friction, coefficient, wear, and corrosion have been broadly researched and illustrated clearly.

Composite Coatings Based on Recombinant Spidroins and Peptides with Motifs of the Extracellular Matrix Proteins Enhance Neuronal Differentiation of Neural Precursor Cells Derived from Human Induced Pluripotent Stem Cells

The production and transplantation of functionally active human neurons is a promising approach to cell therapy. Biocompatible and biodegradable matrices that effectively promote the growth and directed differentiation of neural precursor cells (NPCs) into the desired neuronal types are very important. The aim of this study was to evaluate the suitability of novel composite coatings (CCs) containing recombinant spidroins (RSs) rS1/9 and rS2/12 in combination with recombinant fused proteins (FP) carrying bioactive motifs (BAP) of the extracellular matrix (ECM) proteins for the growth of NPCs derived from human induced pluripotent stem cells (iPSC) and their differentiation into neurons. NPCs were produced by the directed differentiation of human iPSCs. The growth and differentiation of NPCs cultured on different CC variants were compared with a Matrigel (MG) coating using qPCR analysis, immunocytochemical staining, and ELISA. An investigation revealed that the use of CCs consisting of a mixture of two RSs and FPs with different peptide motifs of ECMs increased the efficiency of obtaining neurons differentiated from iPSCs compared to Matrigel. CC consisting of two RSs and FPs with Arg-Gly-Asp-Ser (RGDS) and heparin binding peptide (HBP) is the most effective for the support of NPCs and their neuronal differentiation.

The Structure and Properties of Laser-Cladded Inconel 625/TiC Composite Coatings

This article presents production results concerning metal matrix composite-coatings made using the laser-cladding technology. The enhancement of the wear resistance of the material surface is the one of the main goals accompanying the manufacturing of composite coatings. Nickel-based superalloys are used in several industries because they are characterized by a number of desirable properties including high tensile and fatigue strength as well as resistance to high-temperature corrosion in aggressive environments. One of the most interesting materials from the group of superalloys is Inconel 625, used as a matrix material in tests discussed in this article. However, nickel-based superalloys are also characterized by an insufficient wear resistance of the surface, therefore, in relation to the tests discussed in this article, Inconel 625-based composite coatings were reinforced by adding 10%, 20% and 40% of titanium carbide particles. The addition of hard phases, i.e., TiC, WC or SiC particles can have a positive effect on the erosion resistance of cladded specimens. The aim of the experiment was to determine the impact of the titanium carbide content on the structure of the alloy and its resistance to corrosive wear, enabling the extension of the service life of Inconel 625/TiC composite coatings. The investigation included microhardness tests, corrosion resistance analysis, penetrant tests, macrostructure and microstructure analyses and X-ray diffraction (XRD) tests. The TiC particles increased the hardness of the coatings and, in general, had a negative impact on the corrosion resistance of pure Inconel 625 coatings. However, the increased homogeneity of composite coatings translated into the improvement of corrosion resistance.

Study on Pulse-Reverse Electroplating Process for the Manufacturing of a Graphene-Based Coating

This work investigates the feasibility of increasing the electric conductivity of an AA1370 aluminium wire by using pulse-reverse electrodeposition to realize Cu-Graphene composite coating. The graphene adopted was in the form of nanoplates (GnP). To study the effects of plating parameters, a 2³ factorial plan was developed and tested. During the tests, the following process parameters were varied: the current density, the frequency and the duty cycle. The ANalysis Of VAriance (ANOVA)) was adopted to evaluate their influence on the coated wires' morphology and electrical conductivity resistance. The results show that all the tested conditions allow good compactness to the coating, and the amount of graphene is well incorporated within the microstructure of the copper deposit. In addition, in the best conditions, the electrical resistivity decreases up to 3.4% than the uncoated aluminum.

Composite Coatings of AMg3 Alloy Formed by a Combination of Plasma Electrolytic Oxidation and Fluoropolymer Spraying

This paper presents the results of an investigation of the changes in the corrosion, wear resistance, and wettability of composite coatings formed on the AMg3 alloy through plasma electrolytic oxidation (PEO) and subsequent spraying with an organofluorine polymer. The evaluation of the electrochemical properties of the composite layers revealed a decrease in the corrosion current density compared with the PEO coating (from 3.8 × 10^-8 to 3.1 × 10^-11 A/cm²). The analysis of the wear resistance of composite coatings established that the application of this type of coating reduced the wear of the samples by two orders of magnitude when compared with the PEO layer. Using the contact-angle measurement, it was found that with an increase in the number of polymer spray applications, the wettability of coatings decreased, so the contact angle for the composite coating with triple fluoropolymer application increased by 134.3° compared to the base PEO coating.

Nanoparticles based composite coatings with tunable vascular endothelial growth factor and bone morphogenetic protein-2 release for bone regeneration

Bone healing is a complex cascade involving precisely coordinated spatiotemporal presentation of multiple growth factors (GFs), including osteogenic and angiogenic GFs, and each stage of bone healing requires varying types and content of GFs. In this study, we fabricated a composite nanocoating with tunable vascular endothelial growth factor (VEGF) and bone morphogenetic protein-2 (BMP-2) that was coated on the surface of a polydopamine (PDA)-decorated tertiary calcium phosphate (TCP) scaffold using VEGF-loaded chitosan/bovine serum albumin nanoparticles (CS/BSA-NPs) and BMP-2-loaded poly-L-lysine/oxidized alginate nanoparticles (PLL/OALG-NPs). It was found that VEGF could be efficiently released to promote vascularization in early bone repair stages due to the rapid biodegradation of CS/BSA-NPs, while bone formation can be promoted by a sustained release of BMP-2 from the slowly degrading PLL/OALG-NPs. The composite coating and TCP scaffold can be conjugated due to the excellent adhesive property of PDA. The composite coating can achieve the rapid release of VEGF and sustained release of BMP-2, which can activate GFs for accelerating bone healing.

Tribological Properties of Ti-TiC Composite Coatings on Titanium Alloys

The application of titanium and its alloys under friction conditions is severely restricted, owing to their poor wear resistance. The paper presents the results of studies of the composition, microstructure, and tribological properties of Ti-TiC-based composite coatings formed on titanium alloys by the electroarc treatment in an aqueous electrolyte using a graphite anode. It has been found that TiC grains have a different stoichiometry and do not contain oxygen. The grain size varies from hundreds of nanometers to tens of micrometers, and the micro-hardness of the treated surface reached the value of 29.5 GPa. The wear resistance of the treated surface increased approximately 40-fold, and the friction coefficient with steel decreased to 0.08-0.3 depending on the friction conditions. The formation of a composite material based on Ti-TiC will contribute to the effective protection of titanium alloys from frictional loads in engineering.

Features of Composite Layers Created Using an Aqueous Suspension of a Fluoropolymer

This paper presents a method for the formation of composite-polymer-containing coatings on MA8 Mg alloy by plasma electrolytic oxidation (PEO), followed by the deposition of a fluoropolymer from an aqueous suspension of superdispersed polytetrafluoroethylene. The Scanning Electron Microscope(SEM), Energy Dispersive Spectroscopy(EDS), and X-ray Diffraction(XRD) analyses established morphological features as well as elemental and phase composition of composite coatings. The fact that the pores are filled with a fluoropolymer has been experimentally confirmed. An assessment of the corrosion properties of formed composite coatings revealed a decrease in the corrosion current density by more than four orders of magnitude in comparison with the base PEO layer. The highest resistance to the damaging effects of a corrosive environment, according to the results of long-term exposure tests, was demonstrated by coatings after three treatments with polytetrafluoroethylene. The obtained polymer-containing coatings have antifriction properties, reducing the wear of the coatings by more than 27-fold in comparison with the base PEO layer. It was revealed that composite coatings have superhydrophobic properties: the value of the contact angle reaches 154°, and the hysteresis of the contact angle is less than 10°.

Design and Preparation of Localized Heat-Resistant Coating

Localized heat sources, such as flame guns and high-energy lasers, can cause severe damage to conventional materials. In this study, a novel localized heat-resistant coating with a high in-plane thermal conductivity was designed and prepared. Reduced graphene oxide (rGO) effectively improved the in-plane thermal conductivity of the polyvinyl alcohol (PVA) film, while maintaining the thermal insulation of the resin matrix in the through-plane direction. This characteristic of the rGO/PVA film was combined with the thermal insulation of boron-modified phenolic resin (BPF), and the prepared composite coating with two layers of rGO/PVA films effectively lowered the back-surface temperature in the flame ablation test from 151 to 107 °C. In addition, the area of the ablation-affected region of coating was increased to 103.6 cm² from 31.9 cm², indicating an excellent heat transfer performance. The layer-by-layer structure could realize the compatibility of high in-plane thermal conductivity and good through-plane thermal insulation. The synergy of these two different characteristics is demonstrated to be the key to improving the localized heat-resistant performance of the composite coating. This study effectively expands the application range of high-conductive film, and the obtained coating could act as a shield against butane flame, high energy lasers, and other localized heat.

Corrosion Properties of S-Phase/Cr2N Composite Coatings Deposited on Austenitic Stainless Steel

In order to study the suitability of the S-phase layers as the interlayer for Cr₂N chromium nitride coatings, a number of composite coatings were deposited by the reactive magnetron sputtering (RMS) method on austenitic steel substrates with various initial surface conditions (as delivered and polished) and their corrosion resistance was assessed. Coatings with S-phase interlayer were deposited at three different nitrogen contents in the working atmosphere (15%, 30%, and 50%), which influenced the nitrogen concentration in the S-phase. Coatings with chromium, as a traditional interlayer to improve adhesion, and uncoated austenitic stainless steel were used as reference materials. Detailed microstructural and phase composition studies of the coatings were carried out by means of scanning electron microscopy (SEM), optical microscopy (LM), and X-ray diffraction (XRD) and were discussed in the context of results of corrosion tests carried out with the use of the potentiodynamic polarization method conducted in a 3% aqueous solution of sodium chloride (NaCl). The performed tests showed that the electrochemical potential of the S-phase/Cr₂N composite coatings is similar to that of Cr/Cr₂N coatings. It was also observed that the increase in the nitrogen content in the S-phase interlayer causes an increase in the polarization resistance of the S-phase/Cr₂N composite coating. Moreover, with a higher nitrogen content in the S-phase interlayer, the polarization resistance of the S-phase/Cr₂N coating is higher than for the Cr/Cr₂N reference coating. All the produced composite coatings showed better corrosion properties in relation to the uncoated austenitic stainless steel.

Tribology and Anti-Ablation Properties of SiC-VN-MoS2/Ta Composite Coatings on Carbon/Carbon Composites from 25 to 800 °C

To improve the self-lubrication and anti-ablation performances of C/C (carbon/carbon) composites from 25 to 800 °C, we engineered three layers of composite coatings consisting of SiC–VN–MoS₂/Ta to deposit on the surface of the C/C composites. The tribology and anti-ablation properties of the composite coatings were experimented under dry sliding wear. The equivalent stress and deformation of the composite coatings are studied. The results show that the CoFs (coefficients of friction) of the C/C composites are decreased by 156% at 800 °C due to the new generated self-lubricating compounds from the MoS₂/Ta and VN coating. The anti-ablation of the C/C composites are improved by 25,300% due to the silicon glass, and the generated compounds from V, Mo and Si. The deformation of the C/C substrate under the protection of these coatings looks like a quadrangular star. The cack of the C/C composites is easily generated without the protection from coatings.

An Extensive Review of Natural Polymers Used as Coatings for Postharvest Shelf-Life Extension: Trends and Challenges

Global demand for minimally processed fruits and vegetables is increasing due to the tendency to acquire a healthy lifestyle. Losses of these foods during the chain supply reach as much as 30%; reducing them represents a challenge for the industry and scientific sectors. The use of edible packaging based on biopolymers is an alternative to mitigate the negative impact of conventional films and coatings on environmental and human health. Moreover, it has been demonstrated that natural coatings added with functional compounds reduce the post-harvest losses of fruits and vegetables without altering their sensorial and nutritive properties. Furthermore, the enhancement of their mechanical, structural, and barrier properties can be achieved through mixing two or more biopolymers to form composite coatings and adding plasticizers and/or cross-linking agents. This review shows the latest updates, tendencies, and challenges in the food industry to develop eco-friendly food packaging from diverse natural sources, added with bioactive compounds, and their effect on perishable foods. Moreover, the methods used in the food industry and the new techniques used to coat foods such as electrospinning and electrospraying are also discussed. Finally, the tendency and challenges in the development of edible films and coatings for fresh foods are reviewed.

Hybrid Laser Deposition of Composite WC-Ni Layers with Forced Local Cryogenic Cooling

The purpose of this study was to demonstrate the effect of forced and localized cooling by nitrogen vapours stream under cryogenic conditions during laser deposition of WC-Ni powder on the geometry, microstructure of clad layers and dry sliding wear resistance of the coatings. For this purpose, comparative tests were performed by conventional laser cladding at free cooling conditions in ambient air and by the developed novel process of laser deposition with additional localized cooling of the solidifying deposit by nitrogen vapours stream. Due to presence of gaseous nitrogen in the region of the melt pool and solidifying deposit, the process was considered as combining laser cladding and laser gas nitriding (performed simultaneously), thus the hybrid process. The influence of the heat input and cooling conditions on the geometrical features, dilution rate, share of carbides relative to the matrix, and the fraction share of carbides, as well as hardness profiles on cross sections of single stringer beads was analysed and presented. The XRD, EDS analysis and the sieve test of the experimental powder were used to characterize the composite WC-Ni type powder. The OM, SEM, EDS and XRD test methods were used to study the microstructure, chemical and phase composition of clad layers. Additionally, ball-on-disc tests were performed to determine the wear resistance of representative coatings under dry sliding conditions. The results indicate that the novel demonstrated technique of localized forced cooling of the solidifying deposit has advantageous effect, because it provides approximately 20% lower penetration depth and dilution, decreases tendency for tungsten carbides decomposition, provides more uniform distribution and higher share of massive eutectic W₂C-WC carbides across the coating. While the conventionally laser cladded layers show tendency for decomposition of carbide particles and resolidifying dendritic complex carbides mainly M₂C, M₃C and M₇C₃ containing iron, nickel, and tungsten, and with Ni/Ni₃B matrix. The quantitative relationship between heat input, cooling conditions and the carbides grain size distribution as well as carbides share in relation to the matrix was determined.

Ceria Particles as Efficient Dopant in the Electrodeposition of Zn-Co-CeO2 Composite Coatings with Enhanced Corrosion Resistance: The Effect of Current Density and Particle Concentration

Novel Zn-Co-CeO2 protective composite coatings were deposited successfully from chloride plating solutions. Two different types of ceria sources were used and compared: commercial ceria powder and home-made ceria sol. Electrodeposition was performed by a direct current in the range of 1-8 A dm-2. Two different agitation modes were used and compared, magnetic stirring and ultrasound-assisted stirring (US). The influence of magnetic stirring on the stability of the related plating baths was evaluated via a dynamic scattering method. The results pointed to better stability of the prepared ceria sol. The morphology of the composite coatings was examined by scanning electron microscopy (SEM), and particle content was determined by energy-dispersive X-ray spectroscopy (EDS). The results showed that the increase in the deposition current density was not beneficial to the coating morphology and particle content. The corrosion behavior of the Zn-Co-CeO2 composite coatings was analyzed and compared by electrochemical impedance spectroscopy and polarization resistance. The ultrasound-assisted electrodeposition at small current densities was favorable for obtaining composite coatings with enhanced corrosion stability. The protection was more effective when US was applied and, additionally, upon utilization of ceria sol as a particle source, which was revealed by higher polarization resistance and greater low-frequency impedance modulus values for sol-derived composite coatings deposited under ultrasound.

Ultrasound Supported Galvanostatic Deposition of Zn Coatings Reinforced with Nano-, Submicro-, and Micro-SiC Particles-Weak Acidic Chloride Baths

In this paper, we present results concerning the electrochemical deposition of Zn-SiC composite coatings reinforced with nano-, submicro-, and microparticles. The influence of current density, particle size, and ultrasound on functional parameters which are especially important from a practical point of view (i.e., concentration of particles in coatings, current efficiency, morphology, reflectivity, roughness, hardness, and corrosion resistance) are investigated and discussed. Coatings were deposited from commercial, chloride-based electrolytes dedicated for the deposition of Zn coatings in a weakly acidic environment. Electrodeposited composites contained up to 1.58, 4.08, and 1.15 wt. % of SiC for coatings reinforced with nano, submicro, and micrometric particles, respectively. The process proceeded with relatively high efficiency, exceeding 80% in almost all cases. The results indicate that ultrasounds strongly increase Faradaic efficiency and affect the kinetics of electrode processes and the properties of synthesized coatings. Moreover, the obtained results show that it is possible to synthesize composite coatings with slightly higher mechanical properties while retaining corrosion resistance compared to metallic Zn coatings.

Synthesis and Characterization of Polymer-Based Coatings Modified with Bioactive Ceramic and Bovine Serum Albumin

This study involves the synthesis of hydroxyapatite and describes the preparation and characterization of polymer coatings based on poly(ethylene glycol) diacrylate and poly(ethylene glycol) and modified with bovine serum albumin and hydroxyapatite. Hydroxyapatite was obtained by wet chemical synthesis and characterized by X-ray diffraction and FTIR spectroscopy, and its Ca/P molar ratio was determined (1.69 ± 0.08). The ceramic and bovine serum albumin were used in the preparation of composite materials with the polymeric matrix. The chemical composition of coatings was characterized with FTIR spectroscopy, and their morphology was recorded with SEM imaging. Moreover, the measurements of surface roughness parameters and stereometric research were performed. The prepared coatings were subjected to in vitro studies in simulated body fluid and artificial saliva. Changes in chemical composition and morphology after immersion were examined with FTIR spectroscopy and SEM imaging. Based on the conducted research, it can be stated that applied modifiers promote the biomineralization process. The roughness analysis confirmed prepared materials were characterized by the micrometer-scale topography. The materials morphology and roughness, and the morphology of the newly formed apatite deposit, were dependent on the type of the used modifier, and the artificial fluid used in in vitro studies.

MAPLE Coatings Embedded with Essential Oil-Conjugated Magnetite for Anti-Biofilm Applications

The present study reports on the development and evaluation of nanostructured composite coatings of polylactic acid (PLA) embedded with iron oxide nanoparticles (Fe₃O₄) modified with Eucalyptus (Eucalyptus globulus) essential oil. The co-precipitation method was employed to synthesize the magnetite particles conjugated with Eucalyptus natural antibiotic (Fe₃O₄@EG), while their composition and microstructure were investigated using grazing incidence X-ray diffraction (GIXRD), Fourier transform infrared spectroscopy (FT-IR), thermogravimetric analysis (TGA), transmission electron microscopy (TEM) and dynamic light scattering (DLS). The matrix-assisted pulsed laser evaporation (MAPLE) technique was further employed to obtain PLA/Fe₃O₄@EG thin films. Optimal experimental conditions for laser processing were established by complementary infrared microscopy (IRM) and scanning electron microscopy (SEM) investigations. The in vitro biocompatibility with eukaryote cells was proven using mesenchymal stem cells, while the anti-biofilm efficiency of composite PLA/Fe₃O₄@EG coatings was assessed against Gram-negative and Gram-positive pathogens.

The Effect of Electrochemical Composite Coatings with LaF3-LaB6 Particles in Nickel-Copper Matrix on the Metallurgical Processes in Arc Welding of Low Alloy Ferrite-Pearlite Steels

Development of welding consumables with fluorides and borides of rare earth metals is a promising area for improving the weldability of low alloy steels. As lanthanum fluoride and boride dissociate, lanthanum and boron dissolve in the weld pool and the welding arc plasma is saturated with fluorine. As a result of FeO, MnO, SiO₂ deoxidation and FeS, MnS desulfurization, refractory lanthanum sulfides and oxides La₂O₃, La₂S₃ are formed in the weld pool, which can be the crystallization nuclei in the weld pool and the origin of acicular ferrite nucleation. The paper proposes a model of metallurgical processes in the arc and weld pool, as well as a model of electrochemical adsorption of Ni²⁺ cations in colloidal electrolytes during electrostatic deposition of nano-dispersed insoluble particles of LaF₃ or LaB₆ on the surface of wire. The paper discusses the constructional design of the welding wire and the technology for forming electrochemical composite coatings with copper and nickel matrix. The composite wires applied in the welding of low alloy steels make it possible to refine the microstructure, increase the tensile strength by 4% and the impact toughness of welds by 20%.

Influence of the Prepolymer Type and Synthesis Parameters on Self-Healing Anticorrosion Properties of Composite Coatings Containing Isophorone Diisocyanate-Loaded Polyurethane Microcapsules

Self-healing anticorrosion composite coatings containing isophorone diisocyanate-loaded polyurethane microcapsules were developed, and comprehensive research on prepolymer and microcapsules synthesis, as well as functional composite coatings preparation and characterization, was performed. The influence of the prepolymer type and the concentration of the stabilizing agent used in the synthesis procedure on the properties of the microcapsules was studied in detail. For this purpose, three different prepolymers were prepared from toluene-2,4-diisocyanate (TDI) and either glycerol, 1,4-butanediol, or 1,6-hexanediol, and their chemical properties were investigated. Microcapsules were synthesized from the obtained prepolymers, according to the oil-in-water polymerization method, where 1,6-hexanediol was used as a chain extender, while the concentration of the stabilizing agent in the synthesis procedure was varied. Microcapsules prepared from TDI-glycerol prepolymer, synthesized in the presence of 10 wt% of the stabilizing agent, showed superior chemical, morphological, and thermo-gravimetrical properties; thus, they were incorporated into the coating in the concentration of 20 wt%. The prepared composite coatings demonstrated self-healing and anticorrosion properties, and thus the developed microcapsules show great potential for the incorporation into the composite anticorrosion coatings at critical points where damage can easily occur, providing longer and more efficient anticorrosion protection.

Microstructure Features and High Temperature Oxidation Resistance of In-Situ TiN-Ti Composite Coatings by Plasma Transferred Arc Welding

In order to improve the high temperature oxidation resistance of Ti6Al4V alloy, the in-situ TiN-Ti composite coatings were prepared with Ti-Cr-Ni-Nb powders by plasma transferred arc welding. Nitrogen gas was used as the transport gas and provided N source for the formation reaction of TiN. Microstructure features and high temperature oxidation behaviors of the composite coatings were studied. The phases in the composite coatings were TiN, Ti, CrN, and NiTi. It was clearly observed that in-situ TiN particles were evenly distributed in the Ti matrix. A little Nb atom dissolved in TiN particles, and others dissolved in the Ti matrix. By comparing the curve of Ti6Al4V alloy to that of the composite coatings, the oxidation mass gain of the composite coatings was comparatively less. The oxidation film of the composite coatings was smooth and compact, and no crack was visibly observed. Based on the results of the high temperature tests, the composite coatings exhibited superior high temperature oxidation resistance than Ti6Al4V alloy both at 650 °C and at 850 °C.

Corrosion and Heat Treatment Study of Electroless NiP-Ti Nanocomposite Coatings Deposited on HSLA Steel

Corrosion and heat treatment studies are essential to predict the performance and sustainability of the coatings in harsh environments, such as the oil and gas industries. In this study, nickel phosphorus (NiP)-titanium (Ti) nanocomposite coatings (NiP-Ti nanoparticles (TNPs)), containing various concentrations of Ti nanoparticles (TNPs) were deposited on high strength low alloy (HSLA) steel through electroless deposition processing. The concentrations of 0.25, 0.50 and 1.0 g/L TNPs were dispersed in the electroless bath, to obtain NiP-TNPs nanocomposite coatings comprising different Ti contents. Further, the effect of TNPs on the structural, mechanical, corrosion, and heat treatment performance of NiP coatings was thoroughly studied to illustrate the role of TNPs into the NiP matrix. Field emission scanning electron microscope (FESEM) and energy dispersive spectroscopy (EDX) results confirm the successful incorporation of TNPs into the NiP matrix. A substantial improvement in the mechanical response of the NiP matrix was noticed with an increasing amount of TNPs, which reached to its ultimate values (hardness 675 Hv, modulus of elasticity 18.26 GPa, and stiffness 9.02 kN/m) at NiP-0.5TNPs coatings composition. Likewise, the electrochemical impedance spectroscopy measurements confirmed a tremendous increase in the corrosion inhibition efficiency of the NiP coatings with an increasing amount of TNPs, reaching ~96.4% at a composition of NiP-0.5TNPs. In addition, the NiP-TNPs nanocomposite coatings also unveiled better performance after heat treatment than NiP coatings, due to the presence of TNPs into the NiP matrix and the formation of more stable (heat resistant) phases, such as Ni₃P, Ni₃Ti, NiO, etc., during the subsequent processing.

Special Issue: Advanced Coatings for Corrosion Protection

Corrosion is an important issue in many industrial fields. Among others, coatings are by far the most important technology for corrosion protection of metallic surfaces. The special issue “Advanced Coatings for Corrosion Protection” has been launched as a means to present recent developments on any type of advanced coatings for corrosion protection. Fifteen contributions have been collected on metallic, inorganic, polymeric and nanoparticle enhanced coatings providing corrosion protection as well as partly other functionalities.

Ni/cerium Molybdenum Oxide Hydrate Microflakes Composite Coatings Electrodeposited From Choline Chloride: Ethylene Glycol Deep Eutectic Solvent

Cerium molybdenum oxide hydrate microflakes are codeposited with nickel from a deep eutectic solvent-based bath. During seven days of exposure in 0.05 M NaCl solution, the corrosion resistance of composite coating (Ni/CeMoOxide) is slightly reduced, due to the existence of some microcracks caused by large microflakes. Multielemental analysis of the solution, in which coatings are exposed and the qualitative changes in the surface chemistry (XPS) show selective etching molybdenum from microflakes. The amount of various molybdenum species within the surface of coating nearly completely disappear, due to the corrosion process. Significant amounts of Ce³⁺ compounds are removed, however the corrosion process is less selective towards the cerium, and the overall cerium chemistry remains unchanged. Initially, blank Ni coatings are covered by NiO and Ni(OH)₂ in an atomic ratio of 1:2. After exposure, the amount of Ni(OH)₂ increases in relation to NiO (ratio 1:3). For the composite coating, the atomic ratios of both forms of nickel vary from 1:0.8 to 1:1.3. Despite achieving lower corrosion resistance of the composite coating, the applied concept of using micro-flakes, whose skeleton is a system of Ce(III) species and active form are molybdate ions, may be interesting for applications in materials with potential self-healing properties.

Surface Engineering of Biodegradable Magnesium Alloys for Enhanced Orthopedic Implants

Magnesium (Mg) alloys have been promised for biomedical implants in orthopedic field, however, the fast corrosion rate and mode challenge their clinical application. To push Mg alloys materials into practice, a composite coating with biodegradable and high compatible components to improve anticorrosion property of an Mg alloy (i.e., AZ31) is designed and fabricated. The inner layer is micro-nano structured Mg(OH)₂ through hydrothermal treatment. Then stearic acid (SA) is introduced to modify Mg(OH)₂ for better reducing the gap below a surface-degradation polymer layer of poly(1,3-trimethylene carbonate). Benefited by the SA modification effect, this sandwiched coating avoids corrosive medium penetration via enhancing the adhesion strength at the interface between outer and inner layers. Both in vitro and in vivo tests indicate that the composite coating modified AZ31 perform a better anticorrosion behavior and biocompatibility compared to bare AZ31. Strikingly, a 1.7-fold improvement in volume of newly formed bone is observed surrounding the composite coating modified implant after 12 week implantation. The sandwiched biocompatible coating strategy paves a hopeful way for future translational application of Mg alloys orthopedic materials in clinics.

Microstructure of Coatings on Nickel and Steel Platelets Obtained by Co-Milling with NiAl and CrB2 Powders

Metal matrix composite coatings are developed to protect parts made from materials susceptible to wear, like nickel alloys or stainless steel. The industry-established deposition method is presently an atmospheric plasma spraying method since it allows the production of both well-adhering and thick coatings. Alternatively, similar coatings could be produced by co-milling of ceramic and alloyed powders together with metallic plates serving as substrates. It results in mechanical embedding of the powder particles into exposed metallic surfaces required coatings. The present experiment was aimed at the analysis of microstructure of such coatings obtained using NiAl and CrB₂ powders. They were loaded together with nickel and stainless steel platelets into ball mill vials and rotated at 350 rpm for up to 32 h. This helped to produce coatings of a thickness up to ~40 µm. The optical, scanning, and transmission electron microscopy observations of the coatings led to conclusion that the higher the rotation speed of vials, the wider the intermixing zone between the coating and the substrate. Simultaneously, it was established that the total thickness of the coating deposited at specified conditions is limited by the brittleness of its nanocrystalline matrix. An increase in the hardness of the substrate results in a decrease of the intermixing zone. The above results indicate that even as the method based on mechanical embedding could so far produce thinner coatings than the plasma spraying, in the former case they are characterized by a more uniform nanocrystalline matrix with homogenously distributed fine ceramic particles.

Nanocrystalline Electrodeposited Fe-W/Al2O3 Composites: Effect of Alumina Sub-microparticles on the Mechanical, Tribological, and Corrosion Properties

In this study, nanocrystalline Fe-W alloy and Fe-W/Al₂O₃ composite coatings with various contents of sub-microsized alumina particles have been obtained by electrodeposition from an environmentally friendly Fe(III)-based electrolyte with the aim to produce a novel corrosion and wear resistant material. The increase in volume fraction of Al₂O₃ in deposits from 2 to 12% leads to the grain refinement effect, so that the structure of the coatings change from nanocrystalline to amorphous-like with grain sizes below 20 nm. Nevertheless, the addition of particles to the Fe-W matrix does not prevent the development of a columnar structure revealed for all the types of studied coatings. The observed reduction in both hardness and elastic modulus of the Fe-W/Al₂O₃ composites is attributed to the apparent grain size refinement/amorphization and the nanoporosity surrounding the embedded Al₂O₃ particles. In the presence of 12 vol% of Al₂O₃ in deposits, the wear rate decreases by a factor of 10 as compared to Fe-W alloy tested under dry friction conditions due to the lowering of tribo-oxidation. The addition of alumina particles slightly increases the corrosion resistance of the coatings; however, the corrosion in neutral chloride solution occurs through the preferential dissolution of Fe from the matrix. The obtained results provide a possibility to integrate the nanocrystalline Fe-W/Al₂O₃ composite coatings into various systems working under dry friction conditions, for example, in high-temperature vacuum systems.

Plasma-Deposited Nanocapsules Containing Coatings for Drug Delivery Applications

Coatings consisting in gentamicin-containing nanocapsules have been synthetized by means of an aerosol-assisted atmospheric pressure plasma deposition process. The influence of different parameters affecting the process has been extensively investigated by means of a morphological and chemical characterization of the coatings. Scanning electron microscopy highlighted the presence of nanocapsules whose size and abundance depend on power input and deposition time. A detailed analysis carried out with matrix-assisted laser desorption ionization coupled to high-resolution mass spectrometry allowed to detect and identify the presence of gentamicin embedded in the coatings and its rearrangement, as a result of the interaction with the plasma. The release of gentamicin in water has been monitored by means of UV-vis fluorescence spectroscopy, and its biological activity has been evaluated as well by the disk diffusion assay against Staphylococcus aureus and Pseudomonas aeruginosa. It is confirmed that the antibacterial activity of gentamicin is preserved in the plasma-deposited coatings. Preliminary cytocompatibility investigations indicated that eukaryotic cells well tolerate the release of gentamicin from the coatings.

Antibiofilm Coatings Based on PLGA and Nanostructured Cefepime-Functionalized Magnetite

The aim of our study was to obtain and evaluate the properties of polymeric coatings based on poly(lactic-co-glycolic) acid (PLGA) embedded with magnetite nanoparticles functionalized with commercial antimicrobial drugs. In this respect, we firstly synthesized the iron oxide particles functionalized (@) with the antibiotic Cefepime (Fe₃O₄@CEF). In terms of composition and microstructure, the as-obtained powdery sample was investigated by means of grazing incidence X-ray diffraction (GIXRD), thermogravimetric analysis (TGA), scanning and transmission electron microscopy (SEM and TEM, respectively). Crystalline and nanosized particles (~5 nm mean particle size) with spherical morphology, consisting in magnetite core and coated with a uniform and reduced amount of antibiotic shell, were thus obtained. In vivo biodistribution studies revealed the obtained nanoparticles have a very low affinity for innate immune-related vital organs. Composite uniform and thin coatings based on poly(lactide-co-glycolide) (PLGA) and antibiotic-functionalized magnetite nanoparticles (PLGA/Fe₃O₄@CEF) were subsequently obtained by using the matrix assisted pulsed laser evaporation (MAPLE) technique. Relevant compositional and structural features regarding the composite coatings were obtained by performing infrared microscopy (IRM) and SEM investigations. The efficiency of the biocompatible composite coatings against biofilm development was assessed for both Gram-negative and Gram-positive pathogens. The PLGA/Fe₃O₄@CEF materials proved significant and sustained anti-biofilm activity against staphylococcal and Escherichia coli colonisation.

Highly Stretchable Superhydrophobic Composite Coating Based on Self-Adaptive Deformation of Hierarchical Structures

With the rapid development of stretchable electronics, functional textiles, and flexible sensors, water-proof protection materials are required to be built on various highly flexible substrates. However, maintaining the antiwetting of superhydrophobic surface under stretching is still a big challenge since the hierarchical structures at hybridized micro-nanoscales are easily damaged following large deformation of the substrates. This study reports a highly stretchable and mechanically stable superhydrophobic surface prepared by a facile spray coating of carbon black/polybutadiene elastomeric composite on a rubber substrate followed by thermal curing. The resulting composite coating can maintain its superhydrophobic property (water contact angle ≈170° and sliding angle <4°) at an extremely large stretching strain of up to 1000% and can withstand 1000 stretching-releasing cycles without losing its superhydrophobic property. Furthermore, the experimental observation and modeling analysis reveal that the stable superhydrophobic properties of the composite coating are attributed to the unique self-adaptive deformation ability of 3D hierarchical roughness of the composite coating, which delays the Cassie-Wenzel transition of surface wetting. In addition, it is first observed that the damaged coating can automatically recover its superhydrophobicity via a simple stretching treatment without incorporating additional hydrophobic materials.

Electrophoretic Deposition of Chitosan/45S5 Bioactive Glass Composite Coatings Doped with Zn and Sr

In this research work, the original 45S5 bioactive glass was modified by introducing zinc and/or strontium oxide (6 mol%) in place of calcium oxide. Sr was added for its ability to stimulate bone formation and Zn for its role in bone metabolism, antibacterial properties, and anti-inflammatory effect. The glasses were produced by means of melting and quenching process. SEM and XRD analyses evidenced that Zr and Sr introduction did not modify the glass structure and morphology while compositional analysis (EDS) demonstrated the effective incorporation of these elements in the glass network. Bioactivity test in simulated body fluid (SBF) up to 1 month evidenced a reduced bioactivity kinetics for Zn-doped glasses. Doped glasses were combined with chitosan to produce organic/inorganic composite coatings on stainless steel AISI 316L by electrophoretic deposition (EPD). Two EPD processes were considered for coating development, namely direct current EPD (DC-EPD) and alternating current EPD (AC-EPD). The stability of the suspension was analyzed and the deposition parameters were optimized. Tape and bending tests demonstrated a good coating-substrate adhesion for coatings containing 45S5-Sr and 45S5-ZnSr glasses, whereas the adhesion to the substrate decreased by using 45S5-Zn glass. FTIR analyses demonstrated the composite nature of coatings and SEM observations indicated that glass particles were well integrated in the polymeric matrix, the coatings were fairly homogeneous and free of cracks; moreover, the AC-EPD technique provided better results than DC-EPD in terms of coating quality. SEM, XRD analyses, and Raman spectroscopy, performed after bioactivity test in SBF solution, confirmed the bioactive behavior of 45S5-Sr-containing coating while coatings containing Zn exhibited no hydroxyapatite formation.

Foreign Body Reaction to Implantable Biosensors: Effects of Tissue Trauma and Implant Size

BACKGROUND

Implantable biosensors for continuous glucose monitoring can greatly improve diabetes management. However, their applications are still associated with some challenges and one of these is the gradual functionality loss postimplantation as a consequence of the foreign body response (FBR). Sensor miniaturization in combination with drug-eluting biocompatible coatings is a promising strategy to enhance in vivo performance. However, limited study has been performed to understand the effect of initial trauma and implant size on foreign body reaction as well as in vivo performance of implantable glucose sensors.

METHODS

Different initial trauma was induced by implanting composite coated dummy sensors into rats using various sized needles and 3 different-sized dummy sensors were implanted to examine the size effect. Histological evaluation was performed to relate the inflammatory cell counts and foreign body capsule thickness with the implantation needle size and sensor size respectively. The effect of biocompatible coating on the performance of implantable glucose sensors was determined using both coated amperometric glucose sensors and microdialysis probes.

RESULTS

The results revealed that the degree of acute inflammation was mainly controlled by the extent of the initial trauma: the greater the trauma, the greater the acute inflammatory response. Implant size did not affect the acute inflammatory phase. However, the extent of chronic inflammation and fibrous encapsulation were affected by sensor size: the smaller the size the less the extent of chronic inflammation and fibrous encapsulation. Glucose sensors implanted using 14 gauge needles showed significantly lower initial in vivo response compared to those implanted using 16 gauge needles. This was not observed for sensors with dexamethasone-eluting biocompatible coatings since inflammation was suppressed.

CONCLUSIONS

The results of the current study indicate that the extent of the inflammatory response post-sensor implantation varies as a function of the initial tissue trauma as well as the sensor size. Accordingly, miniaturization of implantable biosensors together with the utilization of a drug-eluting biocompatible composite coating may be a promising strategy to achieve long-term reliable continuous glucose monitoring.