Characterization and corrosion behavior of hydroxyapatite/zirconia composite coating on NiTi fabricated by electrochemical deposition

NiTi alloy is used as biomaterial due to its unique properties, but the high content of Ni (about 50 at.%) in biomedical NiTi is concerned. Hydroxyapatite and hydroxyapatite/zirconia composite coatings were directly electrodeposited on NiTi alloy surface. The coated samples were characterized using X-ray diffraction, scanning electron microscopy, infrared spectroscopy, bonding strength test, polarization and EIS. Results showed that when ZrO₂ was added into the electrolyte, morphology of HAP was changed from thin flake-flower-like crystals to needle-flower-like crystals, and coating was denser. Besides, HAP crystal grains in the coating were preferentially arranged in the [0 0 1] direction. Addition of ZrO₂ could improve the bonding strength between the coating and the substrate. Corrosion resistance of NiTi in the simulated body fluid at 37 °C was significantly improved by almost 60 times by electrodeposition of the hydroxyapatite/zirconia composite coating.     

Microstructure evolution of Fe-based WC composite coating prepared by laser induction hybrid rapid cladding

Fe + 50 wt.% WC composite coating was prepared by laser induction hybrid rapid cladding (LIHRC) on steel substrate. The phase and microstructure of the composite coating were investigated by X-ray diffraction (XRD), environmental scanning electron microscope (ESEM) and energy dispersive spectrum (EDS). The results showed that WC particles were dissolved almost completely to precipitate the coarse herringbone M₆C eutectic carbides and the fine dendritic M₆C carbides, and that the partially dissolved WC particles with an alloyed reaction layer were occasionally observed in the whole coating. The phases of the composite coating were composed of supersaturated solid solution α-Fe, retained austenite, Fe₃C, W₂C, M₆C and M₇C₃. The microstructure evolution in the composite coating was represented by the transformation of three parts such as Fe-based metallic matrix, dispersed carbides and incompletely dissolved WC particles. The microhardness of Fe-based WC composite coating was three times much higher than that of the substrate, but was relatively lower than that of Ni-based WC composite coating by LIHRC.     

Synthesis and electrochemical properties of Li4Ti5O12/C composite by the PVB rheological phase method

Spinel Li₄Ti₅O₁₂/C powders were synthesized successfully by a simple rheological phase method using polyvinylbutyral (PVB) as both template and carbon source. The structure and morphology characteristics of the composite were investigated by X-ray diffraction (XRD), field emission scanning electron microscopy and transmission electron microscopy. The XRD results showed that the composite had a good crystallinity. Its average particle size was about 2.1 μm with a narrow size distribution as a result of homogeneous mixing of the precursors. The in situ carbon coating produced by decomposition of PVB played an important role in improving electrical conductivity, thereby enhancing the rate capacity of Li₄Ti₅O₁₂ as anode material in Li-ion batteries. The Li₄Ti₅O₁₂/C composite, synthesized at 800 °C for 15 h under argon, containing 0.98 wt% of carbon, exhibited better electrochemical properties in comparison with the pristine Li₄Ti₅O₁₂, which could be attributed to the enhanced electrical conductive network of the carbon coating on the particle surface.     

Plasma sprayed Al2O3/FeCrAl composite coatings for electromagnetic wave absorption application

Al₂O₃/FeCrAl composite coatings were fabricated by atmosphere plasma spraying technique. Microstructure and dielectric properties in the frequency range from 8.2 to 12.4 GHz were investigated. The microstructure of composite coatings shows a uniform dispersion of metal particles with litter pores and microcracks in the composite coatings. The relaxation polarization and interfacial polarization in the coatings would contribute to enhance ?′ with rising FeCrAl content, and the associated loss could be considered as a dominating factor enhancing ?″. By calculating the microwave-absorption as a single-layer absorber, for the composite coatings with 41 wt.% FeCrAl content, the reflection loss values exceeding −10 dB are achieved in the frequency range of 9.1-10.6 GHz when the coating thickness is 1.3 mm.     

Preparation and wear resistance of pulse electrodeposited Ni-W/Al2O3 composite coatings

The aim of this work is to obtain the electroplating parameters for preparation of Ni-W/Al₂O₃ composite coating with high tungsten content, high micro-hardness and excellent wear resistance by pulse plating procedure. Our results showed that the duty cycle is a dominant parameter for the tungsten content in the coating and the tungsten content increases significantly with increasing duty cycle. The further analysis showed the great influence of tungsten content on micro-hardness of the coating. A maximum micro-hardness of about 859 Hv was obtained in pulse electrodeposited Ni-W/Al₂O₃ composite with tungsten content of 40 wt.% at a peak current density of 20 A/dm², a duty cycle of 80%, a pulse frequency of 1000 Hz and a particle loading of 10 g/L alumina in the plating bath. Although the hardness of Ni-W/Al₂O₃ composite coating was only slightly affected by the alumina content of the deposits prepared in present investigation, the alumina content effect on the tribological characteristic of Ni-W/Al₂O₃ composite coatings is significant. The friction coefficient was lowered to 0.25 and the wear loss was reduced to 1.05 mg by setting the control factors according to the values mentioned above for obtaining the coating with the highest micro-hardness.     

Microstructure and anti-oxidation property of CrSi2-SiC coating for carbon/carbon composites

To protect carbon/carbon (C/C) composites from oxidation, a new type of oxidation protective coating has been produced by a two-step pack cementation technique. XRD and SEM analysis show, the coating obtained by the first step pack cementation was a porous β-SiC structure, and a new phase of CrSi₂ was generated in the porous SiC coating after heat-treatment according to the second step pack cementation process. Oxidation test shows that, the weight loss of the SiC coated C/C is up to 11.26% after 5 h oxidation in air at 1773 K, and the weight loss of the CrSi₂-SiC coated C/C composites is only 4.15% after oxidation in air at 1773 K for 34 h. The oxidation of C/C composites was primarily due to the reaction of C/C matrix and oxygen diffusing through the penetrable cracks in the coating.     

The electrochemical preparation and microwave absorption properties of magnetic carbon fibers coated with Fe3O4 films

Electrodeposition was employed to fabricate magnetite (Fe₃O₄) coated carbon fibers (MCCFs). Temperature and fiber surface pretreatment had a significant influence on the composition and morphology of Fe₃O₄ films. Uniform and compact Fe₃O₄ films were fabricated at 75 °C on both nitric acid treated and untreated carbon fibers, while the films prepared at 60 °C were continuous and rough. Microwave measurements of MCCF/paraffin composites (50 wt.% of MCCFs, pretreated carbon fibers as deposition substrates) were carried out in the 2-18 GHz frequency range. MCCFs prepared at 60 °C obtained a much higher loss factor than that prepared at 75 °C. However, the calculation results of reflection loss were very abnormal that MCCFs prepared at 60 °C almost had no absorption property. While MCCFs prepared at 75 °C exhibited a good absorption property and obtained −10 dB and −20 dB refection loss in wide matching thickness ranges (1.0-6.0 mm and 1.7-6.0 mm range, respectively). A secondary attenuation peak could also be observed when the thickness of MCCF/paraffin composite exceeded 4.0 mm. The minimum reflection loss was lower.     

A study on wear resistance and microcrack of the Ti3Al/TiAl + TiC ceramic layer deposited by laser cladding on Ti-6Al-4V alloy

Laser cladding of the Al + TiC alloy powder on Ti-6Al-4V alloy can form the Ti₃Al/TiAl + TiC ceramic layer. In this study, TiC particle-dispersed Ti₃Al/TiAl matrix ceramic layer on the Ti-6Al-4V alloy by laser cladding has been researched by means of X-ray diffraction, scanning electron microscope, electron probe micro-analyzer, energy dispersive spectrometer. The main difference from the earlier reports is that Ti₃Al/TiAl has been chosen as the matrix of the composite coating. The wear resistance of the Al + 30 wt.% TiC and the Al + 40 wt.% TiC cladding layer was approximately 2 times greater than that of the Ti-6Al-4V substrate due to the reinforcement of the Ti₃Al/TiAl + TiC hard phases. However, when the TiC mass percent was above 40 wt.%, the thermal stress value was greater than the materials yield strength limit in the ceramic layer, the microcrack was present and its wear resistance decreased.     

SiC/SiO2 coating for improving the oxidation resistive property of carbon nanofiber

The SiC/SiO₂ deposition was performed to improve the oxidation resistive properties of carbon nanofiber (CNF) from electrospinning at elevated temperatures through sol-gel process. The stabilized polyacrylonitrile (PAN) fibers were coated with SiO₂ followed by heat treatment up to 1000 and 1400 °C in an inert argon atmosphere. The chemical compositions of the CNFs surface heat-treated were characterized as C, Si and O existing as SiC and SiO₂ compounds on the surface. The uniform and continuous coating improved the oxidation resistance of the carbon nanofibers. The residual weight of the composite was 70-80% and mixture of SiC, SiO₂ and some residual carbon after exposure to air at 1000 °C.     

Preparation and ablation properties of ZrC-SiC coating for carbon/carbon composites by solid phase infiltration

A novel ZrC-SiC coating was prepared on carbon/carbon (C/C) composites surface by solid phase infiltration and the ablation properties of the ZrC-SiC coated C/C composites under oxyacetylene flame were studied. The results show that the coating prepared on the condition of optimum process parameters exhibits dense surface and outstanding anti-ablation ability. After ablation for 20 s, the mass ablation rates of the coated C/C composites can be lowered to 2.36 × 10⁻³ g/s, 37.1% reduction compared with uncoated C/C composites. The oxide layer composed of ZrO₂ and SiO₂ acts as oxygen diffusion barrier and the evaporation of ZrO₂ and SiO₂ absorbs a great amount of heat from the flame and reduces the erosive attack on the coating.     

Double layer oxidation resistant coating for carbon fiber reinforced silicon carbide matrix composites

Double layer coatings, with celsian-Y₂SiO₅ as inner layer and Y₂Si₂O₇ as outer layer, were prepared by microwave sintering on the surface of carbon fiber reinforced silicon carbide matrix composite. Both celsian, Y₂SiO₅ and Y₂Si₂O₇ were synthesized by in situ method using BAS glass, Y₂O₃ and SiO₂ as staring materials. The sintering temperature was 1500 °C, and little damage was induced to the composite. The composition and micrograph of the fired coating were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The oxidation and thermal shock resistance of samples with doubled-layered coating were characterized at 1400 °C in air. After 150 min oxidation and thermal cycling between 1400 °C and room temperature for 15 times, the weight loss of double layer-coated sample was 1.22% and there were no cracks in the coating.     

Alloying of cold-sprayed Al-Ni composite coatings by post-annealing

A new cold spray coating technique for thick Al coating with finely dispersed Al-Ni intermetallic compounds was tested. For easy powder preparation and high yield, rather than using of Al/compound mixture feed stock, the spraying of pure Al and Ni powders mixture followed by post-annealing was suggested. The powder composition of Al and Ni was 75:25, and 90:10 (wt.%) to expect full consumption of pure Ni into intermetallic compounds. After Al-Ni composite coatings, the Ni particles were finely dispersed and embedded in the Al matrix with a good coating yield. Above 450 °C of post-annealing temperature, the Al₃Ni and Al₃Ni₂ phases were observed in the cold-sprayed Al-Ni coatings. The Ni particles in the Al matrix were fully consumed via compounding reaction with Al at 550 °C of the annealing temperature.     

AgGaS2- and Al-doped GaSe Crystals for IR Applications

We report a systematic study of AgGaS₂- and Al-doped GaSe crystals in comparison with pure GaSe and S-doped GaSe crystals. AgGaS₂-doped GaSe (GaSe:AgGaS₂) crystal was grown by Bridgman technique from the melt of GaSe:AgGaS₂ (10.6 wt.%). Its real composition was identified as GaSe:S (2 wt.%). Al-doped GaSe (GaSe:Al) crystals were grown from the melt of GaSe and 0.01, 0.05, 0.1, 0.5, 1, 2 mass % of aluminium. Al content in the grown crystals is too small to be measured. The hardness of GaSe:S (2 wt.%) crystal grown from the melt of GaSe:AgGaS₂ is 25% higher than that of GaSe:S (2 wt.%) crystal grown by a conventional S-doping technique and 1.5- to 1.9-times higher than that of pure GaSe. GaSe:Al crystals are characterized by 2.5- to 3-times higher hardness than that of pure GaSe and by extremely low conductivity of ≤ 10^− 7 Om^− 1 cm^− 1. A comparative experiment on SHG in AgGaS₂-, Al-, S-doped GaSe and pure GaSe is carried out under the pumps of 2.12-2.9 μm fs OPA and 9.2−10.8 μm ns CO₂ laser. It was found that GaSe:S crystals possess the best physical properties for mid-IR applications among these doped GaSe crystals. GaSe:Al crystals have relatively low conductivity which have strong potential for THz application.     

The microstructure and specific properties of La/HAP composite powder and its coating

La/HAP composite powder, a novel bioactive material, was prepared using co-precipitation method. The La/HAP coating was obtained for the first time through the dip-coating method, starting from the sols of La/HAP and TiO₂ particles. The compositions and coating of as-produced La/HAP composite powder sintered at temperatures from 300 to 750 °C were analyzed by means of X-ray diffraction (XRD). The changes of the ion groups in as-prepared La/HAP composite powder were characterized by using Fourier transform infrared (FTIR) spectroscopy. Their surface morphologies were observed by means of scanning electron microscope (SEM). The results show that the La/HAP composite powder has higher thermostability than pure HAP powder and La can refine HAP particle and restrain the decomposition of HAP. Consequently, in coating process the heat-treatment temperature is lower (750 °C) using the synthesized La/HAP powder than that using pure HAP (900 °C). The La/HAP coating mainly contains HAP, TiP or Ti₃P₅ and TiO₂ phases as well as a little CaTiO₃ crystal, a very ideal composition to enhance bioactivity of biomaterials. These unique properties of the La/HAP composite powder are beneficial to enhance the strength and bioactivity of coating when it is used as a starting material in coating process.     

Influence of bilayer periods on structural and mechanical properties of ZrC/ZrB2 superlattice coatings

ZrC/ZrB₂ multilayered coatings with bilayer periods ranging from 4.4 to 35.5 nm were synthesized by r.f. magnetron sputtering. X-ray diffraction, scanning electron microscopy and nanoindention were employed to investigate the microstructure and mechanical properties of the nanoscale multilayers. The results indicated that all coatings had the clear multilayered structure with mixed ZrB₂(0 0 1), ZrB₂(0 0 2) and ZrC(1 1 1) preferred orientations. The maximum hardness (41.7 GPa) was observed in the multilayer with 27.5-nm thick period, which is about 25% higher than the rule-of-mixture value of the monolithic ZrC and ZrB₂ coatings. It also exhibited the best adhesion. Its critical load was over 70 mN. While through insert ZrB₂ into ZrC layer periodically, higher residual stress built in ZrC layer can be released.     

A SiC whisker-toughened SiC-CrSi2 oxidation protective coating for carbon/carbon composites

A SiC whisker-toughened SiC-CrSi₂ oxidation protective coating was prepared on the surface of C/C composites by a two-step technique of slurry and pack cementation. The oxidation protective ability and thermal stress resistance of the coating exhibit the trend of increase first and decrease afterwards as the SiCw content increases from 0 to 20 wt.%. The compound effect of SiCw and CrSi₂ on the oxidation protective ability of SiC coating is better than their individual ones.     

Surface-modification of anode carbon for lithium-ion battery using chemical vapor infiltration technique

To reduce the high irreversible capacity of the low crystalline carbon fiber for the anode material of lithium-ion battery, pyrolytic carbon (pyrocarbon) was coated at 950 °C from C₃H₈(30%)-H₂ gas system using pressure-pulsed chemical vapor infiltration. Carbon fiber was coated with the dense pyrocarbon film having the laminar texture and the low surface area of 1.9 m² g⁻¹. It was revealed from XRD and Raman spectroscopy that the crystallinity of pyrocarbon is higher than that of the core carbon. Electrochemical properties were measured in ethylene carbonate (EC) and propylene carbonate (PC) base electrolytes. Irreversible capacity was reduced in EC-based electrolyte by coating with 8 mass% pyrocarbon, which would be attributed to the high crystallinity, laminar structure and low surface area of pyrocarbon. Irreversible capacity was also decreased in PC-based electrolyte. The crystallinity of pyrocarbon was not so high as PC-based electrolyte was decomposed in the case of the high crystalline graphite.     

Electrochemical properties of carbon-coated LiFePO4 synthesized by a modified mechanical activation process

Carbon-coated lithium iron phosphate (LiFePO₄/C) composites were synthesized by conventional mechanical activation (MA) process and also by a modified MA process. Phase-pure particles were obtained of ∼100 nm size with a nano-meter thick web of carbon surrounding the particles. The composite prepared by the modified MA process shows good performance as cathode material in lithium cells at room temperature. A high performance was achieved at 0.1 C-rate with >96% utilization of the active material. A stable cycle performance even at higher C-rates was achieved with a cathode that has a total carbon content of only 12 wt%. The use of the modified MA process to synthesize LiFePO₄/C has promise to be an efficient process to decrease the total carbon content of the cathode, resulting in the enhanced energy density.     

Microstructures and tribological properties of plasma sprayed WC-Co-Cu-BaF2/CaF2 self-lubricating wear resistant coatings

A promising WC-Co-Cu-BaF₂/CaF₂ self-lubricating wear resistant coating was deposited via atmospheric plasma spraying (APS) process by using homemade feedstock powders composed of WC-Co, Cu and BaF₂/CaF₂ eutectic. The as-prepared cermet coatings had better frictional behavior comparing with the WC-Co coating. Moreover, the often-occurred decarburization of WC in APS process was noticeably improved due to the binding of copper and BaF₂/CaF₂ phase, which not only offered effective solid lubrication, but also acted as bind phases to mend the microstructure and protected WC from decomposition. The optimized specimen contained 10 wt.% Cu and 10 wt.% BaF₂/CaF₂ in a WC-Co matrix, which had excellent frictional and wear performance. The wear mechanism of the self-lubricating wear resistant coating was discussed with the microstructures, compositions and mechanical properties of the composite materials in detail.     

Influence of preparation technology on the microstructure and anti-oxidation property of SiC-Al2O3-mullite multi-coatings for carbon/carbon composites

Oxidation protective SiC-Al₂O₃-mullite multi-coatings for carbon/carbon (C/C) composites were prepared with a two-step pack cementation process. The influence of preparation temperature and SiO₂/Al₂O₃ ratio of the pack powder on the phase, microstructure and oxidation resistance of the multi-coatings were investigated. It showed that the multi-coatings that contained mullite could be produced at 1700-1800 °C. A denser coating surface was acquired with the decrease of SiO₂/Al₂O₃ ratio in the pack chemistries while a little damnification to the interface of the coating and C/C substrate. The as-prepared coating could effectively protect C/C composites from oxidation at 1600 °C for 81 h.