Characterization of microarc oxidation coatings formed on AM60B magnesium alloy in silicate and phosphate electrolytes

Microarc oxidation coatings on AM60B magnesium alloy were prepared in silicate and phosphate electrolytes. Structure, composition, mechanical property, tribological, and corrosion resistant characteristics of the coatings was studied by scanning electron microscope (SEM), X-ray diffraction (XRD) and microhardness analyses, and by ball-on-disc friction and potentiodynamic corrosion testing. It is found that the coating produced from the silicate electrolyte is compact and uniform and is mainly composed of MgO and forsterite Mg₂SiO₄ phases, while the one formed in phosphate electrolyte is relatively porous and is mainly composed of MgO phase. The thick coating produced from a silicate electrolyte possesses a high hardness and provides a low wear rate (3.55 × 10⁻⁵ mm³/Nm) but a high friction coefficient against Si₃N₄ ball. A relatively low hardness and friction coefficient while a high wear rate (8.65 × 10⁻⁵ mm³/Nm) is recorded during the testing of the thick coating produced from a phosphate electrolyte. Both of these types of coatings provide effective protection for the corrosion resistance compared with the uncoated magnesium alloy. The coating prepared from the silicate electrolyte demonstrates better corrosion behavior due to the compacter microstructure.     

Development of electroless Ni-Zn-P/nano-TiO2 composite coatings and their properties

Ni-Zn-P-TiO₂ composite coatings were successfully obtained on low carbon steel by electroless plating technique. Deposits were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy-dispersive analysis (EDS) studies. The hardness and microstructure of as plated and heat treated Ni-Zn-P and Ni-Zn-P-TiO₂ composite coatings were analyzed. The change in microstructure and higher hardness was noticed for heat treated composite. The corrosion resistance behavior of as plated and heat treated Ni-Zn-P and Ni-Zn-P-TiO₂ coatings was investigated by anodic polarization, Tafel plots and electrochemical impedance spectroscopic (EIS) studies in 3.5 wt% NaCl solution. The composite coating exhibited enhanced corrosion resistance property over Ni-Zn-P coating.     

Stress, microstructure and mechanical properties of graded multilayer tetrahedral amorphous carbon films

Tetrahedral amorphous carbon (ta-C) films deposited using a filtered cathodic vacuum arc (FCVA) system, have high intrinsic stress which limits their application as protective coatings. To reduce the film stress and to improve the adhesion, a multilayer structure is deposited at a gradient substrate negative bias from 1500 V to 80 V. This paper investigates the stress, microstructure and nano-mechanical properties of graded multilayer ta-C film on Si substrates. Compared with that of single-layer films deposited at optimised bias, the graded multilayer film has low stress without a decline in hardness and Young’s modulus. Microstructural evaluation of the multilayer film using visible Raman spectra shows that the average content of the sp³ bonds of the multilayer film remain at a high level. Nanoscratch testing illustrates favorable scratch resistance and good adhesion of the multilayer film. Scanning electron microscope (SEM) observation confirms the collapse of the film surface along the scratching trace. Finally, deposition on single crystal germanium substrates of a durable coating ∼ 1100 nm thick, and composed of three graded multilayer films is demonstrated. PACS 81.05.Uw; 81.15.Jj; 68.65.Ac; 68.55.Nq; 68.60.Bs     

Structural and compositional analyses of nanocrystalline diamond/β-SiC composite films

Nanocrystalline diamond/β-SiC composite films are synthesized by microwave plasma chemical vapor deposition using a gas mixture of H₂, CH₄, and tetramethylsilane (Si(CH₃)₄, TMS) in a single process step. Structural and compositional analyses revealed that the films consist of a mixture of diamond and β-SiC nanocrystalline phases in a desired volume fraction combinatorial form. Transmission electron microscopy analysis confirmed the X-ray diffraction results and showed that the major diffraction lines corresponded to a two-component nanocrystalline composite film. Infrared spectroscopic analysis showed that the content of β-SiC in the films can be increased by increasing the TMS concentration. This correlated very well with electron probe microanalysis and Rutherford backscattering analysis that showed an almost linear correspondence of β-SiC content in the films with the TMS concentration in the gas phase. The phase purity of the diamond crystallites decreased with increase in the β-SiC content in the films, as shown by micro Raman scattering studies. Smooth surface morphologies are measured for these films by using atomic force microscopy; the root mean square roughness was 12 ± 1 nm. The β-SiC volume fraction (vol. %) was identified as an important compositional factor to determine any mechanical and frictional properties of these films. PACS 68.55.-a; 68.55.Nq; 68.60.-p     

Micro- and nanocomposite Ti-Al-N/Ni-Cr-B-Si-Fe-based protective coatings: Structure and properties

A new type of nanocomposite Ti-Al-N/Ni-Cr-B-Si-Fe-based coatings 70–90 μm thick produced by combined magnetron sputtering and a plasma detonation technology is created and studied. Phases Ti₃AlN + Ti₃Al₂N₂ and the phases caused by the interaction of plasma with a thick Al₃Ti + Ni₃Ti coating are detected in the coatings. The TiAlN phase has a grain size of 18–24 nm, and other phases has a grain size of 35–90 nm. The elastic modulus of the Ti-Al-N coating is E = 342 ± 1 GPa and its average hardness is H = 20.8 ± 1.8 GPa. The corrosion rate of this coating is very low, 4.8 μg/year, which is about three orders of magnitude lower than that of stainless steel (substrate). Wear tests performed according to the cylinder-surface scheme demonstrate high wear resistance and high adhesion between the thick and thin coatings.     

The production of nickel–alumina composite coating via electroplating

A series of electroplating works have been conducted to investigate the best condition for the coelectrodeposition of nickel–alumina (Ni/α–Al₂O₃) composite coating. Co-electrodeposition was done onto mild steel as cathode at ambient temperature (27°C) with current density of 30 mA/cm² under α-Al₂O₃ concentration of 2 g/l and various agitation speeds of 50, 100, 150, 200, and 250 rpms. The cross-section of the composite coatings portrayed α-Al₂O₃ particles was co-deposited. Under field emission scanning electron microscopy analysis, the coating shows a coarse surface morphology, while cross-sectional microstructures shows a compact embedding of α-Al₂O₃ particle in the Ni matrix. Elemental analysis by EDX detected the presence of Ni and α-Al₂O₃. Vickers microhardness testing shows that the coating hardness increases almost 60% at the highest agitation speed, i.e., 250 rpm.     

Electrodeposited nickel-cobalt composite coating containing MoS2

Ni-Co/MoS₂ composite coatings were prepared by electrodeposition in a Ni-Co plating bath containing nano-sized MoS₂ particles to be co-deposited. The polarization behavior of the composite plating bath was examined on a PAR-273A potentiostat/galvanostat device. The friction and wear behaviors of the Ni-Co/MoS₂ composite coatings were evaluated with UMT-2MT test rig in a ball-on-disk contact mode. The morphologies of the original and worn surfaces of the composite coatings were observed on scanning electron microscope (SEM). It was found that the introduction of MoS₂ nano-particulates in the electrolyte caused the shift towards larger negatives of the reduction potential of the Ni-Co alloy coating, and the co-deposited MoS₂ showed no significant effect on the electrodeposition process of the Ni-Co alloy coating. However, the co-deposited MoS₂ led to changes in the surface morphology and structure of the composite coating as well. Namely, the peak width of the Ni-Co solid solution for the composite coating is broader as compared to that of the Ni-Co alloy coating. The co-deposited MoS₂ particulates were uniformly distributed in the Ni-Co matrix and contributed to increase tribological properties of the Ni-Co alloy coating.     

Studies on PEO-based sodium ion conducting composite polymer films

A sodium ion conducting composite polymer electrolyte (CPE) prepared by solution-caste technique by dispersion of an electrochemically inert ceramic filler (SnO₂) in the PEO–salt complex matrix is reported. The effect of filler concentration on morphological, electrical, electrochemical, and mechanical stability of the CPE films has been investigated and analyzed. Composite nature of the films has been confirmed from X-ray diffraction and scanning electron microscopy patterns. Room temperature d.c. conductivity observed as a function of filler concentration indicates an enhancement (maximum) at 1–2 wt% filler concentration followed by another maximum at ∼10 wt% SnO₂. This two-maxima feature of electrical conductivity as a function of filler concentration remains unaltered in the CPE films even at 100 °C (i.e., after crystalline melting), suggesting an active role of the filler particles in governing electrical transport. Substantial enhancement in the voltage stability and mechanical properties of the CPE films has been noticed on filler dispersion. The composite polymer films have been observed to be predominantly ionic in nature with t _ion ∼ 0.99 for 1–2 wt% SnO₂. However, this value gets lowered on increasing addition of SnO₂ with t _ion ∼ 0.90 for 25 wt% SnO₂. A calculation of ionic and electronic conductivity for 25 wt% of SnO₂ film works out to be ∼2.34 × 10⁻⁶ and 2.6 × 10⁻⁷ S/cm, respectively.     

Zn-ZrO2 nanocomposite coatings: Elecrodeposition and evaluation of corrosion resistance

The Zn and Zn-ZrO₂ composite coatings were produced by electrodeposition technique using sulphate bath. ZrO₂ particles were characterized using scanning electron microscopy (SEM) and X-ray diffraction (XRD). The ZrO₂ particle size distribution in the plating bath and Zeta potential and the ZrO₂ were measured using dynamic light scattering technique (DLS). The corrosion resistance properties of Zn and Zn-ZrO₂ composite coatings were compared by examining the experimental data acquired through polarization, open circuit potential (OCP) and Tafel measurements. The corrosion environment was 3.5 wt% NaCl solution. The variation of amount of ZrO₂ in the solution on their % wt inclusion in the composite and on composite microhardness was investigated. XRD patterns were recorded for Zn and Zn-ZrO₂ coatings to compare their grain size. The SEM images of coatings before and after corrosion under chemical and electrochemical conditions were presented. The results were analyzed to establish the superiority of Zn-ZrO₂ composite over Zn coating.     

Structural and sensing properties of nanocrystalline SnO<Subscript>2</Subscript> films deposited by spray pyrolysis from a SnCl<Subscript>2</Subscript> precursor

We report the fabrication and characterization of tin dioxide gas sensing layers. The tin dioxide layers were synthesized using a convenient, simple and low-cost technique of spray pyrolysis. The formation of stoichiometric SnO₂ layers with fine-grain structure is revealed by Rutherford backscattering spectroscopy. The microstructure, phase, nanoparticle size distribution and surface morphology were studied by transmission electron microscopy, electron diffraction and atomic force microscopy. Most of the grains were of 10–20 nm size; however, some particles were up to 100 nm in size and had a microtwin lamellae structure of SnO₂ phase (cassiterite) with lattice parameters a= 0.474 nm and c= 0.319 nm. The sensitivity of the layers with respect to 1000–10000 ppm CH₄ in air was obtained from both resistivity (S_R) and capacity (S_C) measurements at 330 °C and values of S_R=5–7 and S_C=22–31 were extracted. PACS 68.43.-h; 68.55.-a; 81.05.Hd; 81.07.-b; 81.15.Rs     

Biocorrosion studies of TiO<Subscript>2</Subscript> nanoparticle-coated Ti–6Al–4V implant in simulated biofluids

The corrosion behaviors of the TiO₂ nanoparticles coated bioimplant Ti–6Al–4V exposed to three different simulated biofluids (SBF), namely, (1) NaCl solution, (2) Hank’s solution, and (3) Cigada solution, were studied by using micro-Raman spectroscopy, electrochemical techniques, and scanning electron microscopy (SEM) with energy dispersive X-ray spectroscopy (EDS). The different electrochemical impedance spectroscopy models were applied to fit the data obtained from the implants before and after the coating of TiO₂ nanoparticles (50–100 nm). It was found that the TiO₂ nanoparticle coatings increased the thickness of the pre-existing oxide layer on the Ti–6Al–4V surface, serving to improve the bioimplant corrosion resistance.     

Microstructure and corrosion properties of thick WC composite coating formed by plasma cladding

The thick Ni-coated WC coatings, in a matrix of Nickel-based alloys, were prepared on AISI 1045 steel using plasma cladding equipment. A pre-placed layer of uniform mixture, with different weight fractions of Ni-coated WC powder and Nickel-based alloy powder, on the steel substrate was melted at the high temperature of the plasma jet. The coating composition, microstructure and microhardness were analyzed by X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive spectrometer (EDS) and microhardness testing. The experimental results show that the metallurgical bond was formed between the coating and substrate. The XRD results show that the coatings contain γ-Ni, carbides (such as M₂₃C₆ and M₇C₃) and boride (such as Fe₂B, Fe₃B phases). SEM shows that all the coatings are crack-free with lower porosity (<1%). It is found that the microhardness and the electrochemical behavior of the coatings are depended on the content of Ni-coated WC powder. The corrosion mechanism for the coatings may be due to the microgalvance corrosion between the phases in the cladding coatings.     

Structure and properties of DLC–MoS2 thin films synthesized by BTIBD method

Diamond-like carbon (DLC)–MoS₂ composite thin films were synthesized using a biased target ion beam deposition (BTIBD) technique in which MoS₂ was produced by sputtering a MoS₂ target using Ar ion beams while DLC was deposited by ion beam deposition with CH₄ gas as carbon source. The structure and properties of the synthesized films were characterized by X-ray diffraction, X-ray absorption near edge structure (XANES), Raman spectroscopy, nanoindentation, ball-on-disk testing, and corrosion testing. The effect of MoS₂ target bias voltage, ranging from −200 to −800 V, on the structure and properties of the DLC–MoS₂ films was further investigated. The results showed that the hardness decreases from 9.1 GPa to 7 GPa, the Young?s modulus decreases from 100 GPa to 78 GPa, the coefficient of friction (COF) increases from 0.02 to 0.17, and the specific wear rate coefficient (k) increases from 5×10⁻⁷ to 5×10⁻⁶ mm³ N⁻¹ m⁻¹, with increasing the biasing voltage from 200 V to 800 V. Also, the corrosion resistance of the DLC–MoS₂ films decreased with the raise of biasing voltage. Comparing with the pure DLC and pure MoS₂ films, the DLC–MoS₂ films deposited at low biasing voltages showed better tribological properties including lower COF and k in ambient air environment.     

Effect of La surface treatments on corrosion resistance of A3xx.x/SiCp composites in salt fog

The influence of the SiC_p proportion and the matrix concentration of four aluminium metal matrix composites (A360/SiC/10p, A360/SiC/20p, A380/SiC/10p, A380/SiC/20p) modified by lanthanum-based conversion or electrolysis coating was evaluated in neutral salt fog according to ASTM B 117. Lanthanum-based conversion coatings were obtained by immersion in 50 °C solution of La(III) salt and lanthanum electrolysis treatments were performed in ethylene glycol mono-butyl ether solution. These treatments preferentially covered cathodic areas such as intermetallic compounds, Si eutectic and SiC_p. The kinetic of the corrosion process was studied on the basis of gravimetric tests. Both coating microstructure and nature of corrosion products were analyzed by scanning electron microscopy (SEM), atomic force microscopy (AFM), energy dispersive X-ray analysis (EDS) and low angle X-ray diffraction (XRD) before and after accelerated testing to determine the influence of microstructural changes on corrosion behaviour during exposure to the corrosive environment. The corrosion process was more influenced by the concentration of alloy elements in the matrix than by the proportion of SiC_p reinforcement. Both conversion and electrolysis surface treatments improved the behaviour to salt fog corrosion in comparison with original composites without treatment. Additionally, electrolysis provided a higher degree of protection than the conversion treatment because the coating was more extensive.     

Nanocomposite TiN films with embedded MoS2 inorganic fullerenes produced by combining supersonic cluster beam deposition with cathodic arc reactive evaporation

We report the production and characterization of nanocomposite thin films consisting of a titanium nitride matrix with embedded molybdenum disulphide fullerene-like nanoparticles. This was achieved by combining a cluster source generating a pulsed supersonic beam of MoS₂ clusters with an industrial cathodic arc reactive evaporation apparatus used for TiN deposition. Cluster-assembled films show the presence of MoS₂ nanocages and nanostructures and the survival of such structures dispersed in the TiN matrix in the co-deposited samples. Nanotribological characterization by atomic force microscopy shows that the presence of MoS₂ nanoparticles even in very low concentration modifies the behaviour of the TiN matrix. PACS 62.20.Qp; 62.23.Pq; 68.55.-a; 81.07.-b     

Investigation of the characteristics and corrosion resistance of Al2O3/TiN coatings

Al₂O₃ /TiN double and Al₂O₃/Cr/TiN triple coatings were produced on stainless steel substrates using plasma-detonation techniques. Investigation of the microstructure and characteristics of the coatings after the preparation was performed by X-ray diffraction (XRD), transmission electron microscopy (TEM) and Auger electron spectroscopy (AES). The corrosion resistance of the coatings was studied in several electrolytic solutions (0.5 M H₂SO₄, 1 M HCl, 0.75 M NaCl) using electrochemical techniques (open circuit potential, cyclovoltammetry and potentiodynamic polarization). The obtained results showed, in most of the cases, an improvement of the corrosion resistance, except in NaCl solutions. The effect of the controlled thickness of TiN and Cr layers as well as the additional treatment with a high-current electron beam was also investigated. Nuclear reaction analysis (NRA), Rutherford backscattering spectroscopy (RBS) and scanning electron microscopy (SEM) were applied for the characterization of the samples before and after the corrosion experiments.     

Synthesis,characterization and magnetic properties of Co<Subscript>3</Subscript>O<Subscript>4</Subscript> nanotubes

Well-aligned Co₃O₄ nanotubes were synthesized within the nanochannels of porous anodic alumina membranes using a single-source chemical vapor deposition method. Scanning electron microscopy and transmission electron microscopy showed that the Co₃O₄ nanotubes are highly ordered with uniform diameter in the range of 100–300 nm and length up to tens of microns. X-ray diffraction, the Raman spectrum, energy-dispersive spectroscopy and selected-area electron diffraction demonstrated that the nanotubes are composed of pure cubic phase polycrystalline Co₃O₄. Magnetic measurements using a SQUID magnetometer suggested the presence of a strong antiferromagnetic interaction with Weiss constant θ= -248 K. The real and imaginary parts of the ac susceptibility at f= 10 Hz had a maximum at 4.0 K, and the field dependence of the magnetization at 1.8 K showed a small hysteresis loop with a coercivity of ∼ 98 Oe. PACS 81.07.De; 81.15.Gh; 78.30.-j; 75.75.+a; 61.46.Np     

In situ formation of low friction ceramic coatings on carbon steel by plasma electrolytic oxidation in two types of electrolytes

In situ formation of ceramic coatings on Q235 carbon steel was achieved by plasma electrolytic oxidation (PEO) in carbonate electrolyte and silicate electrolyte, respectively. The surface and cross-section morphology, phase and elemental composition of PEO coatings were examined by means of scanning electron microscopy (SEM), X-ray diffraction (XRD) and energy-dispersive X-ray spectroscopy (EDS). The bond strength of the coating was determined using a direct pull-off test. The hardness as well as tribological properties of the ceramic coating was primarily studied. The results indicated that the coating obtained in carbonate electrolyte was Fe₃O₄, while the coating achieved from silicate electrolyte was proved to be amorphous. Both kinds of coatings showed coarse and porous surface. The Fe₃O₄ coatings obtained in carbonate electrolyte showed a high bonding strength to the substrate up to 20 ± 2 MPa and the value was 15 ± 2 MPa for the amorphous coatings obtained in carbonate electrolyte. The micro hardness of the amorphous coating and the Fe₃O₄ coating was 1001 Hv and 1413 Hv, respectively, which was more than two and three times as that of the Q235 alloy substrate (415 Hv). The friction coefficient exhibited by amorphous coating and Fe₃O₄ coating was 0.13 and 0.11, respectively, both lower than the uncoated Q235 substrate which ranged from 0.17 to 0.35.     

Physical and electrochemical characterizations of Ni-SiO2 nanocomposite coatings

Advances in materials performance often require the development of composite system. In the present investigation, SiO₂-reinforced nickel composite coatings were deposited on a mild steel substrate using direct current electrodeposition process employing a nickel acetate bath. Surface morphology, composition, microstructure and crystal orientation of the Ni and Ni-SiO₂ nanocomposite coatings were investigated by scanning electron microscope, energy dispersive X-ray spectroscopy and X-ray diffraction analysis, respectively. The effect of incorporation of SiO₂ particles in the Ni nanocomposite coating on the microhardness and corrosion behaviour has been evaluated. Smooth composite deposits containing well-distributed silicon oxide particles were obtained. The preferred growth process of the nickel matrix in crystallographic directions <111>, <200> and <220> is strongly influenced by SiO₂ nanoparticles. The average crystallite size was calculated by using X-ray diffraction analysis and it was ~23 nm for electrodeposited nickel and ~21 nm for Ni-SiO₂ nanocomposite coatings. The crystallite structure was fcc for electrodeposited nickel and Ni-SiO₂ nanocomposite coatings. The incorporation of SiO₂ particles into the Ni matrices was found to improve corrosion resistance of pure Ni coatings. The corrosion potential (E _corr) in the case of Ni-SiO₂ nanocomposite coatings had shown a negative shift, confirming the cathodic protective nature of the coating. The Ni-SiO₂ composite coatings have exhibited significantly improved microhardness (615 HV) compared to pure nickel coatings (265 HV)     

电流密度对铝合金微弧氧化膜物理化学特性的影响

利用微弧氧化(MAO)技术，在LYl2铝合金上沉积了显微硬度达42.14GPa的超硬陶瓷膜.采用x射线衍射仪和显微硬度计研究了阳极电流密度j_a和阴极、阳极电流密度比j_c/j_a对MAO膜相构成和力学特性的影响.此外，利用扫描电子显微镜和恒电位仪分别对膜的微结构和抗点腐蚀特性进行了分析.结果表明，高j_a制备的膜主要含α-Al₂O₃相，低j_a制备的膜主要含γ-Al₂O₃相.显微硬度测试表明，这类膜有较高的硬度，但以j_a=15A/dm²和j_c/j_a=0.7制备的陶瓷膜硬度最高.抗点腐蚀测试表明，j_c/j_a对陶瓷膜的微结构有很强的影响. 关键词： 微弧氧化 显微硬度 电流密度 抗点腐蚀