Coatings and Surface Modification of Alloys for Tribo-Corrosion Applications

Coatings and Surface Modification of Alloys for Tribo-Corrosion Applications

11 January 2024 | Robert J. K. Wood, Ping Lu
This review summarizes nearly 195 papers and reviews published over the past 15 years on the tribocorrosion of coatings and surface modifications, compared to only 37 works published up to 2007. The research is vibrant and growing, covering emerging deposition, surface modification, testing techniques, environmental influences, and modelling developments. The growth reflects the need for machines to operate in harsh environments, with increased service life, lower running costs, and improved safety factors. Research has also focused on multifunctional coating surfaces and functionally graded systems. The review covers a range of coating types for various applications, including molten-, solution-, PVD-, and PEO-based coatings, with CVD coatings being less popular. Emerging technologies include duplex surface engineering and coating systems. Surface performance shows a strong balance between wear, friction, and corrosion rates, often with antagonistic relationships and complex interactions at different scales. Tribologically induced stresses drive damage propagation and accelerate corrosion, emphasizing coating defect density. Environmental factors like pH, DO₂, CO₂, salinity, and temperature significantly influence tribocorrosion performance. Coating solutions include electrodeposited coatings, hard and tough coatings, and high-impedance coatings like doped diamond-like carbon. Hybrid and multilayered coatings control damage penetration and manage stresses. The review highlights the importance of microstructure, active phases, and surface films in tribocorrosion performance. New techniques reveal surface responses to tribocorrosion, such as scanning electrochemical microscopy. Modelling tribocorrosion has not fully embraced the range of coatings and the fact that some coatings/environments result in reduced wear, making synergistic/antagonistic mechanisms difficult to model. The review also discusses coating development, including techniques like molten deposition, vapor deposition, and solution-based methods. It covers various coatings, such as TiN, CrN, TiZrN, and DLC, and their tribocorrosion performance. The review highlights the importance of surface hardness, adhesion, and microstructure in tribocorrosion resistance. It also discusses the role of environmental factors, such as pH and temperature, in tribocorrosion. The review concludes that while hard coatings show promise, challenges like porosity, cracks, and adhesion issues limit their effectiveness. Multilayered coatings and duplex treatments are recommended to improve tribocorrosion resistance. The review also discusses the use of PEO and boriding processes for surface modification, and the role of machine learning in tribocorrosion mapping. Overall, the review emphasizes the need for further research to understand synergistic/antagonistic mechanisms and improve tribocorrosion models.This review summarizes nearly 195 papers and reviews published over the past 15 years on the tribocorrosion of coatings and surface modifications, compared to only 37 works published up to 2007. The research is vibrant and growing, covering emerging deposition, surface modification, testing techniques, environmental influences, and modelling developments. The growth reflects the need for machines to operate in harsh environments, with increased service life, lower running costs, and improved safety factors. Research has also focused on multifunctional coating surfaces and functionally graded systems. The review covers a range of coating types for various applications, including molten-, solution-, PVD-, and PEO-based coatings, with CVD coatings being less popular. Emerging technologies include duplex surface engineering and coating systems. Surface performance shows a strong balance between wear, friction, and corrosion rates, often with antagonistic relationships and complex interactions at different scales. Tribologically induced stresses drive damage propagation and accelerate corrosion, emphasizing coating defect density. Environmental factors like pH, DO₂, CO₂, salinity, and temperature significantly influence tribocorrosion performance. Coating solutions include electrodeposited coatings, hard and tough coatings, and high-impedance coatings like doped diamond-like carbon. Hybrid and multilayered coatings control damage penetration and manage stresses. The review highlights the importance of microstructure, active phases, and surface films in tribocorrosion performance. New techniques reveal surface responses to tribocorrosion, such as scanning electrochemical microscopy. Modelling tribocorrosion has not fully embraced the range of coatings and the fact that some coatings/environments result in reduced wear, making synergistic/antagonistic mechanisms difficult to model. The review also discusses coating development, including techniques like molten deposition, vapor deposition, and solution-based methods. It covers various coatings, such as TiN, CrN, TiZrN, and DLC, and their tribocorrosion performance. The review highlights the importance of surface hardness, adhesion, and microstructure in tribocorrosion resistance. It also discusses the role of environmental factors, such as pH and temperature, in tribocorrosion. The review concludes that while hard coatings show promise, challenges like porosity, cracks, and adhesion issues limit their effectiveness. Multilayered coatings and duplex treatments are recommended to improve tribocorrosion resistance. The review also discusses the use of PEO and boriding processes for surface modification, and the role of machine learning in tribocorrosion mapping. Overall, the review emphasizes the need for further research to understand synergistic/antagonistic mechanisms and improve tribocorrosion models.
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Understanding Coatings and Surface Modification of Alloys for Tribo-Corrosion Applications