Iranian Journal of Materials Science and Engineering

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In the present study, Zirconium modified aluminide coating on the nickel-base superalloy IN-738LC was first created by high activity high temperature aluminizing based on the out-of-pack cementation method. Then, Zr coatings were applied to simple aluminide coatings by sputtering and heat treatment in order to study the effect of Zr on the coating microstructure and oxide spallation. Microstructural studies were conducted by using scanning electron microscopy (SEM), Energy Dispersive X-ray Spectrometry (EDS), and x-ray diffraction (XRD) microanalysis. The results indicated that zirconium modified aluminide coating, like aluminide coating, has a two-layer structure including a uniform outer layer of NiAl and an interdiffusion layer in which zirconium is in a form of solid solution in the coating. Furthermore, the 300nm Zr-coated NiAl demonstrated an excellent scale adhesion, a slow oxidation rate and lower amounts of some other elements such as Ti and Cr in its oxide layer leading to a pure aluminide oxide layer. 

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In the research, Titanium dioxide/Graphene Oxide thin films at different concentration of graphene oxide (0.0, 0.015, 0.030, 0.045 and 4.5 g/ml) were prepared by spin coating method. Characterization of the samples was performed using X-ray diffraction and Field Emission Scannig Eelectron Microscope and Atomic Force Microscope. X-ray diffraction results show that by adding the graphene oxide, the peak associated with (001) reflection is observed at the angle of 10.5°. The analysis of Eenergy Dispersive X-ray also confirms the formation of graphene oxide sheets. Considering the excellent photo catalytic and antibacterial properties of titanium dioxide, the effect of adding the different concentration of graphene oxide on these properties has been investigated. The results show that the presence of graphene oxide increases the inhibition of Escherichia coli bacterial growth.
 

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Nickel phosphorus alloy coatings were prepared by electrodeposition route from sulfate electrolyte bath at various current densities. SEM studies reveal spherical grains covered the entire surface with uniform distribution. EDX results showed a linear increase of P content in the developed deposits with current density and therefore, enhancing the grains size and drop of the hardness values. XRD studies reveal monocrystalline orthorhombic alloys at a low amount of phosphorus (10.88 wt. %). Corrosion tests show that 1 A.dm-2 is the best applied current density giving the nobler Ecorr (-171.4 mV) and the lower icorr (4.64 µA/cm²).

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The main purpose of this investigation is to assess the effect of post-deposition annealing treatment on the electrochemical behavior of TiN coating developed on AISI 304 stainless steel substrate using cathodic arc evaporation physical vapor deposition (CAE-PVD). Post-annealing treatment at 400 ºC was performed on the coated substrate for 1 h. The studied samples were characterized using X-ray diffraction (XRD), scanning electron microscope (SEM), potentiodynamic polarization (PDP), and electrochemical impedance spectroscopy (EIS) tests. The preferred orientation of TiN (111) was identified by XRD patterns and the crystallinity of the coating increased after annealing treatment. SEM observations indicated that TiN coatings free of cracks were successfully developed on the substrate. The electrochemical measurements elucidated that the annealed coating had better corrosion resistance compared to that of the as-deposited coating with a lower current corrosion density. This investigation implied that improved corrosion performance of the TiN coating can achieved by performing post-deposition annealing treatment.

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Copper oxide thin layers were elaborated using the sol-gel dip-coating. The thickness effect on morphological, structural, optical and electrical properties was studied. Copper chloride dihydrate was used as precursor and dissolved into methanol. The scanning electron microscopy analysis results showed that there is continuity in formation of the clusters and the nuclei with the increase of number of the dips. X-ray diffractogram showed that all the films are polycrystalline cupric oxide CuO phase with monoclinic structure with grain size in the range of 30.72 - 26.58 nm. The obtained films are clear blackin appearance, which are confirmed by the optical transmittance spectra. The optical band gap energies of the deposited films vary from 3.80 to 3.70 eV. The electrical conductivity of the films decreases from 1.90.10^-2 to 7.39.10^-3 (Ω.cm)^-1

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The goal of the present study is to prepare a room temperature cured hydrophobic and self-cleaning nano-coating for power line insulators. As a result, the installed insulators operating in power lines can be coated without being removed from the circuit and without the need to cut off power. For this purpose, hydrophobic silica nanoparticles were synthesized by sol-gel method using TEOS and HMDS. The synthesized hydrophobic silica nanoparticles were characterized by XRD, FTIR, SEM, and TEM analyses to investigate phase formation, particle size, and morphology. Then the surface of the insulator was cleaned and sprayed by Ultimeg binder solution, an air-dried insulating coating, as the base coating. Then the hydrophobic nano-silica powder was sprayed on the binder coated surface and left to be air-cured at room temperature. After drying the coating, the contact angle was measured to be 149^o. Pull-off test was used to check the adhesion strength of the hydrophobic coating to the base insulator. To evaluate the effect of environmental factors, UV resistance and fog-salt corrosion tests were conducted. The results showed that 150 hours of UV radiation, equivalent to 9 months of placing the samples in normal conditions, did not have any significant effect on reducing the hydrophobicity of the applied coatings.

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This study investigates the synthesis of Al/MoS₂ nanocomposite coating by the electro spark deposition (ESD) method for its lubricating properties. ESD method was selected because it is a very easy, rapid, and cost-saving method and the resulting coating has a strong bonding with the substrate. As a substrate, a Ti-6Al-4V alloy sheet containing 6.12 % Al, 4.06 % V, 0.19% Fe, and 0.05 % Ni was used. For coating, an aluminum-molybdenum disulfide composite electrode in the form of a cylindrical rod was employed. Three frequencies of 5, 8, and 11 kHz, three current limits of 15, 25, and 35 amps, and three duty cycles of 50, 60, and 70% were used in the coating operation. AFM analysis was used to study the topography, morphology, and calculate roughness. The samples were then subjected to hardness tests. To determine the wear resistance of the samples, pin on disk tests were performed. XRD analysis was performed to identify the phases on the surface of the coated samples. SEM was used to examine the microstructure of the coating before and after wear testing, in order to determine the wear mechanism. The results indicated that the Al/MoS2 nanocomposite coating was synthesized on the substrate surface. The hardness of the reference sample is 353 Vickers, and that of the coated samples is about 200 Vickers. For the reference sample, the roughness was measured at 15.7 nm, and for the coated sample at 268.1 nm. As spark energy increased, the coefficient of friction increased by approximately 0.09. As spark energy increased, the wear rate increased by 27%. A significant increase in the Lancaster coefficient occurred around 5 joules of energy. According to the wear rate results, the sample with the lowest thickness wears 4% less than the sample with the highest thickness. The wear rate of sample 351170 is 78% lower than that of sample 150550.

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The principal goal of this research is to produce a CrN/Cu multilayer coating and a CrN single-layer
coating and also compare their electrochemical and antibacterial behavior. In this investigation, the coatings were
applied to the stainless steel substrate by cathodic arc evaporation a sub-division of physical vapor deposition
(CAE-PVD). The present phases were characterized and the thickness of the coatings was measured using X-ray
diffraction (XRD) and field emission scanning electron microscopy (FE-SEM), respectively. Rockwell-C tester was
used to evaluate the adhesion quality. Also, to evaluate the mechanical properties of the coatings such as modulus
of elasticity and hardness, a nanoindentation test was used and the indentation effect and coating topography were
evaluated using atomic force microscopy (AFM). Studying the electrochemical behavior of the coatings was done
using electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization (PDP) tests in Ringer's
solution. The results of EIS tests showed that the CrN coating had higher polarization resistance in comparison to
the CrN/Cu coating and an increasing trend of polarization resistance related to both coatings was identified by
rising the time of immersion. Also, using the PDP curves, the CrN and CrN/Cu coating current densities were
estimated at 1.835×10-8 and 2.088×10-8, respectively. The antibacterial activity of CrN and CrN/Cu coatings was
evaluated by the spot-inoculation method. The results of the antibacterial test indicated that compared to CrN
coating, CrN/Cu coating had a better impact on the control of the bacteria growth.

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In this paper, an investigation was carried out to test the suitability of potential additive materials in
WOKA 3533 (WC-10Co4Cr) cermet HVOF coating subjected to slurry erosion in ash conditions. The additives
namely molybdenum carbide, yttrium oxide, and zirconium oxide were added in equal percentages (3 wt.%) in
WOKA cermet powder. High-velocity oxy-fuel (HVOF) spraying was performed to develop the additive-based
WOKA cermet coatings. The slurry erosion in ash conditions was tested using the pot tester. Microstructural and
mechanical properties of traditional and additive-based WOKA cermet coatings were also tested in the present
study; for example, microstructure, crystalline phases of as-sprayed coatings, and microhardness. Results present a
comparison of surface erosion wear of different cermet coatings. It was found that the yttrium oxide was a suitable
additive for the WOKA cermet coatings than the molybdenum carbide. However, zirconium oxide is unsuitable for
WOKA cermet coatings in erosion wear applications.

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We report a simple and practical approach for the easy production of superhydrophobic coatings based on TiO₂-SiO₂@PDMS. In this study, we used tetraethylorthosilicate (TEOS) and titanium tetraisopropoxide (TTIP) as a precursor for the sol-gel synthesis of SiO₂ and TiO₂, respectively. Afterward, the surface of nanoparticles was modified by 1,1,1,3,3,3-hexamethyldisilazane (HMDS) before being combined with polydimethylsiloxane (PDMS). The hydrophobic property of coatings was evaluated by static contact angle measurements. The phase composition and structural evolution of the coatings were examined by X-ray diffraction (XRD), and Fourier transform infrared spectroscopy (FTIR) analysis. It was shown that changing the weight ratio of the solution composition of the coating can affect the hydrophobicity of the surface. The best sample has shown a superhydrophobic property with a 153˚ contact angle which contained (75%TiO₂-25%SiO₂) and PDMS at a weight ratio of 1:1. Moreover, the results showed that the superhydrophobic coating retains its hydrophobic properties up to a temperature of 450 ˚C, and at higher temperatures, it converts to a super hydrophilic with a water contact angle close to 0 ˚. The SiO₂-TiO₂@PDMS coating degrades methylene blue by about 55% and was shown to be capable of photocatalytically decomposing organic pollutants.

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Elevating component performance through advanced surface coatings finds its epitome in the domain of laser cladding technology. This technique facilitates the precision deposition of metallic, ceramic, or cermet coatings, accentuating their superiority over conventional methods. The application spectrum for laser-clad metallic coatings is extensive, encompassing critical components. Central to the efficacy of laser cladding is the modulation of laser parameters—encompassing power, speed, and gas flow—which decisively influence both process efficiency and coating properties. The meticulous calibration of these parameters holds the key to producing components endowed with refined attributes while ensuring the sustainable continuation of the process. As such, this study embarks on an empirical investigation aimed at transcending existing process limitations. It delves into the characterization of laser-clad WC-17Co coatings on AISI H13 and AISI 4140 steels. The importance of WC-17Co coatings lies in their capacity to enhance wear resistance, extend component life, reduce maintenance costs, and improve the performance of various industrial components across diverse sectors. On the other hand, the substrates have pivotal roles. AISI H13 is lauded for its exceptional hot work capabilities, while AISI 4140 steel is renowned for its robust strength and endurance. Through rigorous evaluation, the resultant deposited coatings offer crucial insights into the efficacy of manufacturing parameters. Employing a comprehensive suite of analytical techniques including laser confocal microscopy, Vickers microhardness assessment, and micro-adhesive wear testing, the study thoroughly characterizes the samples. The outcomes underscore the achievement of homogenous coatings marked by elevated hardness and exceptional wear resistance, thereby signifying a substantial enhancement over the substrate materials.

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The coated β-tricalcium phosphate (β-TCP) with dicalcium phosphate dihydrate (DCPD) has attracted much attention in the biomaterials field due to the increase in its osteoconductivity. Besides, the porous bioceramic scaffolds with controlled pore sizes are significant in stimulating bone-like cell activity. In this study, the effect of the setting-time process and acidic-calcium phosphate (CaP) concentrations on the fabrication and properties of porous DCPD/ β-TCP scaffolds were studied. Subsequently, the specimens were examined using X-ray diffraction (XRD), scanning electron microscopy (SEM), compression strength and Fourier transforms infrared (FTIR). The study results revealed that the porous DCPD/ β-TCP scaffolds with macro- and micropore sizes were successfully obtained after the 300-600 µm of porous β-TCP granules were exposed to an acidic-CaP solution. Furthermore, the setting-time process and acidic-CaP concentrations increased the DCPD interlocking between granules, and the mechanical strengths of scaffolds increased up to 0.5 MPa. Meanwhile, the porosity levels were changed based on the formation of DCPD crystals. This study was expected to provide novel insights to researchers in the field of bioceramics through its investigation on the creation of porous DCPD/ β-TCP scaffolds.

 

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In this research, a nickel-tungsten coating as a catalyst for hydrogen evolution reaction (HER) with different current densities was synthesized and the resulting electrocatalytic properties and morphology were assessed. Linear sweep voltammetry (LSV), electrochemical impedance spectroscopy (EIS), and chronoamperometry in 1 M NaOH were used to evaluate the electrocatalytic activity for HER. By increasing the current density of electrodeposition up to 500 mA/cm², a columnar morphology was observed. The cyclic voltammetry test (CV) revealed that when the plating current density increases, C_dl has increased from 248 to 1310 µF/cm² and the active surface area increases 5 times. The results showed that by modifying the coating morphology, the current density of the hydrogen evolution increased up to two times.
 

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Abstract
The power line insulators are permanently exposed to various environmental pollutants such as dust and fine particles. This may lead to flashovers and therefore widespread power blackouts and heavy economic damage. One way to overcome this problem is to make the insulator surface superhydrophobic. In this research, the superhydrophobic properties of the insulators were improved by applying room-temperature cured composite coatings consisting of epoxy and hydrophobic nano-silica particles. Either octadecyl trichlorosilane (ODTS) or hexamethyldisilazane (HMDS) was used to coat the silica nanoparticles and make them hydrophobic. Then, the hydrophobic silica was added to a mixture of epoxy resin and hardener. The suspension was applied on the surfaces of a commercial porcelain insulator and cold cured at ambient temperature. The coating increased the water contact angle from 50° to 149°. Even after 244 h exposure to the UV light, the samples preserved their hydrophobic properties. The adhesion of the coating was rated as 4B according to the ASTM D3359 standard. The coating decreased the leakage current by 40% and increased the breakdown voltage by 86% compared to the uncoated sample and showed promise for making power line insulators self-cleaning.
 

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In this study, we thoroughly examine β-Bi₂O₃ thin films as potential photocatalysts. We produced these films using an environmentally friendly Sol Gel method that is also cost-effective. Our research focuses on how different precursor concentrations, ranging from 0.1 M to 0.4 M, affect the photocatalytic performance of these films. We conducted a comprehensive set of tests to analyze various aspects of the films, including their structure, morphology, topography, optical properties, wettability, and photocatalytic capabilities. These tests provided us with a well-rounded understanding of the films' characteristics. To assess their photocatalytic efficiency, we used Methylene Blue (MB) as a contaminant and found that the films, particularly those with a 0.1 M concentration, achieved an impressive 99.9% degradation of MB within four hours. The 0.1 M film had a crystalline size of 39.7 nm, an indirect band gap of 2.99 eV, and a contact angle of 51.37°. Our findings suggest that β-Bi₂O₃ films, especially the 0.1 M variant, have promising potential for treating effluents from complex industrial dye processes. This research marks a significant step in utilizing sustainable materials to address pollution and environmental remediation challenges.

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In this research study, a composite coating of Ni-Co/SiC-CeO₂ was prepared on a copper substrate using the pulse electrodeposition technique. The effects of electrodeposition parameters, including current density, duty cycle, and frequency, on the properties of the prepared coating were investigated. The selected current density values were 0.1, 0.2, and 0.3 A/cm², the duty cycle options were 10, 20, and 30%, and the frequency values were 10, 100, and 1000 Hz. Increasing the current density enhanced the microhardness of the coating but reduced its corrosion resistance. This behavior can be attributed to the grain refinement occurring within the coating as the current density increases. On the other hand, an increase in duty cycle resulted in a decrease in microhardness, which can be attributed to a decrease in the concentration of nanoparticles within the coating. The lower corrosion resistance observed at higher duty cycles could be attributed to the decrease in off-time, causing the pulse electrodeposition conditions to approach a DC (direct current) state. Furthermore, higher frequencies were found to be associated with increased microhardness and improved corrosion resistance of the coatings. The coatings with the highest corrosion resistance exhibited a corrosion current density of 0.29 µA/cm² and a polarization resistance of 1063 Ω.cm² in a 3.5% NaCl solution. These coatings were prepared using a current density of 0.2 A/cm², a duty cycle of 10%, and a frequency of 1000 Hz.