The present study investigates the possibility to apply a vacuum furnace thermal post-treatment as an alternative solution for flame sprayed NiCrBSi wear and corrosion-resistant coatings, deposited on a low alloyed structural steel. The controlled atmosphere offers advantages regarding the fusion of the coating, porosity reduction, and degassing. An improvement of the applied heating-cooling cycle was performed through the variation of time and temperature. The best performing samples were selected by comparing their porosity and roughness values. The chosen samples were subsequently characterized regarding their microstructure, microhardness, sliding wear, and corrosion behavior. The experimental work confirms that the use of a vacuum remelting post-process reduces the porosity below 1% and leads to the formation of a larger quantity of hard boron-containing phases, promoting a significant decrease of the wear rate, while maintaining a good corrosion behavior.

In order to modify the surface of light metals and alloys, plasma electrolytic oxidation (PEO) is a useful electrochemical technique. During the oxidation process, by applying a positive high voltage greater than the dielectric breakdown value of the oxide layer, the formation of a ceramic film onto the substrate material is enabled. The resulting surface presents hardness, chemical stability, biocompatibility, and increased corrosion wear resistance. The current study aims to investigate the corrosion resistance and tribological properties of PEO-modified coatings on titanium substrates produced by applying either direct or pulsed current in a silicate-alkaline electrolyte. In this way, a uniform TiO₂ layer is formed, and subsequently, electrophoretic deposition of hydroxyapatite particles (HAP) is performed. The morpho-structural characteristics and chemical composition of the resulting coatings are investigated using scanning electron microscopy combined with energy dispersive spectroscopy analysis and X-ray diffraction. Dry sliding wear testing of the TiO₂ and HAP-modified TiO₂ coatings were carried out using a ball-on-disc configuration, while the corrosion resistance was electrochemically evaluated at 37 °C in a Ringer’s solution. The corrosion rates of the investigated samples decreased significantly, up to two orders of magnitude, when the PEO treatment was applied, while the wear rate was 50% lower compared to the untreated titanium substrate.

Efficient and low-cost electrocatalysts for the hydrogen evolution reaction (HER) in alkaline media are essential for sustainable hydrogen production. In this study, Ni electrocatalysts were deposited on pencil graphite using a simple one-step pulsed current electrodeposition method, from both acidic Watts and alkaline citrate baths. The influence of bath type and electrodeposition parameters—current density and temperature—on catalyst morphology and performance for HER was systematically investigated by scanning electron microscopy and electrochemical methods. Linear sweep voltammetry, chronopotentiometry, and electrochemical impedance spectroscopy (EIS) were used to evaluate the electrocatalytic activity, stability, and HER mechanism. The best catalytic performance was achieved for the Ni electrocatalyst deposited from the citrate bath at 50 mA cm⁻² and 40 °C, showing an exchange current density of 0.93 mA cm⁻², a Tafel slope of −208 mV dec⁻¹, and overpotentials of −210 mV and −386 mV at 10 and 100 mA cm⁻², respectively, in 1 M KOH solution. Chronopotentiometry confirmed improved stability and an overpotential reduction of approximately 92 mV as compared to pure Ni, while EIS revealed the lowest charge transfer resistance. It was shown that the electrocatalysts deposited from the citrate bath outperform those from the Watts bath, and electrodeposition at 40 °C is optimal for achieving the highest electrocatalytic activity for HER.

Without proper post-processing (often using flame, furnace, laser remelting, and induction) or reinforcements’ addition, Ni-based flame-sprayed coatings generally manifest moderate adhesion to the substrate, high porosity, unmelted particles, undesirable oxides, or weak wear resistance and mechanical properties. The current research aimed to investigate the addition of ZrO₂ as reinforcement to the self-fluxing alloy coatings. Mechanically mixed NiCrBSi-ZrO₂ powders were thermally sprayed onto an industrially relevant high-grade steel. After thermal spraying, the samples were differently post-processed with a flame gun and with a vacuum furnace, respectively. Scanning electron microscopy showed a porosity reduction for the vacuum-heat-treated samples compared to that of the flame-post-processed ones. X-ray diffraction measurements showed differences in the main peaks of the patterns for the thermal processed samples compared to the as-sprayed ones, these having a direct influence on the mechanical behavior of the coatings. Although a slight microhardness decrease was observed in the case of vacuum-remelted samples, the overall low porosity and the phase differences helped the coating to perform better during wear-resistance testing, realized using a ball-on-disk arrangement, compared to the as-sprayed reference samples.