In recent decades, batch hot-dip galvanized (HDG) steel has proven itself in practical applications due to the good corrosion resistance of its components. Despite the importance of the mechanical-load-bearing capacity of these coatings, the wear behavior has, so far, only been investigated very sporadically and not systematically, so a quantification of the wear behavior and statements on the mechanisms are vague. Therefore, two body wear tests with bonded abrasive grain were carried out. Varying the friction rolls, load, and total number of cycles, the wear behavior was investigated. The mass loss and the layer thickness reduction were measured at different intervals. After the test, the microstructure in the cross-section and the hardness according to Vickers (0.01 HV) were evaluated. The results showed that the wear behavior of HDG coatings against abrasive loads can be characterized with the selected test conditions. Initially, the applied load removed the soft η-phase. As the total number of cycles increases, the η- and ζ-phases deform plastically, resulting in a lower mass reduction compared to that expected from the measured layer thickness. The characteristic structure of a batch HDG coating with hard intermetallic Zn-Fe phases and an outer pure zinc phase has demonstrated effective resistance to abrasion.

Directed Energy Deposition-Laser (DED-L) enables high-performance coatings through melting and successive powder deposition. Its compositional flexibility suits functionally graded layers that enhance corrosion and wear resistance. This study aimed to improve parameters for producing dense, defect-free, graded Ni- and Fe-based coatings by varying the scanning speed and deposition strategy (monodirectional versus bidirectional, with/without layer rotation), while keeping the power and hatch distance constant. Laser and electron microscopy were used to link parameters to porosity and uniformity. Optimal settings minimized pores, improved interlayer bonding and preserved geometry; inadequate parameters yielded porous, irregular deposits. A bidirectional path with 90° rotation appeared best. Ongoing research activities are needed to assess its properties.

Traditionally, repairing coated substrates requires completely removing damaged, wear-resistant layers before recoating. This process leads to high costs, extended downtime, and material waste. Flexible brazing tapes, which are composed of alloy powder and an organic binder, offer an alternative to full coating removal for targeted repairs. Despite this, the process of vacuum brazing these tapes may lead to the formation of defects, including pores caused by trapped gases or residual binder, which compromise coating durability and corrosion resistance. This study focuses on the utilization of laser remelting as a method for post-processing nickel- and iron-based mixed alloy brazing tapes, with the aim of improving the integrity of the coating. Surface quality was assessed via microscopy and microhardness testing by systematically varying laser power, scanning speed, and hatch distance. Among the parameters studied, the most suitable laser parameter combination was found to be 350 W laser power, 250 mm/s scanning speed, and a hatch distance of 0.02 mm. These parameters yielded crack- and pore-free coatings with a remelting depth of 160.3 ± 17.2 µm and a microhardness of 701 ± 23 HV1, which is an 85% increase over as-brazed samples. Wear testing revealed a reduced coefficient of friction, and electrochemical corrosion tests showed lower corrosion current density and enhanced repassivation behavior in remelted coatings. These improvements demonstrate that laser remelting significantly enhances the microstructure, hardness, wear resistance, and corrosion performance of brazed coatings, providing an effective method for localized repair while minimizing material consumption and processing duration.

Perovskite‐based oxides are promising electrocatalysts for the oxygen evolution reaction due to their flexible composition, tunable electronic structure, and robust nature. However, their activity and durability in proton exchange membrane (PEM)–relevant acidic conditions are not fully understood, limiting their use in water electrolyzers. This review critically discusses recent advances in perovskite‐based electrocatalysts, covering design, synthesis strategies, morphological engineering, reaction mechanisms, and degradation pathways. Fundamental design principles based on A‐/B‐site engineering, defect chemistry, metal–oxygen covalency, active‐site optimization, and controlled surface reconstruction are discussed together with emerging oxide pathway mechanisms. Particular emphasis is placed on bridging fundamental electrochemical studies with practical implementation through membrane electrode assembly design, catalyst‐layer optimization, in situ evaluation, and realistic performance benchmarking. Finally, current challenges associated with standardization, scalability, and industrial implementation are highlighted, and future research directions for developing durable, low‐PGM perovskite electrocatalysts for PEM water electrolysis are outlined.