Aluminium layers were coated onto the surface of pure titanium using hot-dip aluminising technology, and then the aluminium layers were in situ oxidised to form oxide ceramic coatings, using the micro-arc oxidation (MAO) technique. The microstructure and composition distribution of the hot-dip aluminium coatings and ceramic layers were studied by using scanning electron microscopy and energy-dispersive X-ray spectroscopy. The phase structure of the MAO layers was studied using X-ray diffraction. The surface composition of the MAO layer was studied by X-ray photoelectron spectroscopy. The wear resistance of the pure titanium substrate and the ceramic layers coated on its surface were evaluated by using the ball-on-disc wear method. Therefore, aluminising coatings, which consist of a diffusion layer and a pure aluminium layer, could be formed on pure titanium substrates using the hot-dip aluminising method. The MAO method enabled the in-situ oxidation of hot-dip pure aluminium layers, which subsequently led to the formation of ceramic layers. Moreover, the wear resistance values of the ceramic layers were significantly higher than that of the pure titanium substrate.

Cr coatings with a thickness of about 19 μm were synthesized on Zr-4 cladding using plasma-enhanced arc ion plating. A Zr-Cr micro-diffusion layer was formed via Cr ion cleaning before deposition to enhance the interface bonding strength. Cr coatings exhibit an obvious columnar crystal structure with an average grain size of 1.26 μm using SEM (scanning electron microscopy) and EBSD (electron backscatter diffraction) with a small amount of nanoscale pores on the surface. A long-term aqueous test at 420 ± 3 °C, 10.3 ± 0.7 MPa and isothermal oxidation tests at 900~1300 °C in air were conducted to evaluate the Cr-coated Zr-4 cladding. All the results showed that the Cr coatings had a significant protective effect to the Zr-4 alloy. However, the corrosion deterioration mechanism is different. A gradual thinning of the Cr coating was observed in a long-term aqueous test, but a cyclic corrosion mechanism of void initiation–propagation–cracking at the oxide film interface is the main corrosion characteristic of the Cr coating in isothermal oxidation. Different corrosion models are constructed to explain the corrosion mechanism.