The development of emerging high-tech technologies comes with a growing demand for composite materials with outstanding mechanical properties and wear resistance. Herein, we fabricated organic-inorganic self-stratifying gradient coatings based on silicon density by chemically bonding octa- and mono-amino polyhedral oligomeric silsesquioxane (POSS) onto the polyimide (PI) resin. The microstructure and chemical characteristics of POSS-PI-based composite coatings were investigated. The enhancements to the mechanical properties and wear resistance of the PI-based composites due to the gradient structure were also investigated. As expected, the addition of POSS significantly increased the composites’ thermal stability and mechanical properties. In particular, the tensile strength and nano-indentation hardness of the 4 wt.% POSS-PI composites were enhanced by 28.6% and 68.4%, respectively. Furthermore, compared with that of pure PI, the wear rate of the POSS-PI self-stratifying coatings decreased by 78.9%, which was due to the enhanced cross-linking density and gradient structure that resulted from the self-stratifying of POSS.

Prior to the laser processing, the surface of the TiC-reinforced particles underwent a metallization process with Ni-P, with the objective of enhancing the wettability between the TiC and the Ti6Al4V, thereby ensuring enhanced wear resistance of the titanium-based composite (TMC) coatings. In this study, the chemical deposition method was utilized to synthesize three types of metallized TiC with varying phosphorus contents. The P contents of these samples were determined to be 9.12 wt.% (HP metallized TiC), 6.55 wt.% (MP metallized TiC), and 1.71 wt.% (LP metallized TiC). It was observed that the thickness of the coatings increased in a gradual manner with the decrease in P. Furthermore, the coating of the LP metallized TiC was found to possess the highest degree of crystallinity and a microcrystalline structure. The 50 wt.% TiC-Ti6Al4V composite coatings (TMC-Nickel-free, TMC-HP, TMC-MP, and TMC-LP) were produced by laser fusion deposition using untreated TiC and three metallized TiC enhancements. The findings indicate that TMC-LP exhibits cracking only during the initial processing stage. Surface metallization has been shown to enhance the wear resistance of composite coatings through several mechanisms, including increased bonding of the ceramic phase to the metal matrix and the formation of hard Ti₂Ni compounds. The wear rates of TMC-HP, TMC-MP, and TMC-LP were reduced by 22%, 43%, and 72%, respectively, in comparison to TMC-Nickel-free.

The irradiation of atomic oxygen (AO) severely restricts the application of polymeric lubricating coatings in low Earth orbit (LEO). Herein, octa- and mono-amino polyhedral oligomeric silsesquioxanes (POSSs) were chemically bonded onto polyimide/molybdenum disulfide (PI/MoS₂) composite coatings with a gradient structure based on Si density. The gradient coatings presented better wear resistance under different loads; notably, the wear rate decreased by 83.5%. Additionally, the effects of AO exposure on the surface morphologies, chemical structure, and tribological properties of the gradient coatings were investigated in detail. The results indicated that the mass loss and wear rates under AO irradiation decreased significantly, which can be attributed to the passivated network-like SiO₂ layer that covered the coating surface after AO irradiation. As a result, the addition of POSS significantly improved the tribological properties and AO resistance.