Protective coatings are the most widely used corrosion protection method for construction materials in different environmental conditions. They isolate metals from aggressive media, making the structure more durable. Today, alongside good anti-corrosive properties, coatings need to be safe for the environment and harmless to those who apply them. The high volatile organic compound (VOC) content in conventional solvent-borne coatings presents a huge ecological problem. A solution for indispensable solvent emission reduction is the application of powder coatings. This study evaluates the corrosion performance and surface morphology of polyester and epoxy–polyester powder coatings. Electrochemical impedance spectroscopy (EIS), open circuit potential (OCP) measurement, salt spray chamber and humidity chamber testing followed by adhesion testing were used to investigate the protective properties of powder coatings. Scanning electron microscope (SEM) with energy-dispersive X-ray spectroscopy (EDX) was used to analyse the surface morphology and chemical composition, whereas the microstructure and coating uniformity were determined by optical microscope examination. The research revealed a negative influence of coating surface texture on coating thickness and consequently a lack of barrier and adhesion properties. The epoxy–polyester powder coating showed a better performance than the polyester coating. All tested coatings showed uniform structure.

This review paper provides a comprehensive overview of selected 3D surface texture parameters defined by ISO 25178-2, with a focus on their metrological aspects in high-resolution measurements using atomic force microscopy (AFM). The parameters Sa, Sz, Sq, Sdq, and Sdr are analyzed in terms of their practical application, sensitivity to measurement conditions, and role in assessing surface functionality. Through a review of the literature and simulations of surface profiles with controlled geometric variations, the study demonstrates how the selected parameters respond to changes in step pitch, step width, slope, and lateral calibration errors. Experimental AFM measurements performed on a certified step height standard further illustrate the impact of calibration on the quality of measurement results. Special emphasis is placed on the importance of evaluating measurement uncertainty. The results confirm the need for rigorous instrument calibration and uncertainty assessment to ensure reliable and comparable surface characterization across different instruments and laboratories.

During exploitation, the properties of the epoxy coating deteriorate and therefore, it is necessary to modify it with metal particles. In this paper, spherical aluminium nanoparticles (Al NP) of 100 nm with 99.9% purity were used to modify the epoxy coating for the better corrosion protection of grey cast iron. Pure Al has a high corrosion resistance and can form a thin protective film that prevents its further oxidation, thus, becoming inert and environmentally friendly. To examine these facts, different concentrations (0.5, 0.75, 1.0, 3.0, and 6.0 wt.%) of Al nanoparticles were dispersed in the epoxy coating. The surface of the modified nanocomposite coating was analysed using scanning electron microscopy (SEM) and energy dispersive spectrometry (EDS). Furthermore, the physical properties such as colour, thickness, hardness, and adhesion to the cast iron surface were tested as well. The same properties were tested by exposing the sample plates to corrosive conditions in the climate chamber. Their anticorrosion properties were investigated using electrochemical impedance spectroscopy (EIS) by their immersion in 3.5 wt.% NaCl solution as a corrosive medium. The coating with 0.75% Al NP showed the best corrosion resistance after 10 days of exposure in salt water, while the sample with 1.0% Al NP showed the best corrosion resistance after exposure to the icing/deicing process.

The paper investigates the effects of DC plasma nitriding on surface roughness, hardness, microstructure, micro-abrasion, and corrosion resistance of AISI 316L Austenitic Stainless (AS) steel. The nitriding has been conducted for durations ranging from 4 to 24 h at a temperature of 430 °C in a commercial vacuum furnace, Rübig PN90/70. Micro-abrasion resistance has been tested using the calotest device with a measurement diameter of craters produced on the sample surface after 10 to 60 s of wear. Corrosion resistance has been tested using the Electroimpedance Spectroscopy (EIS) method in a 3.5% NaCl water solution. The surface roughness parameters and hardness of the samples increased with longer nitriding times, attributed to the saturation of austenite and the formation of iron and chromium nitrides. Nitriding for longer than 8 h resulted in the formation of a thicker compound layer that is hard and brittle, leading to reduced wear resistance compared with shorter nitriding times. EIS measurements revealed that nitrided samples had lower corrosion resistance compared with the untreated sample. The corrosion stability was not significantly affected by nitriding time. Different nitriding times have a great influence on resistance to pitting corrosion. This study provides valuable insights into the effects of plasma nitriding on the properties of AS steel, highlighting the importance of optimizing nitriding parameters for specific applications.

Increasing attention is given to waterborne coatings for corrosion protection due to the lower ecological impact on the environment. It has been found that by using waterborne coatings, the emission of harmful volatile organic compounds (VOCs) is reduced by more than 50 g/L. However, they require longer drying time, their anti-corrosion performance is not as good as solvent-borne coatings and they still have not been developed for all corrosion environments. Another way to reduce VOCs is by using infrared (IR) drying technology. With catalytic infrared radiation, it is possible to cure all surfaces at notably reduced costs compared to traditional systems and in total respect for the environment, thanks to significant energy savings and minimal CO₂ emissions. The aim of this paper was to evaluate corrosion protective properties of waterborne coatings which were dried with traditional and accelerated drying techniques, i.e., under atmospheric conditions and by using IR technology. Two different coating systems were applied, with and without Zn in the primer. To achieve this goal, the test samples were subjected to electrochemical, corrosion, and physical tests. It was shown that infrared technology does not affect the quality of the coating and it drastically reduces the intercoating interval. A coating system with zinc in the primer showed better overall protection properties after being subjected to impedance and salt spray testing, but generally, solvent-borne coatings still have higher durability than waterborne in extreme marine conditions according to recent research. Microstructure and porosity remained intact and the atomic force microscope confirmed that the flash-off was conducted correctly since there were no pinholes and blisters detected on the coating’s surface. This study can serve as a foundation for further investigations of IC-dried waterborne coatings because there are not many at the moment.