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Ni-based alloys are among the materials of choice in developing high-quality coatings for ambient and high temperature applications that require protection against intense wear and corrosion. The current study aims to develop and characterize NiCrBSi coatings with high wear resistance and improved adhesion to the substrate. Starting with nickel-based feedstock powders, thermally sprayed coatings were initially fabricated. Prior to deposition, the powders were characterized in terms of microstructure, particle size, chemical composition, flowability, and density. For comparison, three types of powders with different chemical compositions and characteristics were deposited onto a 1.7227 tempered steel substrate using oxyacetylene flame spraying, and subsequently, the coatings were inductively remelted. Ball-on-disc sliding wear testing was chosen to investigate the tribological properties of both the as-sprayed and induction-remelted coatings. The results reveal that, in the case of as-sprayed coatings, the main wear mechanisms were abrasive, independent of powder chemical composition, and correlated with intense wear losses due to the poor intersplat cohesion typical of flame-sprayed coatings. The remelting treatment improved the performance of the coatings in terms of wear compared to that of the as-sprayed ones, and the density and lower porosity achieved during the induction post-treatment had a significant positive role in this behavior.
Femtosecond laser-induced nano structuring offers a novel approach to enhance the performance of porous transport layers (PTLs) in anion-exchange membrane water electrolysis. By applying ultrashort laser pulses to nickel felts, distinct surface morphologies were generated, including high-spatial-frequency laser-induced periodic surface structures (HSFL-LIPSS), irregular ablated surfaces, and hybrid structures. Surface area analysis revealed increases of up to 4-fold for LIPSS, 6-fold for hybrid structures (LIPSS+Ablation), and 9-fold for ablated surfaces compared to untreated fibers. Electrochemical testing showed reduced overpotentials for laser-treated samples, comparable to state-of-the-art electrodes despite the absence of catalyst layers. Overpotentials could be reduced by up to 6.5 % at 10 mA cm−2 and by up to 9.6 % at 100 mA cm−2 compared to the unprocessed felt. Notably, ablated structures, with the highest surface areas, exhibited microcavities that may entrap oxygen bubbles, limiting active site and reaction rates. The LIPSS structures demonstrated the lowest activation losses and highest current density (1.32 A cm⁻² at 2.0 V) due to their periodic morphology and enhanced electrolyte flow, representing a 17 % improvement at 2.0 V compared to the untreated felts. Moreover, Tafel slopes down to 66 mV dec−1 denote a performant kinetic while oxidation charge measurements revealed pronounced peaks for laser-treated samples, with ablated surfaces achieving the highest charge of 16.76 ± 1.64 C cm⁻². Chronopotentiometry revealed the LIPSS structures showing the highest resistance to degradation among the structured samples.
These findings suggest femtosecond laser nano structuring as a promising method to improve PTL performance. Further application of catalyst layers could amplify the electrochemical efficiency of these advanced materials.
The present paper presents one- and two-step approaches for electrochemical Pt and Ir deposition on a porous Ti-substrate to obtain a bifunctional oxygen electrode. Surface pre-treatment of the fiber-based Ti-substrate with oxalic acid provides an alternative to plasma treatment for partially stripping TiO2 from the electrode surface and roughening the topography. Electrochemical catalyst deposition performed directly onto the pretreated Ti-substrates bypasses unnecessary preparation and processing of catalyst support structures. A single Pt constant potential deposition (CPD), directly followed by pulsed electrodeposition (PED), created nanosized noble agglomerates. Subsequently, Ir was deposited via PED onto the Pt sub-structure to obtain a successively deposited PtIr catalyst layer. For the co-deposition of PtIr, a binary PtIr-alloy electrolyte was used applying PED. Micrographically, areal micro- and nano-scaled Pt sub-structure were observed, supplemented by homogenously distributed, nanosized Ir agglomerates for the successive PtIr deposition. In contrast, the PtIr co-deposition led to spherical, nanosized PtIr agglomerates. The electrochemical ORR and OER activity showed increased hydrogen desorption peaks for the Pt-deposited substrate, as well as broadening and flattening of the hydrogen desorption peaks for PtIr deposited substrates. The anodic kinetic parameters for the prepared electrodes were found to be higher than those of a polished Ir-disc.
Since high costs restrict the wide-range implementation of green hydrogen production capacities based on proton exchange membrane water electrolysis (PEMWE), efforts on cost reduced components need to be made. Beside the necessary noble metal catalyst, the membrane material is a main cost driver. In this work, a novel glass fibre reinforced PFSA/ssPS composite membrane is investigated as an alternative to widely used Nafion®. These membranes are processed into membrane-electrode-assemblies (MEAs) in conjunction with catalyst-coated substrates, prepared via electrochemical catalyst deposition. This approach is promising to reduce costs due to less expensive raw materials and due to increasing catalyst utilization by graded catalyst layers. Characterisation of the components and entire MEAs was performed ex-situ as well as in-situ via PEMWE operation.
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.
Tape brazing constitutes a cost-effective alternative surface protection technology for complex-shaped surfaces. The study explores the characteristics of high-temperature brazed coatings using a cobalt-based powder deposited on a stainless-steel substrate in order to protect parts subjected to hot temperatures in a wear-exposed environment. Microstructural imaging corroborated with x-ray diffraction analysis showed a complex phased structure consisting of intermetallic Cr-Ni, C-Co-W Laves type, and chromium carbide phases. The surface properties of the coatings, targeting hot corrosion behavior, erosion, wear resistance, and microhardness, were evaluated. The high-temperature corrosion test was performed for 100 h at 750 C in a salt mixture consisting of 25 wt.% NaCl + 75 wt.% Na2SO4. The degree of corrosion attack was closely connected with the exposure temperature, and the degradation of the material corresponding to the mechanisms of low-temperature hot corrosion. The erosion tests were carried out using alumina particles at a 90 impingement angle. The results, correlated with the microhardness measurements, have shown that Co-based coatings exhibited approximately 40% lower material loss compared to that of the steel substrate.
The study introduces flexible and scalable manufacturing approach for electrodes utilizing boron-doped silicon as conductive support for iridium nanoparticles, addressing the challenges of cost and scarcity associated with noble catalysts for oxygen evolution reaction (OER). Colloidal Ir nanoparticles are synthesized via pulsed-laser ablation (≈4–7 nm) and decorated on B-doped Si (≈100 nm) through electrostatic adsorption. Titanium substrates are ultrasonically sprayed with Si:B – Ir and Ir nanoparticles with very low iridium loading of 12 wt.%. Crystalline Ir phases (Ir(111), Ir(200)) are observed and known to enhance the OER mechanism. Additionally, atom probe tomography confirms that the Si support particles contained 0.03-0.5 at.% of boron throughout the entire particle, while electrical permittivity and through-plane measurements reveal a positive impact of B-doped Si on the electrical conductivity of the nanocatalysts and of the ultralow-loaded catalyst coated Ti substrates (0.12 mgIr cm−2), respectively. Rotating disk electrode results show pronounced oxidation peaks for decorated Ir nanoparticles. The Si:B-Ir 4 nm catalyst exhibits the highest turnover frequency (2.62 s−1) and a competitive electrochemical surface area (25 m2 gIr−1) compared to Si:B-Ir 7 nm (0.96 s−1; 37.5 m2 gIr−1) and Ir black (0.24 s−1; 5 m2 gIr−1). The overall analysis of the parameters highlights a performant catalytic efficiency, through balancing activity and reaction kinetics effectively.
Electrodeposited Mo-rich NiMo catalysts offer enhanced catalytic activity for the alkaline hydrogen evolution reaction (HER) and provide an electrically conductive, binder-free substrate connection, making them promising catalysts for green hydrogen production. However, creating Mo-rich deposits is challenging, as the codeposition process typically favors Ni. Optimal deposition conditions for Mo-rich NiMo catalysts remain insufficiently explored. This article investigates Mo-rich NiMo electrodeposition from an ammonia-free citrate bath using NaSO4 as a chlorine-free support electrolyte. The effects of the deposition parameters, 1) sodium molybdate concentration in the electrolyte, 2) deposition current density, and 3) enhanced mass transport via working electrode rotation on the alkaline HER activity, were studied. The electrodeposits, containing 44–66 wt% Mo, exhibited increased surface area due to a rough, cracked morphology and variable oxygen content of the catalyst. The oxygen content was linked to HER activity, revealing an inhibiting effect. The lowest overpotential of 118 mV at −10 mA cm−2 for the alkaline HER was achieved using an electrolyte with 0.02 mol L−1 sodium molybdate, a deposition current density of 600 mA cm−2, without electrode rotation. Respective samples combined a favorable Ni:Mo ratio comprising 56 wt% Mo content with increased surface area and low oxygen content.
