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Coatings
✓ Coating can be defined as a layer of material, formed naturally or deposited

Coatings
artificially on the surface of an object made of another material.
✓ The coating has a laminar structure. Figure, shows the single layer and multi-
layer coatings as examples.
✓ Between the coating and the
substrate there exists an
interface with intermediate

Kagzi Shakil A.
properties, which facilitates
adherence of the coating to the
substrate.
1 2

Coatings Coatings

✓ In the case of some coatings this layer bears the name as intermediate layer.
✓ In some cases it difficult to distinguish between the coating and intermediate
layer.
✓ Generally coatings are done to provide different characteristics to the surface
of the components as compared to the material of the component.
✓ These characteristics may be in terms of:
○ lowering friction,
Types of coating
○ increase in corrosion resistance,
○ Increase in heat resistance, ✓ The single layer coating (single coating, monolaminar) is a coating deposited
○ anti-wear, anti-reflection or on an appropriately prepared substrate in one process.
○ to have shiny appearance to have an aesthetic look. 3 ✓ It may consist of single material such as Cr or alloy such as Ti3CN, Ti3AlN. 4

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Coatings Coatings
Types of coating Types of coating

✓ The multilayer coating may consist of layers of the same material, ✓ The external chromium layer gives the coating a shiny appearance and does
separated by a sublayer, or they may be of different materials. not tarnish. The internal nickel layer binds it to the substrate.
✓ The aim of applying multi-layer ✓ Products made from steel and zinc
coatings is the intensification alloys are sometimes coated with
of the protective or decorative three layer coatings of copper-nickel-
or other function. chromium or four layer coatings of
✓ Double-layer nickel-chrome, nickel-chromium- nickel-chromium
electroplated coating applied with a particularly high corrosion
on automotive and motorcycle resistance.
components. 5
✓ Anti-wear, heat resistant, anti reflection coating may include several layers. 6

Coatings Coatings based on materials

Modification in multilayer coating:
✓ Coatings may be divided in two groups: (1) metallic and (2) non-metallic coatings.
✓ Multiple coating - comprising two or more layers of the same material,
deposited in technological environments so that their physico-chemical Metallic coatings –
properties differ slightly. Eg. multilayer of Nickel coating from different bath ✓ Such coatings are made from different metals, metal alloys and metal composites,
✓ Sandwiched coating - comprising several layers of different materials, with at and deposited on substrates.
least one of them occurring twice and not directly on top of same material, ✓ Coating metals: zinc, nickel, chromium, aluminum, tin, cadmium, copper, lead,
e.g., Ni-Cr-Ni-Cr silver, gold, iron, cobalt, indium, ruthenium, rhodium, palladium, and platinum.
✓ Self - stratifying paint - deposited in the form of a liquid (or powder) mixture, ✓ Often, refractory metals are also used, such as titanium, zirconium, hafnium,
stratifying during drying (or melting) into a bottom sublayer with strong Vanadium, niobium, tantalum, molybdenum and tungsten.
adhesion to substrate which is usually metallic. ✓ Metallic coatings are usually deposited on expensive, precision components, rather
✓ Its top sublayer (surface), may have high resistance to environmental hazards. small in size, which may also be exposed to mechanical hazards in service
7
conditions. 8

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Coatings based on materials Non-Metallic coating

✓ Coatings may be divided in two groups: (1) metallic and (2) non-metallic coatings. Paint:

Non-metallic coatings: ✓ It consist of a binder as a major constituent and colour pigment. Binder holds the
pigment inside the solution.
✓ These coatings are made from organic materials (paint, rubber, plastic) and ✓ They are mostly deposited in liquid phase which solidifies after drying.
inorganic (enamels, ceramics). It may be of natural and synthetic origin. ✓ Typical pigments are titanium white, chrome yellow, minium, graphite, etc.,
✓ Most often used coating materials (or their basic constituents) are: ✓ Depending on the binder used, we distinguish the following types of paints: oil,
○ Paint cellulose, emulsion, latex, limewash, silicate, thixotropic, ceramic etc.
○ Varnish
○ Resins Varnish:
○ Cement ✓ They are the substances which can produce a film (filmogenic).
○ Asphalts ✓ They may be prepared from natural or synthetic resins or esters of cellulose and
9 10
organic solvents

Coatings based on materials Coatings based on materials

Non-metallic coatings:
Non-metallic coatings:
Resins:
Varnish (contd..):
✓ They are amorphous organic substances of different chemical composition.
✓ It also often contains:
✓ They may be semi-liquid to vitreous, not soluble in water, soluble in organic
○ Pigments, plasticizers (softeners used for high polymer substances to ensure
solvents or totally insoluble and non-melting.
their workability) and
✓ It may be of two types (1) Natural and (2) Synthetic resins
○ Siccatives (quick dryers - chemical compounds accelerating the drying of
✓ Natural resins - collected mainly from living plants (contemporary), less often
varnish, e.g., naphthanates, cobalt and calcium).
effluents from living plants which found their way into the soil (young fossils) or
✓ After being deposited in thin layers on surfaces, they form closely adhered coating
from extinct plants (old fossils)
film on the surface.
✓ Synthetic resins - surrogates of natural resins for varnishing (malein resins) or
✓ Best known and broadly used are varnishes such as asphalt, oil-asphalt, oil-resin,
vitreous and dense products of polycreation (acrylic, polystyrene, phenol,
nitrocellulose, zapon, etc. 11 12
polyester and epoxy resins).

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Coatings based on materials Coatings

Non-metallic coatings: ✓ Other coatings:
✓ Lubricants:
✓ Cement: ○ Solid Lubricants:
✓ It is the binder, obtained synthetically from various materials. The following types ○ They are of solid or semi-solid (semi-liquid) consistence, comprise the
of cements used in surface engineering: lubricant oil and a densifier.
○ Acid and alkali-resistant organic cements (with a natural resin base), ○ Different synthetic and natural oils are used. Thickeners are mainly barium,
○ Acid and alkali-resistant bituminous and tar cements (in which the binder is lithium, aluminum, sodium, and strontium and calcium soaps.
constituted by high boiling point fractions of distillation of gas pitch and ○ Lubricants with organic thickeners are most often used for corrosion
petroleum) protection.
○ Acid-resistant litharge-glycerin (PbO litharge + glycerin) ○ Sometimes additives are also used, e.g., oxidation inhibitors, corrosion
✓ Asphalt: inhibitors, additives enhancing the stability of the film and resistance to high
○ It is mixture of higher molecular hydrocarbon, generally used for sealing loads.
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pipelines.

Coatings Coatings
✓ Other coatings: ✓ Other coatings:
✓ Lubricants: ✓ Lubricants:
○ Protective lubricant: ○ Metal ceramics:
○ They (including anti-corrosion) are usually solid, less often semi-liquid. ○ These materials are obtained by the combination, of ceramic with metals.
○ They serve to protect metallic surfaces from corrosion, including electro- ○ As binding metals, usually applied are iron, chromium, nickel, tantalum,
chemical corrosion during storage and transport. titanium, aluminum, etc. in the amounts of 10% to 30%.
○ It provides partial insulation of the metal surface from the aggressive ○ The ceramic components are usually oxides, carbides, borides, nitrides,
environment (they block the passage of vapors, moisture and gases) and silicides and sulfides.
reduction of wettability of the metal by water. ○ Surface engineering uses materials in the form of thermally sprayed powder,
○ They also exhibit antifriction properties. or metal and nonmetal compounds, deposited in vacuum.
○ They are prepared from oils and from petrolatum paraffin and ceresines. ○ In many friction applications where high strength, corrosion resistance and
○ In many cases, additives enhancing certain properties are added to protective
15
refractoriness should be combined with good tribological properties. 16
lubricants.

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Coatings Application of Coatings

✓ Other coatings: ✓ From the point of view of application, coatings can be divided into four groups:
✓ Lubricants: ○ Protective,
○ Rubbers: ○ Decorative,
○ It are products of vulcanization (curing - the process of hot transformation of ○ Decorative-protective and

rubber with an appropriate amount of sulfur and accelerants). ○ Technical.

○ Rubbers are characterized by good anti-corrosion properties, sunlight Protective coatings

resistance, as well as resistance to temperature and atmospheric effects.
○ In surface engineering, rubber is used mainly as acid-resistant lining of ✓ Protective coatings are those coatings whose task is exclusively protection of the
reservoirs, pipelines, etc. object from the harmful effect of the environment,
✓ These environment consist of mainly the corrosive atmosphere and chemicals, as
well as from mechanical hazards.
✓ Types based on service life: Temporary and permanent coating
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✓ Types based on electrochemical reaction: Cathodic and anodic coating.

Application of Coatings Application of Coatings

Protective coatings Protective coatings

✓ Includes temporary coating serving protection during transport/storage/ ✓ Some of the coating is performed by electro chemical interaction between the
sometime during service condition. substrate and coating material.
✓ This temporary coating gets removed by stripping, grinding or washing off. ✓ Both substrate and coating in this case must be metallic.
✓ Their composition is based on e.g., oils, greases, asphalts, waxes, some varnishes ✓ Protective coating is divided into Anodic coatings and Cathodic coatings.
and some plastics. ✓ In anodic coating:
✓ The Permanent protection coating serve to secure the surfaces of products during ○ Due to mechanical damage of the coating
service. ○ Or due to the presence of porosity
✓ These are the majority of metallic coatings and many paints, varnishes and
Substrate metal will act as cathode. An electrochemical cell is generated in the
enamels, metal ceramic, ceramic, rubber and latex.
presence of an electrolyte. This causes the coating metal to be corroded and
✓ Coating besides being strong it must adhere tightly to the substrate, has no
19 substrate will not be subjected to corrosion. (eg. Galvanised Zn on SS) 20
cracks, pores and delaminations, scratches and other flaws.

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Application of Coatings Application of Coatings

Protective coatings Protective coatings

✓ Cathodic coatings are made of a metal whose electrode potential in given ✓ As soon as the substrate metal is exposed a galvanic cell is formed in the presence
environmental conditions is more electropositive than the potential of the of an electrolyte.
substrate metal. ✓ The coating metal forms the cathode, and the substrate forms the anode.
✓ That is it is made of a nobler metal than that of the substrate. More nobler means ✓ In consequence, the electrochemical reaction causes an intensified corrosion
more corrosion resistant than substrate. process.
✓ Consequently, they protect the substrate metal only when they are totally tight ✓ Examples of cathodic coatings are nickel, copper, silver, lead, tin, and gold plating
21 22
(without porosity cracks, flaking, spalling and scratches). on iron and steel. Some of the anodic coatings are aluminium and aluminium alloy.

Application of Coatings Application of Coatings

Protective coatings Decorative coatings

✓ Paint coatings effectively protect the metallic substrate only when they are multi- ✓ This depends on color, luster and resistance to tarnishing and also, perhaps,
layered. surface finish of the coating (hammer finish, webbling, crystal), as well as shine
✓ Typical are 4-layered coatings: primer, surfacer, enamel, varnish. properties (fluorescence, phosphorescence, radioactivity).
✓ The anti-corrosion function is fulfilled mainly by the primers, pigmented by ✓ Decorative coatings may be both metallic and non-metallic.
elements with rustproof action, e.g., lead minimum, zinc yellow and zinc dust. ✓ Among metals used in the manufacture of decorative coatings are chromium,
✓ Good protective properties are also exhibited by nonmetal ceramic, plastic, enamel gold, rhodium, palladium and platinum.
and cement coatings, the last especially in strongly corrosive environments. ✓ Among non-metallic coatings, paints are the most broadly used. Almost all paint
coatings have decorative functions.
Decorative coatings ✓ Usually, the natural environment penetrates easier to the substrate metal
✓ Decorative coatings, once called ornamental, serve predominantly to give the metal through a thin layer (through pores, leaks and other flaws), but protection is not
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or non-metal object an aesthetic external appearance. the main function of the decorative coating.

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Application of Coatings Application of Coatings

Decorative coatings Protective-Decorative coatings

✓ Such coatings are designed to be used in gentler conditions than their protective ✓ Corrosion protection is assured by sandwiched layers of nickel or copper and
counterparts. Thin layer of coatings are provided. nickel or brass and nickel.
✓ Nickel is used for the protection of steel, copper and zinc substrates.
Protective-Decorative coatings
✓ External chrome coating of 0.25μm to 1.5μm in multilayer coating, protects the
✓ Such coatings are designed to be used in gentler conditions than their protective underlying layers against tarnishing, enhances wear resistance and makes the
counterparts. Thin layer of coatings are provided. coating tighter.
✓ It serves both to protect the object against corrosion and light mechanical ✓ A gold coating of 25 to 30 μm thickness insulates copper alloys well from
damage, and to give the surface an aesthetic appearance. aggressive atmospheric effects.
✓ Regarding electrolytic coatings, the protective-decorative role is fulfilled by
nickel, chrome, and copper-nickel-chrome coatings on condition that they are
25 26
sufficiently thick (greater than 25 μm).

Application of Coatings Application of Coatings

Technical coatings Technical coatings

✓ The technical coatings serve to give the object certain physical properties: ✓ Most frequently, as resistance coatings wear, hard chrome-plated layers of 10 to
mechanical, electrical and thermal. 30 μm thickness are used.
✓ For high sliding velocities and high unit loads, electroplated silver or indium
a. Coatings with enhance tribological properties
coatings of 500 to 1500 μm, as well as porous chrome coatings, are used.
✓ In the majority of cases better tribological properties are exhibited by harder ✓ Among non-metallic coatings, very high hardness and excellent tribological
than by softer metal coatings. properties are exhibited by nitride, oxide, and carbide and boride coatings,
✓ The hardness of electroplated coatings ranges from the hardness of lead to that deposited in vacuum by PVD and CVD techniques.
of rhodium.
b. Coatings with enhance electrical properties
✓ Moreover, hardness may also differ for coatings of the same material, depending
on both composition and conditions of deposition. ✓ These coatings serve first and foremost to enhance electrical conductivity of
27 28
terminals and are used in electrical and electronics applications.

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Application of Coatings Application of Coatings

Technical coatings Technical coatings

b. Coatings with enhance electrical properties c. Technological coatings

✓ Since very good electrical conductivity is exhibited by silver, very often silver ✓ It may also protect the product against diffusion by undesired elements.
coatings are deposited on copper, brass and bronze substrates with the thickness ✓ The tin and copper coatings, as well as alloys: tin-zinc or zinc-lead, enhanced the
of 12μm or greater in moisture condition or under sliding contacts. solderability of joined surfaces.
✓ Sometimes a very thin (0.2 to 1 μm) electrodeposited layers of gold, silver, ✓ The thickness of tin coatings is 5 to 15 μm, which insignificantly oxidize and
rhodium or indium are used. therefore require the use of fluxes.
✓ Alloy coatings composed of 70% tin and 30% zinc. they are well suited for
c. Technological coatings
soldering and for service in tropical climates.
✓ These coatings serve to enhance different properties of semi-finished products
during the execution of the technological process of manufacture. 29 30

Application of Coatings Application of Coatings

Technical coatings Technical coatings

c. Technological coatings d. Corrective coatings

✓ To protecting against diffusion of carbon, nitrogen, the two elements together ✓ Such coatings are used to re-create the initial dimensions or shape of a
and other elements in thermochemical treatment operations, coatings are component partially worn in the course of service.
applied as electroplated or in the form of pastes. ✓ Various metal and alloy coatings, thermally sprayed or applied by welding and
✓ They fulfill the role of a blockade, stopping the passage of a given element to a laser beam techniques.
given (coated) fragment of the component which is subjected to thermochemical ✓ In the case of re-creation of dimensions, especially when close tolerances are
treatment. required, the coatings applied are electroplated
✓ Electroplated coatings are usually copper or tin, as well as alloys of copper and ✓ Iron, chrome and nickel are used for the regeneration of steel components.
tin with a thickness of up to 25 μm.
✓ This paste coatings may reach thicknesses of over 1 mm. 31 32

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Application of Coatings Application of Coatings

Technical coatings Technical coatings

e. Catalytic coatings e. Catalytic coatings

✓ These coatings serve to change the rate of reaction in the gaseous environment ✓ These coatings serve various purposes, such as to reduce the content of carbon
with which it is in contact. monoxide or nitrides in gas and carbonaceous exhausts emitted to the
✓ It also sometimes used to raise or lower the temperature at which the reactions atmosphere.
occur.
f. Coating that enhance the thermo-physical coatings
✓ Since a large area of contact between the coating and the surrounding gas is
required, the real surface should be developed as much as possible by sprayed ✓ These coatings are applied in order to enhance resistance to:
coatings. ○ The effect of elevated temperatures,
✓ The coating material may be metallic or metal ceramic (mixtures of oxides of ○ Emissivity
cerium, copper, manganese, aluminum, nickel, cobalt, lanthanum, neodymium, 33 ○ Thermal conductivity properties etc. 34

etc.)

Classification based on methods for coatings Classification based on methods for coatings
a. Galvanizing Classification based on methods for coatings

✓ Coatings of this type are deposited directly from a galvanic bath or with the a. Galvanizing
application of an external source of electric current.
Electroplated (electrolitic) coatings:
✓ The following groups of coatings belong to this category:
✓ Alternating current allows the obtaining of superior technological results.
Electroplated (electrolitic) coatings:
✓ e.g., higher cathode current density, better penetration and good refinement of
✓ The electroplated coating is a metal coating applied in a process of electrolysis, the crystallized coating grains.
with the application of an external source of electric current. ✓ Here coating is deposited on objects immersed in an electrolyte tank.
✓ It is usually direct current. In some of the most recent applications, pulsed ✓ Plated objects connected with the negative pole of the current source constitute
alternating current may be used (Electropulse plating). the cathode.
✓ While the anode is formed by plates of the throwing metal which replenishes the
35 36
loss of that metal in the electrolyte, or by insoluble materials (lead, graphite).

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Classification based on methods for coatings Classification based on methods for coatings
Classification based on methods for coatings a. Galvanizing

a. Galvanizing Chemical coatings –

Electroplated (electrolitic) coatings: ✓ These are metal coatings obtained by way of chemical reaction, without the
participation of externally supplied electric current.
✓ In such cases, loss of metal in the electrolyte is replenished by the addition of
✓ Exchange of metal - the less noble metal (more electronegative) displaces the
appropriate salts.
nobler metals (more electropositive) from the solution.
✓ The vast majority of coatings is manufactured by this method; most frequently
✓ For example, a steel object immersed in a solution of copper sulphate is covered
zinc, nickel and chromium.
with copper, the process continuing only until the moment of covering the entire
object (i.e., moment when contact between bath and substrate ends).
✓ As a result, only very thin coatings (0.02 to 0.5 μm) are obtained. These are mainly
37 used as decorative but sometimes as technical coatings. 38

Classification based on methods for coatings Classification based on methods for coatings
b. Immersion coatings b. Immersion coatings

✓ Immersion coatings are obtained by immersion of the entire object or of its Hot dip coatings:
portion in a bath of the coating material.
✓ Before dipping the component in liquid bath, the object is degreased, sand blasted
✓ The coating material may be solid or liquid.
and covered with fluxes by immersion or spraying.
✓ If it is solid than it must be melted to form a bath which gets solidified on substrate
✓ The component is then dipped in the bath.
on cooling.
✓ Properties of hot dip coatings are decided by surface preparation, chemical
✓ The liquid gets dries out to form a film of the surface of substrate.
composition of the metallic material (purity and composition of alloy) and its
Hot dip coatings: temperature, time of soaking of the objects in the bath and by the substrate
material.
They are the coating in which solid coating material are melted in a pot or a tank
furnace, using the energy of gas burned in burners or electric energy.
39 40

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Classification based on methods for coatings Classification based on methods for coatings
b. Immersion coatings c. spray coatings

Gel coatings: ✓ The coating is done by depositing a layer of substance which is generated by
dispersion (usually with the aid of a spray gun) into tiny particles.
✓ These are manufactured in colloidal systems in the form of sol, transformed into
✓ This Tiny particles may be of powdered material applied with high kinetic energy.
gel (e.g., due to polycondensation) and next into a coating through e.g., firing.
✓ Owing to this energy, the particles, upon making contact with the sprayed surface,
Paint coatings: exert pressure which assures good adhesion of the coating to the substrate.
✓ Coating through spray under normal temperature condition comes under painting.
✓ The material is used is liquid (e.g., paints, varnishes) or pseudo-liquid (fluidized
✓ While coating is sprayed after heating to plastic or melting state is called thermal
beds, suspensions of powdered materials, e.g., plastics in fluidizing gas.
spraying.
✓ The painted coating has the form of a coherent, more or less hard, smooth, shiny
substance, adhering to the substrate after drying of the layer of filmogenic
material. 41 42

Classification based on methods for coatings Classification based on methods for coatings
c. spray coatings c. spray coatings

Smeared coatings: Pneumatically sprayed coatings:

✓ They are applied by the brush, roller or sponge. ✓ They are obtained with the use of compressed air, dispersing the coating material.
✓ The decorative quality of this painting is low. ✓ The pressure of the compressed air depends on material viscosity and on nozzle
diameter.
Flow coatings:
✓ The thickness of a single deposition is 10 to 30 μm.
✓ They are obtained by pouring paint, flowing from many nozzles (so-called multi-
Hydro-dynamically sprayed coatings:
stream flow) under low pressure, covering the contours of the painted object.
✓ Flow coatings are smoother than immersion coatings; their thickness is in the ✓ They are obtained without air, under pressure and are obtained by dispersion of
range of 12 to 32 μm. the paint material without contact with a stream of air.
43 44

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Classification based on methods for coatings Classification based on methods for coatings
c. spray coatings c. spray coatings

Hydro-dynamically sprayed coatings: Thermal spray coatings:

✓ The are obtained by sudden decompression of a stream of paint material, fed ✓ Resistance - when the coating material is melted in a resistance heated pot.
under high pressure (up to 25 MPa) and flowing at high velocity (even exceeding ✓ Arc - when the coating material is melted in a zone of arc discharges (in arc
100 m/s) through a small diameter nozzle. plasma) or when the material is passed through such a zone.
✓ Induction - when the powdered coating material is passed through a zone of
Thermal spray coatings:
induction plasma.
✓ Depending on the method of generating heat to melt or plastify the coating ✓ Plasma - when the coating material is melted in an electric arc strongly extended
material, the following types of coatings are distinguished: by the flow of plasmogenic gas or when the coating material is passed through the
✓ Through Flame - when the particles are heated by passing through a gas oxygen arc zone.
flame. 45 46

Nano coatings Nano coatings

✓ Nanocoatings are a type of nanocomposite. The layer thickness of a nanocoating is ✓ Nanocoatings are helpful in changing the properties of metal. Such coating are
usually 1–100 nm. called as “responsive coatings”.
✓ Nanocomposite films include -
○ Multilayer thin films (a), in which the phases are separated along the thickness Eg. To change the transmission of visible and IR radiation in glass.
of the film, To introduce new properties such as ‘self-cleaning’ effects.
○ Granular films (b), in which the different phases are distributed within each
plane of the film ✓ Responsive nanocoatings are those where the properties of the material in the
coating react to environmental conditions, such as light or heat, either in a passive
or an active way.
✓ These coatings allow the properties of some materials to change, such as glass, by
conferring new or improved properties.
47 48
a b

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Nano coatings Nano coatings

Responsive coatings (Contd..)- Responsive coatings (Contd..)-

✓ The use of glass is very common in modern buildings, since it allows the ✓ Low-e (low emissivity) coating consist of thin silver film, about 10 nm thick,
construction of transparent and seemingly lightweight structures. surrounded by dielectric layers.
✓ However, there is large heat transfer due to transmittance of visible and IR light. ✓ Metallic layers have been widely used to increase the reflectivity of light (and
✓ Heat also get dispersed easily from the glass in winter. reduce transmittance) for years, but they have the disadvantage of giving a
✓ In order to address these problems, various types of nanocoatings that modulate mirror-like appearance.
light transmission in glass are under investigation. ✓ Silver (Ag) loses its metallic appearance when scaled to a nano-film (10nm),
✓ The aim is to reduce indoor heating in summer, so less air conditioning is required thus eliminating this problem.
to keep the atmosphere cool, with consequent energy saving. ✓ Low-e coatings are a type of passive nanocoatings, since the properties of the
✓ One of the such coating is Low-e (low emissivity) coating. layers are undisturbed during its operation
49 50

Nano coatings Nano coatings

Responsive coatings (Contd..)- Responsive coatings (Contd..)-

✓ Another type of coating are smart or Dynamic coating, in which the properties ✓ Smart coatings can also change their optical properties due to a change of external
changes with the environmental condition (radiation, temperature, etc.). temperature (thermochromic) or light incidence (photochromic).
✓ When the effect is a change in the colour (including a change to transparency), ✓ Another example of smart coatings is a family of wavelength-selective films for
they are called chromogenic smart materials. manufacturing ‘heat mirrors’.
✓ In the case of electrochromic coatings, the application a small voltage induces a ✓ One of these materials is indium tin oxide (ITO), an infrared absorber.
change in transmittance. ✓ Indium oxide (In2O3) and tin oxide (SnO) are sputtered in an alternating mixing
✓ In the case of gaschromic coatings which change their transmittance in the ratio.
presence of specific gases. ✓ A 300 nm ITO coating on glass provides more than 80 % transmittance.
✓ This properties can be varied by changing the thickness and material composition
It uses tungsten oxide thin films (WO3) which go from colourless to blue in the
of the coating. So that a combination of materials could be used to produce smart
presence of hydrogen and a thin film of suitable catalyst on WO3 film. 51 52
windows that reflect solar energy in summer but transmit solar energy in winter.

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Nano coatings Nano coatings

Responsive coatings (Contd..)- Tribological coatings :

✓ ITO is transparent conducting material with low resistivity. ● These are those coatings that are applied to the surface of a component in order
✓ This property of ITO, makes it useful for smart screen in mobile phones, where to control its friction and wear.
glass is coated with ITO. ● Tribological coatings play a key role in the performance of the internal mechanical
✓ A range of sputter deposition techniques or electron beam evaporation is used components of a vehicle, such as the engine and powertrain.
often to deposit ITO. ● They are also key elements in cutting tools and machinery in general.
✓ Glass is poor conductor. When ITO is coated on glass, Capacitive touchscreens ● By reducing wear and friction, these coatings increase the lifetime of the working
develops. material
✓ Any touch command performed with a conductive object will cause the
capacitance to drop. The capacitive touchscreen will then respond with the
appropriate action.
53 54

Nano coatings Nano coatings

Tribological coatings (Contd..) - Tribological coatings (Contd..) -

✓ They also reduce the dissipation of energy as heat, thus increasing the efficiency of ✓ Thus, nanocomposite coatings are now being investigated as alternatives to the
the moving part. traditional approach of using specific alloying elements in single-phase coating
✓ In machinery and tools, tribological coatings can reduce (or eliminate) the need for materials to improve, for instance, properties such as hardness.
lubricants, increase cutting speed, increase the rate of material removal, reduce ✓ Multilayer coating offers more advantages than the single advantage in single
maintenance costs or reduce processing cycle times. traditional coating.
✓ Traditional materials used in coatings for tribological applications are carbides, ✓ This layers may be of WC/C, TiN/NbN, or TiAlN/CrN
cemented carbides, metal ceramic oxides, nitrides and carbon-based coatings.
✓ In nanomaterial properties are controlled by the microstructure.

Eg. mechanical properties (e.g. hardness), the chemical properties (e.g.

corrosion resistance) and the electrical properties can be improved. 55 56

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Nano coatings Nano coatings

Hydrophilic/Hydrophobic coatings - Hydrophilic/Hydrophobic coatings -

This characteristic depends on the surface ✓ If θw is less than 10°, the surface is
tensions (γsv, γsl, γsv) and contact angle (θ). considered as superhydrophilic, and the
water tends to spread over the surface.
It is defined by young’s equation - ✓ When the θw is equal to 0°It is also known as
a superwetting surface.
✓ It is a special case of the superhydrophilic
sv - between solid and vapour (gas) surface where the liquid spreads at a very
sl - between solid and liquid high speed as the liquid droplet meets the
surface.
lv - between vapour and liquid ✓ Liquids also tend to climb against gravity on
57 58
this kind of surface when kept vertical.

Nano coatings Nano coatings

Hydrophilic/Hydrophobic coatings - Hydrophilic/Hydrophobic coatings -

✓ Surfaces with θw＞90° indicate non-wetting ✓ There are two kinds of superhydrophobic -
behavior. “lotus leaf” and “rose petal”
✓ Let, θRoll-off is a critical inclination angle at ✓ For “lotus leaf” surface, water droplets tend
which the liquid droplet trends to slide/roll to slide off the surface if the surface is tilted
off the surface. at a small angle.
✓ Surfaces with 150°＜ θw＜ 90° are known as ✓ It requires to have low θRoll-off (＜10°).
hydrophobic. ✓ A “rose petal” surface usually possesses high
✓ When the hydrophobicity increases, θw of adhesion force, where water droplet sticks
the droplets with the surface increases on the surface, although the surface is tilted
✓ When θw is higher than 150°, the surface is upside down (θRoll-off ＞90°).
generally recognized as superhydrophobic. 59 60

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Nano coatings Nano coatings

Hydrophilic/Hydrophobic coatings - Hydrophilic/Hydrophobic coatings -

✓ Hydrophilic coatings readily spread water around the object when exposed to ✓ The layer is so thin that it does not scatter light meaning that it appears
moisture, thus enhancing its lubricity and significantly reducing surface friction. transparent to our eyes.
✓ Photocatalytic coatings (self-cleaning‘ glass) which use the catalytic properties of ✓ This type of technology helps prevent goggles used for skiing or swimming
titanium dioxide (TiO2). When irradiated with UV light, the coating becomes steaming up.
superhydrophilic, hence it is easier to clean. ✓ It is reported by the researchers that the surface of a ZnO single-crystal is
✓ Superhydrophilic coatings are also useful for rendering a surface fog-resistant. relatively hydrophilic (Pesika et al., 2002).
✓ The film of anti-fog agent (soap, hydrogels, hydrophilic nanoparticles and colloids) ✓ ZnO/TiO2 composite exhibits superhydrophilicity with a water contact angle of
creates a thin film that - less than 5 degree without UV irradiation (Chen et al., 2014).
○ Reduces surface tension ✓ The TiO2-coated film shows a water contact angle of 72 degree in the absence of
○ Does not allow the formation of water droplets but rather forces the water light while upon irradiation with UV light, the contact angle reduces to 0 degree,
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molecules to spread on the surface. giving rise to photo-induced superhydrophilicity.

Nano coatings Nano coatings

Hydrophilic/Hydrophobic coatings - Hydrophilic/Hydrophobic coatings -

✓ Hydrophobic layers are being developed for many applications that require ✓ Lotus Effect - It refers to self-cleaning properties that are a result of
resistance to dirt and ease of cleaning. superhydrophobicity as exhibited by the leaves of Nelumbo, the lotus flower.
✓ Superhydrophobic coatings are often defined as self-cleaning since dirt cannot ✓ Dirt particles are picked up by water droplets due to the micro- and nanoscopic
adhere easily to the surface and the motion of the water droplets on the surface architecture on the surface, which minimizes the droplet's adhesion to that
‘mechanically’ cleans it. surface.
✓ Superhydrophobic coatings can be made from many different materials. The ✓ a recent study has revealed honeycomb-like micro-structures on the taro leaf,
following are known possible bases for the coating: which makes the leaf superhydrophobic. The measured contact angle on this leaf
○ Manganese oxide polystyrene (MnO2/PS) nano-composite in this study is around 148 degrees.
○ Zinc oxide polystyrene (ZnO/PS) nano-composite
✓ the ‘lotus-effect’ with high contact angle and low sliding angle, resulted from
○ Precipitated calcium carbonate
○ Carbon nano-tube structures
micro- and nanoscale hierarchical structures: nanostructures contributed to high
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○ Silica nano-coating contact angle.

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Nano coatings Nano coatings

Hydrophilic/Hydrophobic coatings - Hydrophilic/Hydrophobic coatings -

✓ Superhydrophobic products are a coating—can be obtained by creating a micro- or ✓ Surfaces can be made hydrophobic without the use of coating through the altering
nano-sized structure on a surface which has super-repellent properties. of their surface microscopic contours, as well.
✓ These very tiny structures are by their nature very delicate and very easily ✓ The basis of hydrophobicity is the creation of recessed areas on a surface whose
damaged by wear, cleaning or any sort of friction. wetting expends more energy than bridging the recesses expends.
✓ If the structure is damaged even slightly it loses its superhydrophobic properties. ✓ This so-called Wenzel-effect surface or lotus effect surface, which has less contact
✓ It is used mainly in sealed environments which are not exposed to wear or area by an amount proportional to the recessed area, giving it a high contact angle.
cleaning, such as electronic components (like the inside of smart phones) and air ✓ The recessed surface has a proportionately diminished attraction foreign liquids or
conditioning heat transfer fins, to protect from moisture and prevent corrosion. solids and permanently stays cleaner.
✓ This has been effectively used for roofs and curtain walls of structures that benefit
from low or no maintenance.
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Thanks!
For attending lecture by:

Dr. Kagzi Shakil A.

Thanks!

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