International Journal of Surface Science and Engineering (5 papers in press)

Regular Issues

• Performance analysis of high-speed laser cladding Fe55 alloy coatings via inside-laser powder feeding  
  by Yu Xie, Shuokun Ma, Tuo Shi, Siqi Yu, Shuguang Wang 
  Abstract: To improve the surface performance of 304 stainless steel, a Fe55 alloy coating with excellent wear and corrosion resistance was fabricated using high-speed laser cladding with an innovative inside-laser powder feeding method. The effects of laser power, defocus distance, and scanning speed on the coating morphology were studied. SEM and XRD analyses were conducted along with microhardness, wear, and electrochemical corrosion tests. Optimal parameters were identified: 1850 W laser power, 24 m/min scanning speed, +2 mm defocus, 16.8 g/min powder feed rate, and 80% overlap. The resulting coating was smooth, defect-free, had a dilution rate below 5%, and showed improved hardness and corrosion resistance compared to the stainless steel substrate. This efficient and eco-friendly technique has promising potential for advanced surface enhancement applications.
  Keywords: laser high-speed cladding; inside-laser powder feeding; Fe55 alloy; surface coating; microstructure.
  DOI: 10.1504/IJSURFSE.2025.10071352
   
  
• Nano-tribological characterisation and biocompatibility of antibacterial coating for biomedical application  
  by Omar Hussain, Sheikh Shahid Saleem 
  Abstract: Surface modification strategies are becoming more common to enhance the biological properties of bone implant applications. In this work, multilayer RF-magnetron sputtered Ti/TaN coatings deposited on Ti6Al4V were investigated. Biocompatibility, antibacterial properties, and coating effectiveness were assessed. It was observed that the coating layers played an important role in biocompatibility. Energy-dispersive-spectroscopy confirms the presence of the coating elements. In-vitro tests with HCT-116 cells showed greater viability (survival rate of 96.62%) on the coated sample. Critical loads associated with coating failure were obtained using FESEM micrographs. The cohesive failure began at L_C1 (72.2997 mN) whereas the critical normal load threshold for the thin film coating was obtained at L_C2 (291.3407 mN). The results of this work indicate the viability of deposited coating for implant application.
  Keywords: biomaterials; thin film; RF magnetron sputtering; biomedical.
  DOI: 10.1504/IJSURFSE.2025.10071893
   
  
• Geometric interpretation of the increase in the number of photons using ultra-thin films  
  by Myung Sik Choi, Byeongdeok Lee, Sangwoo Kim, Changhyun Jin 
  Abstract: Until now, surface treatment methods have been subject to many restrictions because each material has different properties. In addition, the effect of surface treatment has been approached qualitatively rather than quantitatively. This study demonstrates the remarkable improvement in the optical intensity of a matrix upon depositing an ultra-thin film layer, regardless of the morphology, dimension, type, and size. Thus, a new optical energy amplification mechanism, in which the number of photons can be increased, is proposed using a geometrical approach. In particular, the flame chemical vapour deposition used here was achieved within seconds. Moreover, based on the purpose of the process, the reduction of the metal oxide and the deposition of the amorphous carbon could be easily controlled. The powerful optical results were investigated for various material surfaces such as Au-SnO₂ nanowires, porous Si substrates, and Al₂₃ substrates.
  Keywords: thin film; photon; amorphous carbon; flame chemical vapour deposition.
  DOI: 10.1504/IJSURFSE.2025.10072898
   
  
• The effect of Ni element content on the performance of 3Cr13+2.0wt%B coatings  
  by Huafei Zhao, Qiangqiang Zhang, Yaowei Yong, Mengmeng Cao, Yuhe Ma, Zheng Zhang 
  Abstract: To enhance ductile iron performance under harsh conditions, this study investigates the effect of nickel content on laser-clad 3Cr13+2.0wt%B coatings. Results show that adding 1.0 wt% Ni achieves optimal metallurgical bonding and coating quality (average thickness >1.2 mm). The microstructure comprises α-Fe, γ-Fe, (Cr,Fe)7C3, Fe2B, and γ-(Fe,Ni) phases, with microhardness 4.15 times that of the substrate. Under identical abrasion, the wear rate decreases to 0.135 × 10^-3 g/m, dominated by mild abrasive and oxidative wear. In 3.5% NaCl salt spray tests, the self-corrosion potential increases by 0.052 V, with reduced corrosion current and enhanced impedance, indicating superior corrosion resistance. The addition of 1.0 wt% Ni simultaneously improves coating quality, hardness, wear resistance, and corrosion performance.
  Keywords: laser cladding; ductile iron; 3Cr13; wear resistance; corrosion resistance.
  DOI: 10.1504/IJSURFSE.2025.10072478
   
  
• A fretting fatigue life model considering the effects of contact stress and cyclic stress amplitude  
  by Kyungmok Kim 
  Abstract: This article developed a fretting fatigue life model of metallic materials. A fretting fatigue model incorporating imposed contact pressure and cyclic stress amplitude was established based on a bearing life theory. Fretting fatigue lifetime data of various metallic materials were collected from the literature. The effect of contact pressure on the number of fretting cycles to failure was investigated. It was identified that at low contact pressures, the number of fretting cycles to failure can be described by an inverse power-law function of contact stress. When the contact pressure exceeded the critical value, the number of fretting cycles to failure remained almost constant, regardless of the imposed contact pressure. Finally, a direct comparison between predicted and measured lifetime values was performed. The results revealed small errors (less than 13%) between predicted and measured values, attributed to the variance in fretting fatigue tests.
  Keywords: fretting fatigue; fatigue lifetime; contact pressure; fatigue model; cyclic stress amplitude.
  DOI: 10.1504/IJSURFSE.2025.10072580