Nano-Engineered Surface Coating Techniques for Enhanced Wear and Corrosion Resistance in Engineering Components

Abstract

Engineering components operating in aggressive mechanical and chemical environments are frequently subjected to severe wear, friction, oxidation, and corrosion, which significantly reduce operational efficiency and service life. Conventional surface treatment methods often provide limited protection under high-temperature, high-pressure, and corrosive operating conditions, necessitating the development of advanced protective coating technologies. This research investigates nano-engineered surface coating techniques for enhancing wear and corrosion resistance in engineering components through advanced material engineering and surface modification approaches. The proposed study focuses on the application of nanostructured coatings using techniques such as physical vapor deposition, chemical vapor deposition, thermal spraying, and electrochemical coating methods to improve surface durability and mechanical performance. Various nano-coating materials, including ceramic-based, metallic, and composite nanomaterials, are analyzed to evaluate their influence on hardness, friction reduction, oxidation resistance, and electrochemical stability. Experimental investigations and microstructural characterization techniques are employed to study coating adhesion behavior, surface morphology, coating thickness uniformity, and degradation mechanisms under aggressive environmental conditions. Performance assessment is conducted using parameters such as wear rate, coefficient of friction, corrosion current density, surface hardness, adhesion strength, and thermal stability. Comparative analysis demonstrates that nano-engineered coatings significantly improve resistance to abrasive wear, pitting corrosion, and surface degradation compared with conventional coating systems.