Russian researchers develop advanced protective coatings to extend industrial equipment lifespan

Scientists at Novosibirsk State Technical University, in partnership with the Budker Institute of Nuclear Physics of the Siberian Branch of the Russian Academy of Sciences, have developed multifunctional protective coatings designed to significantly extend the service life of industrial components operating in extreme conditions.

The research, conducted under a grant from the Russian Science Foundation, focuses on creating steel–coating composite systems that combine high wear resistance with enhanced corrosion and heat resistance. The technology is aimed at applications in mechanical engineering, particularly for critical components used in the oil and gas and chemical industries.

According to the website of Novosibirsk State Technical University, modern industrial equipment frequently operates under aggressive conditions, including exposure to acids, high temperatures, steam and abrasive particles. The combined impact of these factors accelerates surface degradation, leading to premature equipment failure and increased maintenance costs.

The newly developed coatings are engineered to outperform the base material of steel components by forming durable surface layers capable of withstanding multiple damaging influences simultaneously. According to the research team, the primary objective has been to create a cost-effective solution capable of delivering a multiple increase in the failure-free operational lifespan of industrial products.

The coatings are produced using a unique industrial electron accelerator, ELV-6, developed at the Budker Institute. The system generates a relativistic electron beam with energies of up to 2.5 MeV, which is directed into open air to fuse metal-containing powder mixtures onto steel substrates.

The high-energy beam penetrates the deposited powder layer, melting it while simultaneously fusing a thin surface layer of the base metal. Intensive mixing of molten materials forms a metallurgically bonded coating up to 5 mm thick. A broad transition zone between the coating and the steel substrate ensures strong adhesion within the composite structure.

The researchers prioritised boron-based compounds, particularly borides, known for their exceptional hardness, strength and chemical resistance in aggressive environments. The compositions were further enhanced with micro-additives of tantalum and chromium, which rapidly form protective passive films when exposed to acids, significantly improving corrosion resistance.