Deposition Methods of Multilayer Hard Coatings for Improving Tribological Performance: A Mini-Review
DOI:
https://doi.org/10.31643/2027/6445.37Keywords:
multilayer hard coatings, CVD, PVD, magnetron sputtering, transition metal nitrides.Abstract
Multilayer hard coatings remain among the most effective engineering solutions for reducing friction and wear and for extending the service life of components operating under high contact loads. However, their practical performance is governed not by multilayering per se, but by the extent to which the selected deposition technology enables reproducible control over three key parameters: layer density and defectiveness, adhesion to the substrate and/or interlayers, and architectural tunability through interface quality. This mini-review systematizes deposition approaches relevant to tribological applications and proposes a generalized classification comprising chemical processes (sol–gel, chemical vapor deposition (CVD), atomic layer deposition (ALD), hydrothermal synthesis, electrodeposition, anodization, and electroless coatings), physical vacuum techniques of the PVD family (magnetron sputtering, cathodic arc deposition, hollow cathode discharge (HCD) ion plating, ion beam assisted deposition (IBAD), among others), as well as hybrid and functional solutions (PVD+CVD, composite, self-lubricating, and nanocomposite systems). It is demonstrated that the selection of a deposition process for multilayer architectures must be based on technological constraints that directly affect interface stability and coating durability, including the deposition temperature window and conformality, interfacial diffusion-induced boundary blurring, residual stresses, and critical defects such as porosity, macroparticles, and growth-related imperfections. Practical guidelines are formulated for correlating “architecture–deposition regime–microstructure–tribological behavior,” and key directions for future research are identified, including interface and defect engineering, targeted hybridization of deposition processes to compensate for intrinsic limitations (conformality, density, adhesion, and interface stability), and the use of predictive modeling validated by comparable tribological testing.
Downloads
References
Yan W, Zhang Z, Zhang Y, Chen L, Zhang X, Liao B, Ying, M. Research on Ti-GLC/TiCN/TiN Composite Multilayer Coating with Ultra-Low Friction Coefficient in Various Environments. Surfaces and Interfaces. 2021; 26:101426. https://doi.org/10.1016/j.surfin.2021.101426
Mamayeva A, Kenzhegulov A, Panichkin A, Kshibekova B, Bakhytuly N. Deposition of Carbonitride Titanium Coatings by Magnetron Sputtering and Its Effect on Tribo-Mechanical Properties. Kompleksnoe Ispolzovanie Mineralnogo Syra = Complex Use of Mineral Resources. 2022; 321(2):65-78. https://doi.org/10.31643/2022/6445.19
Muradova S, Negim E-S, Makhmetova A, Ainakulova D, Mohamad N. An Overview of the Current State and the Advantages of Using Acrylic Resins as Anticorrosive Coatings. Kompleksnoe Ispolzovanie Mineralnogo Syra = Complex Use of Mineral Resources. 2023; 327(4):90–98. https://doi.org/10.31643/2023/6445.44
Khamseh S, Alibakhshi E, Mahdavian M, Saeb MR, Vahabi H, Lecomte J-S, Laheurte P. High-Performance Hybrid Coatings Based on Diamond-Like Carbon and Copper for Carbon Steel Protection. Diamond and Related Materials. 2017; 80:84–92. https://doi.org/10.1016/j.diamond.2017.10.008
Jehn HA. Multicomponent and Multiphase Hard Coatings for Tribological Applications. Surface and Coatings Technology 2000; 131(1–3):433–440. https://doi.org/10.1016/S0257-8972(00)00783-0
Bakhytuly N, Kenzhegulov A, Nurtanto M, Aliev A, Kuldeev E. Microstructure and Tribological Study of TiAlCN and TiTaCN Coatings. Kompleksnoe Ispolzovanie Mineralnogo Syra = Complex Use of Mineral Resources. 2023; 327(4):99–110. https://doi.org/10.31643/2023/6445.45
Ryaguzov A, Nemkayeva R, Guseinov N, Kudabayeva M. Nanocomposite Materials Based on Amorphous SiC-Containing DLC Structures Modified with Rhodium Nanoparticles. Diamond and Related Materials. 2024; 144:111034. https://doi.org/10.1016/j.diamond.2024.111034
Yessengaziyev A, Mukangaliyeva A, Toishybek A, Yersaiynova A, Bakhytuly N. Studies the Crucial Role of Selection of Extractant to Extract Niobium from Sulfuryl Fluoride Solution and Optimization of Extraction Conditions. Acta Metallurgica Slovaca 2024; 30(3):120–126. https://doi.org/10.36547/ams.30.3.2060
Ospanov K, Smailov K, Nuruly Y. Patterns of Non-Traditional Thermodynamic Functions ΔrG0/n and ΔfG0(Averaged) Changes for Cobalt Minerals. Chemical Bulletin of Kazakh National University 2020; 96:22–30. https://doi.org/10.15328/cb1005
Serdiuk IV, Petrushenko SI, Stolbovyi VO, Fijalkowski M. Influence of Technological Parameters of Deposition on Physical and Mechanical Properties of Vacuum-Arc Multilayer Nitride Coatings Based on Chromium and Niobium. Metallofizika i Noveishie Tekhnologii = Metallophysics and Advanced Technologies. 2024; 46(1):23–46. https://doi.org/10.15407/mfint.46.01.0023
Grand View Research. Hard Coatings Market Size, Share & Growth Report, 2030. Available online: https://www.grandviewresearch.com/industry-analysis/hard-coatings-market-report (accessed on 6 January 2026).
ConsaInsights. Hard Coatings Market Size, Market Share, Companies & Forecast Up To 2033. Available online: https://www.consainsights.com/reports/hard-coatings-market (accessed on 6 January 2026).
Market Data Forecast. Global Hard Coatings Market—By Material Type (Nitrides, Oxides), By Application (Cutting Tools, Decorative Coatings), By Deposition Technique (PVD and CVD), By End-Use (General Manufacturing, Transportation) & By Region—Global Industry Analysis, Size, Share, Growth, Investment & Forecast. Available online: https://www.marketdataforecast.com/market-reports/hard-coatings-market (accessed on 6 January 2026).
Bobzin K. High-Performance Coatings for Cutting Tools. CIRP Journal of Manufacturing Science and Technology. 2017; 18:1-9. https://doi.org/10.1016/j.cirpj.2016.11.004
Matthews A, Eskildsen SS. Engineering Applications for Diamond-Like Carbon. Diamond and Related Materials. 1994; 3:902-911. https://doi.org/10.1016/0925-9635(94)90297-6
Kawata K, Sugimura H, Takai O. Characterization of (Ti,Al)N Films Deposited by Pulsed D.C. Plasma-Enhanced Chemical Vapor Deposition. Thin Solid Films. 2001; 386(2):271-275. https://doi.org/10.1016/S0040-6090(00)01672-2
Fang T-H, Jian S-R, Chuu D-S. Nanomechanical Properties of TiC, TiN and TiCN Thin Films Using Scanning Probe Microscopy and Nanoindentation. Applied Surface Science. 2004; 228:365–372. https://doi.org/10.1016/j.apsusc.2004.01.053
Dubar M, Dubois A, Dubar L. Wear Analysis of Tools in Cold Forging: PVD versus CVD TiN Coatings. Wear. 2005; 259:1109–1116. https://doi.org/10.1016/j.wear.2005.01.006
Springer RW, Hosford, C.D. Characterization of Aluminum–Aluminum Nitride Coatings Sputter Deposited Using the Pulsed Gas Process. J. Vac. Sci. Technol. 1982; 20:462–465. https://doi.org/10.1116/1.571334
Ståhl J-E. Metal Cutting: Theories and Models; Lund University: Lund, Sweden. 2012, 580. ISBN 978-9163713361.
Ataibis V, Taktak S. Characteristics and Growth Kinetics of Plasma Paste Borided Cp–Ti and Ti6Al4V Alloy. Surface and Coatings Technology. 2015; 279:65-71. https://doi.org/10.1016/j.surfcoat.2015.08.023
Mareus R, Mastail C, Anğay F, Brunetière N, Abadias G. Study of Columnar Growth, Texture Development and Wettability of Reactively Sputter-Deposited TiN, ZrN and HfN Thin Films at Glancing Angle Incidence. Surface and Coatings Technology. 2020; 399:126130. https://doi.org/10.1016/j.surfcoat.2020.126130
Aiso T, Wiklund U, Kubota M, Jacobson S. Effect of Si and Al Additions to Carbon Steel on Material Transfer and Coating Damage Mechanism in Turning with CVD Coated Tools. Wear. 2016; 368–369:379–389. https://doi.org/10.1016/j.wear.2016.10.011
Leyland A, Bin-Sudin M, James AS, Kalantary MR, Wells PB, Matthews A, Housden J, Garside B. TiN and CrN PVD Coatings on Electroless Nickel-Coated Steel Substrates. Surface and Coatings Technology. 1993; 60:474–479. https://doi.org/10.1016/0257-8972(93)90135-B
Lautenschlager EP, Monaghan P. Titanium and Titanium Alloys as Dental Materials. International Dental Journal. 1993; 43(3):245–253. PMID: 8406955.
Yan H, Wang J, Cai M, Wang X, Song S, Zhang L, Li H, Li W Fan X, Zhu M. Towards Long-Term Corrosion and Wear Protection of Al Alloy: Synergy of Ti3C2Tx Flake and Micro-Arc Oxidation Coating. Corrosion Science. 2020; 174:108813. https://doi.org/10.1016/j.corsci.2020.108813
Wang J, Pan Ya, Feng R, Cui H, Gong B, Zhang L, Gao Z, Cui X, Zhang H, Jia Zh. Effect of electrolyte composition on the microstructure and bio-corrosion behavior of micro-arc oxidized coatings on biomedical Ti6Al4V alloy. Journal of Materials Research and Technology. 2020; 9(2):1477-1490. https://doi.org/10.1016/j.jmrt.2019.11.073
Yang S, Wiemann E, Teer DG. The Properties and Performance of Cr-Based Multilayer Nitride Hard Coatings Using Unbalanced Magnetron Sputtering and Elemental Metal Targets. Surface and Coatings Technology. 2004; 188–189:662–668. https://doi.org/10.1016/j.surfcoat.2004.07.032
Bin-Sudin M, Leyland A, James AS, Matthews A, Housden J, Garside B. Substrate Surface Finish Effects in Duplex Coatings of PAPVD TiN and CrN with Electroless Nickel-Phosphorus Interlayers. Surface and Coatings Technology. 1996; 81:215–224. https://doi.org/10.1016/0257-8972(95)02529-4
Shtansky DV, Kiryukhantsev-Korneev PV, Bashkova IA, Sheveiko AN, Levashov EA. Multicomponent Nanostructured Films for Various Tribological Applications. International Journal of Refractory Metals and Hard Materials. 2010; 28:32–39. https://doi.org/10.1016/j.ijrmhm.2009.07.014
Saba F, Kabiri E, Vahdati Khaki J, Haddad Sabzevar M. Fabrication of Nanocrystalline TiC Coating on AISI D2 Steel Substrate via High-Energy Mechanical Alloying of Ti and C. Powder Technology. 2016; 288:76–86. https://doi.org/10.1016/j.powtec.2015.10.030
PalDey S, Deevi SC. Single Layer and Multilayer Wear Resistant Coatings of (Ti,Al)N: A Review. Materials Science and Engineering: A. 2003; 342:58–79. https://doi.org/10.1016/S0921-5093(02)00259-9
Martin JM, Pascal H, Donnet C, Le Mogne T, Loubet JL, Epicier T. Superlubricity of MoS2: Crystal Orientation Mechanisms. Surface and Coatings Technology. 1994; 68–69:427–432. https://doi.org/10.1016/0257-8972(94)90197-X
Yang S, Cooke K, Sun H, Li X, Lin K, Dong H. Development of Advanced Duplex Surface Systems by Combining CrAlN Multilayer Coatings with Plasma Nitrided Steel Substrates. Surface and Coatings Technology. 2013; 236:2–7. https://doi.org/10.1016/j.surfcoat.2013.07.017
Mi P, He J, Qin Y, Chen K. Nanostructure Reactive Plasma Sprayed TiCN Coating. Surface and Coatings Technology. 2017; 309:1–5. https://doi.org/10.1016/j.surfcoat.2016.11.033
Musil J. Hard Nanocomposite Coatings: Thermal Stability, Oxidation Resistance and Toughness. Surface and Coatings Technology. 2012; 207:50–65. https://doi.org/10.1016/j.surfcoat.2012.05.073
Liu S, Yang Y, Ji R, Zeng XT, Clegg WJ. AlN/CrN Multilayer Structures with Increased Thermal Stability. Scripta Materialia. 2017; 130:242–246. https://doi.org/10.1016/j.scriptamat.2016.12.020
Saoula N, Madaoui N, Tadjine R, Erasmus RM, Shrivastava S, Comins JD. Influence of Substrate Bias on the Structure and Properties of TiCN Films Deposited by Radio-Frequency Magnetron Sputtering. Thin Solid Films. 2016; 616:521–529. https://doi.org/10.1016/j.tsf.2016.08.047
Komarov FF, Konstantinov VM, Kovalchuk AV, Konstantinov SV, Tkachenko HA. The Effect of Steel Substrate Pre-Hardening on Structural, Mechanical, and Tribological Properties of Magnetron Sputtered TiN and TiAlN Coatings. Wear. 2016; 352–353:92–101. https://doi.org/10.1016/j.wear.2016.02.007
Warcholiński B, Gilewicz A, Kukliński Z, Myśliński P. Arc-Evaporated CrN, CrN and CrCN Coatings. Vacuum. 2008; 83:715–718. https://doi.org/10.1016/j.vacuum.2008.05.005
Kanda K, Takehana S, Yoshida S, Watanabe R, Takano S, Ando H, Shimakura F. Application of Diamond-Coated Cutting Tools. Surface and Coatings Technology. 1995; 73:115–120. https://doi.org/10.1016/0257-8972(94)02370-0
Zhu F, Zhu K, Hu Y, Ling Y, Wang D, Peng H, Xie Z, Yang R, Zhang Z. Microstructure and Young’s Modulus of ZrN Thin Film Prepared by Dual Ion Beam Sputtering Deposition. Surface and Coatings Technology. 2019; 374:997–1005. https://doi.org/10.1016/j.surfcoat.2019.06.094
Vetter J, Burgmer W, Dederichs HG, Perry AJ. The Architecture and Performance of Multilayer and Compositionally Gradient Coatings Made by Cathodic Arc Evaporation. Surface and Coatings Technology. 1993; 61:209–214. https://doi.org/10.1016/0257-8972(93)90227-F
Rousseau AF, Partridge JG, Mayes ELH, Toton JT, Kracica M, McCulloch DG, Doyle ED. Microstructural and Tribological Characterisation of a Nitriding/TiAlN PVD Coating Duplex Treatment Applied to M2 High Speed Steel Tools. Surface and Coatings Technology. 2015; 272:403–408. https://doi.org/10.1016/j.surfcoat.2015.03.034
Yan H, Cai M, Wang J, Zhang L, Li H, Li W, Fan X, Zhu M. Insight into Anticorrosion/Antiwear Behavior of Inorganic–Organic Multilayer Protection System Composed of Nitriding Layer and Epoxy Coating with Ti3C2Tx MXene. Applied Surface Science. 2021; 536:147974. https://doi.org/10.1016/j.apsusc.2020.147974
Zhu L, He J, Yan D, Xiao L, Dong Y, Zhang J, Liao H. Synthesis and Microstructure Observation of Titanium Carbonitride Nanostructured Coatings Using Reactive Plasma Spraying in Atmosphere. Applied Surface Science. 2011; 257:8722–8727. https://doi.org/10.1016/j.apsusc.2011.05.056
Liu Y, Yu S, Shi Q, Ge X, Wang W. Multilayer Coatings for Tribology: A Mini Review. Nanomaterials. 2022; 12:1388. https://doi.org/10.3390/nano12091388
Kenzhaliyev B, Koizhanova A, Fischer D, et al. Study of Efficiency of Organic Activator Application to Process Difficult-to-Beneficiate Polymetallic Ridder Ores. Transit. Met. Chem. 2025. https://doi.org/10.1007/s11243-025-00637-7
Kenzhaliyev B, Fischer D, Temirova S, Ultarakova A, Baltabekova Z, Bakhytuly N, Smailov K. Removal of Hexavalent Chromium Ions from Industrial Effluents Using Natural and Modified Diatomite, Taurite, Lewatit M500, and Activated Carbon. Processes. 2025; 13:997. https://doi.org/10.3390/pr13040997
Abdulvaliev RA, Surkova TY, Baltabekova Z, Yessimova DM, Stachowicz M, Smailov KM, Dossymbayeva ZD, Ainur B. Effect of Amino Acids on the Extraction of Copper from Sub-Conditional Raw Materials. Kompleksnoe Ispolzovanie Mineralnogo Syra = Complex Use of Mineral Resources. 2024; 335(4):50–58. https://doi.org/10.31643/2025/6445.39
Kenzhaliyev B, Surkova T, Berkinbayeva A, Baltabekova Z, Smailov K, Abikak Y, Saulebekkyzy S, Tolegenova N, Omirbek T, Dosymbaeva Z. Innovative Methods for Intensifying the Processing of Zinc Clinker: Synergy of Microwave Treatment and Ultrasonic Leaching. Metals. 2025; 15:246. https://doi.org/10.3390/met15030246
Kenzhaliyev B, Berkinbayeva A, Baltabekova Z, Moldabayeva G, Smailov K, Saulebekkyzy S, Tolegenova N, Karim D, Omirbek T. Investigation of Phase Transformations in Technogenic Raw Materials Under Microwave Treatment for Enhanced Zinc Leaching. Processes. 2025; 13:1099. https://doi.org/10.3390/pr13041099
Kenzhaliyev B, Berkinbayeva A, Smailov K, Baltabekova Z, Saulebekkyzy S, Tolegenova N, Yessengaziyev A, Bakhytuly N, Tugambay S. Microwave Pre-Treatment for Efficient Zinc Recovery via Acid Leaching. Materials. 2025; 18:2496. https://doi.org/10.3390/ma18112496
Berkinbayeva A, Saulebekkyzy S, Kenzhaliyev B, Smailov K, Yessengaziyev A, Nurtazina N, Karim D, Birlikzhan Y. Sodium Percarbonate for Eco-Efficient Cyanide Detoxification in Gold Mining Tailings. Metals. 2025; 15(10):1162. https://doi.org/10.3390/met15101162
Kenzhaliyev B, Surkova T, Yessimova D, Baltabekova Z, Abikak Y, Abdikerim B, & Dosymbayeva Z. Extraction of Noble Metals from Pyrite Cinders. ChemEngineering. 2023; 7(1):14. https://doi.org/10.3390/chemengineering7010014
Koizhanova A, Kenzhaliyev B, Magomedov D, Kamalov E, Yerdenova M, Bakrayeva A, & Abdyldayev N. Study of Factors Affecting the Copper Ore Leaching Process. ChemEngineering. 2023; 7(3):54. https://doi.org/10.3390/chemengineering7030054
Koizhanova AK, Berkinbayeva AN, Sedelnikova GV, Kenzhaliyev BK, Azlan MN, & Magomedov DR. Research of biochemical gold recovery method using high-arsenic raw materials. Metalurgija. 2021; 60(3-4):423-426.
Khadem M, Penkov OV, Yang HK, et al. Tribology of Multilayer Coatings for Wear Reduction: A Review. Friction. 2017; 5:248–262. https://doi.org/10.1007/s40544-017-0181-7
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2026 N. Bakhytuly, K.M. Smailov, A.K. Kenzhegulov, M.A. Kudabayeva, A.M. Yessengaziyev, D.D. Karim, T.M. Arynbayev
This work is licensed under a Creative Commons Attribution 4.0 International License.
