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Layer-by-layer Synthesis and Transfer of Freestanding Conjugated Microporous Polymer Nanomembranes

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Bilayer Coating Systems: Functional Interlayers and Top Layers for Enhanced Performance.

Natalia A Shapagina¹, Vladimir V Dushik¹

¹Frumkin Institute of Physical Chemistry and Electrochemistry, Russian Academy of Sciences, Leninsky Prospect 31-4, 119071 Moscow, Russia.

Materials (Basel, Switzerland)

|November 27, 2025

Summary

This review covers protective and functional bilayer coatings, detailing methods like electroplating and chemical vapor deposition. Bilayer coatings enhance adhesion, corrosion resistance, and wear resistance for advanced manufacturing applications.

Keywords:

bilayer coatings corrosion resistance duplex coatings functional sublayers mechanical properties

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Area of Science:

Materials Science and Engineering
Surface Engineering

Background:

Single-layer coatings often have limitations in protective and functional properties.
Bilayer coatings offer synergistic effects by combining different material functionalities.

Purpose of the Study:

To review and summarize effective technologies for producing protective and functional bilayer coatings.
To highlight the advantages of bilayer architectures over single-layer coatings.

Main Methods:

Electroplating and electroless metallization
Chemical vapor deposition (CVD)
Thermal spray and vacuum arc deposition
Conversion treatments
Laser modification
Organic layer deposition

Main Results:

Bilayer coatings demonstrate enhanced adhesion and superior corrosion resistance via pore sealing or superhydrophobic states.
Improved wear and crack resistance are achieved through complementary functionalities.
Diverse industrial applications benefit from tailored bilayer coating properties.

Conclusions:

Bilayer coatings represent a significant advancement in surface engineering for demanding applications.
Selection and design of bilayer coatings are crucial for optimizing performance in aerospace, automotive, medical, and energy sectors.