The paper summarizes current knowledge of growth defects in physical vapor deposition (PVD) coatings. A detailed historical overview is followed by a description of the types and evolution of growth defects. Growth defects are microscopic imperfections in the coating microstructure. They are most commonly formed by overgrowing of the topographical imperfections (pits, asperities) on the substrate surface or the foreign particles of different origins (dust, debris, flakes). Such foreign particles are not only those that remain on the substrate surface after wet cleaning procedure, but also the ones that are generated during ion etching and deposition processes. Although the origin of seed particles from external pretreatment of substrate is similar to all PVD coatings, the influence of ion etching and deposition techniques is rather different. Therefore, special emphasis is given on the description of the processes that take place during ion etching of substrates and the deposition of coating. The effect of growth defects on the functional properties of PVD coatings is described in the last section. How defects affect the quality of optical coatings, thin layers for semiconductor devices, as well as wear, corrosion, and oxidation resistant coatings is explained. The effect of growth defects on the permeation and wettability of the coatings is also shortly described.

In this work, we present functionalization of AISI 316 L surfaces by nanosecond Nd:YAG laser texturing and adsorption of superhydrophobic fluoroalkylsilane functionalized 30-nm silica nanoparticles. Surface modification by varying the distance between laser-produced micro(μ)-channels leads to different surface roughnesses. After nanosilica coating, the superhydrophilic laser-textured surfaces change into superhydrophobic surfaces with the same μ-roughness. A higher μ-channel density leads to more hydrophobic surfaces after coating. This enables a study of the combined effect of surface wettability and morphology on the friction coefficient and wear resistance. Experiments were performed in dry and water environments. In the case of dry friction, increased μ-roughness leads to a higher friction coefficient, and the water-repellency modification by nanosilica particles has no influence on the tribological behaviour. In contrast, in the water environment, the wettability presents an important contribution to the properties of contact surfaces: hydrophobic surfaces exhibit a lower friction coefficient, especially at higher densities of μ-channels. Energy-dispersive X-ray spectroscopy analysis of surfaces before and after the tribological experiments is performed, revealing the difference in weight % of Si in the worn surface compared to the unworn surface, which varies according to the nature of the surface morphology due to laser texturing in both dry and water environments.

Adjusting ink's solvent composition with respect to the solvents volatility enabled printing of flat, nano-thick dielectric structures of high-performance.

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