Sustainability assessment and economic evaluation of novel coating solutions for replacing hard chromium coatings

Ηard chromium (HC) has been the dominant protective coating for a wide range of applications offering high hardness (750-1050 HV), and excellent wear and corrosion resistance However, the hard chrome plating process involves the use of hexavalent chromium, (Cr(VI)), which is highly toxic, carcinogenic and mutagenic and associated with severe respiratory problems. Thus the emission and wastes of the process are dangerous for the workers and the environment. Consequently, on February 15^th 2019, REACH Committee has set a stricter regulation frame for the use of Cr(VI) substances, proposing authorization and limits to the use of chromium trioxide[1]. To address this challenges, the replacement of HC coatings with novel nickel-based nanocomposite coatings is investigated. The European research project MOZART promotes the incorporation of silicon carbide and graphene nanoparticles (NPs) in the Nickel matrix leading to two novel coatings with enhanced physicochemical, mechanical and environmental properties are examined in the framework of the. In this study, a sustainability assessment of two coatings is performed, comprising Life Cycle Assessment and Life Cycle Cost analyses according to the ISO 14040-44 standards with a functional unit of 1m² of coated surface, with 10um coating thickness. The results demonstrate significant improvement of human carcinogenic toxicity and freshwater ecotoxicity reduction while the economic performance proving the feasibility of the new coatings.

[1] REACH: Commission imposes strict conditions over the use of hazardous chemicals used in automotive, aerospace and medical sectors - Internal Market, Industry, Entrepreneurship and SMEs. Retrieved December 5, 2025, from https://single-market-economy.ec.europa.eu/news/reach-commission-imposes-strict-conditions-over-use-hazardous-chemicals-used-automotive-aerospace-2019-02-15_en