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<p>Premature loss of non-stick functionality remains a major reliability issue for PTFE-based coatings used in baking cookware, yet the underlying failure mechanisms are often insufficiently understood. In this study, a comprehensive failure analysis was conducted to elucidate the degradation pathways of a typical aluminized substrate or PTFE coating system under simulated service conditions. Coating morphology, thickness uniformity, adhesion strength, tribological behavior, wettability evolution, and electrochemical corrosion performance were systematically evaluated. The results demonstrate that coating failure is dominated by progressive functional degradation rather than interfacial adhesion failure, as the aluminized layer maintains adequate bonding strength to the substrate. Pronounced thickness non-uniformity is identified as a critical factor accelerating failure, creating localized weak regions susceptible to stress concentration, wear-induced thinning, and electrolyte penetration. Friction and wear testing reveals shear-driven material redistribution and central thinning within the wear track, despite the establishment of a relatively stable friction regime associated with transfer film formation. Time-dependent wettability degradation further facilitates water and chloride ion ingress, triggering corrosion processes at the coating or substrate interface. Based on the identified failure mechanisms, targeted prevention strategies focusing on surface pretreatment optimization, coating thickness control, and mitigation of wear- and corrosion-assisted degradation are proposed. The findings provide practical insights for improving the durability and service reliability of non-stick cookware coatings.</p>

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Study on Failure Analysis of Non-stick Coating for Baking Pots

  • 期刊论文

  • 发表日期：

    2026年3月30日

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  • Tao Wang,
  • Wangping Wu

摘要

Premature loss of non-stick functionality remains a major reliability issue for PTFE-based coatings used in baking cookware, yet the underlying failure mechanisms are often insufficiently understood. In this study, a comprehensive failure analysis was conducted to elucidate the degradation pathways of a typical aluminized substrate or PTFE coating system under simulated service conditions. Coating morphology, thickness uniformity, adhesion strength, tribological behavior, wettability evolution, and electrochemical corrosion performance were systematically evaluated. The results demonstrate that coating failure is dominated by progressive functional degradation rather than interfacial adhesion failure, as the aluminized layer maintains adequate bonding strength to the substrate. Pronounced thickness non-uniformity is identified as a critical factor accelerating failure, creating localized weak regions susceptible to stress concentration, wear-induced thinning, and electrolyte penetration. Friction and wear testing reveals shear-driven material redistribution and central thinning within the wear track, despite the establishment of a relatively stable friction regime associated with transfer film formation. Time-dependent wettability degradation further facilitates water and chloride ion ingress, triggering corrosion processes at the coating or substrate interface. Based on the identified failure mechanisms, targeted prevention strategies focusing on surface pretreatment optimization, coating thickness control, and mitigation of wear- and corrosion-assisted degradation are proposed. The findings provide practical insights for improving the durability and service reliability of non-stick cookware coatings.