This Ph.D. thesis explores the formation and application potential of Mo₂BC protective coatings for aluminum forming, along with the structural and mechanical properties of isostructural X₂BC phases (X = Mo, Ti, V, Zr, Nb, Hf, Ta, W) and their phase stability. It also examines the impact of silicon additions on the thermal stability of sputtered amorphous Al₂O₃ thin films. Previous work established the formation of Mo₂BC coatings at 900°C using combinatorial magnetron sputtering, which constrained substrate material choices. This research employs high power pulsed magnetron sputtering (HPPMS) to lower the synthesis temperature to 380°C. The study analyzes the plasma characteristics to understand the reduced synthesis temperature, revealing that the energetic ionized species population and energy distribution are significantly enhanced in the HPPMS regime compared to direct current magnetron sputtering (DCMS). This indicates that low-temperature synthesis of Mo₂BC is surface diffusion controlled. The application potential of Mo₂BC coatings for aluminum is investigated through theoretical and experimental studies of interfacial interactions, which demonstrate stronger chemical bonds at the Mo₂BC-Al interface than within aluminum clusters. A systematic study of Mo₂BC-type phases with various transition metals reveals their structural and mechanical properties. Additionally, the research identifies a significant increase in therma
