I am still experimenting with different coatings, to see what might be the most viable. I've mostly stopped offering the PVD coatings because of a combination of high cost and marginal corrosion resistance. The molecular build up of those coatings is in columns so moisture still can reach the steel and potentially cause pitting. On the plus side, the coating does hold oil well, which provides more protection. All in all it just isn't something I'm ready to put my seal of approval on.
I've also been looking at some tooling grade DLC coatings, which would give much better corrosion resistance but the high temperature of those processes has unpredictably affected the temper on some of the blades I sent out. We experimented with gas nitriding, which more or less turned some blades into glass. I might post a video of that experiment someday. It was pretty funny. We also gave salt bath nitriding a try, which didn't seem to adversely affect the substrate toughness but the black oxide top coating was still susceptible to red rusting. A few hours in some salt water and those blades turned the water orange with rust.
I've even tried some different electroless nickel coatings and even nickel boron, just to see how they would stack up. Of course with those you don't get any color options, just a metal color but I figured it was at least worth looking at. While they didn't rust in the traditional sense, they did turn a strange marbled blue, which is the nickel oxidizing. I'll keep looking for new options and keep my fingers crossed...
So far the most interesting option I've found has been Cerakote. It goes on thin, so it doesn't really create extra drag, it is durable and very corrosion resistant. We've learned however that not all Cerakote applicators are created equal and the end result is highly dependent on the abilities of the applicator. Dirty blasting media or bad prep work can cause flaking and poor application practices can cause the coating to be less durable, so stay away from applicators who aren't recommended by NIC Industries. lol We have met someone here in Idaho who is great, the same gentleman who did the first batch of SK-4 blades but ultimately I would want to bring this in house if we were to offer Cerakote as a factory option. If it becomes something we end up bringing in house, I could always offer recoating services to make an old blade look new again. The exotic, expensive coatings are technically more durable but a Cerakoted blade would be far less problematic to strip and recoat and the variety of coating colors is phenomenal.
-Guy