Frictional Wear and Corrosion Behavior of AlCoCrFeNi High-Entropy Alloy Coatings Synthesized by Atmospheric Plasma Spraying

Mu, Yongkun; Zhang, Liangbo; Xu, Long; Prashanth, K.G.; Zhang, Nizhen; Ma, Xindi; Xu, Yulai; Jia, Yandong; Wang, Gang

doi:10.3390/e22070740

Cited by 45 publications

(11 citation statements)

References 40 publications

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“…Higher cooling rate results in a more refined dendritic structure, resulting in a smoother surface. Finer microstructures offer improved hardness, which in turn offer higher wear resistance [65][66][67]. It may be observed that in general, the wear resistance of the HPSC decreases with increasing load and/temperature combination due to accelerated conditions (which is as expected).…”

Section: Wear Behaviorsupporting

confidence: 57%

Mechanical and Tribological Behavior of Gravity and Squeeze Cast Novel Al-Si Alloy

Chandra

Krishna

Ravi

et al. 2022

Metals

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The automotive industry traditionally reduces weight primarily by value engineering and thickness optimization. However, both of these strategies have reached their limits. A 6% reduction in automotive truck mass results in a 13% improvement in freight mass. Aluminum alloys have lower weight, relatively high specific strength, and good corrosion resistance. Therefore, the present manuscript involves manufacturing Al-based alloy by squeeze casting. The effect of applied pressure during the squeeze cast and gravity cast of a novel Al-Si alloy on microstructural evolution, and mechanical and wear behavior was investigated. The results demonstrated that squeeze casting of the novel Al-Si alloy at high-pressure exhibits superior mechanical properties and enhanced wear resistance in comparison to the gravity die-cast (GDC) counterpart. Squeeze casting of this alloy, at high pressure, yields fine dendrites and reduced dendritic arm spacing, resulting in grain refinement. The finer dendrites and reduced dendritic arm spacing in high-pressure squeeze cast alloy than in the GDC alloy were due to enhanced cooling rates observed during the solidification process, as well as the applied squeeze pressure breaks the initial dendrites that started growing during the solidification process. Reduced casting defects in the high-pressure squeeze cast alloy led to a reduced coefficient of friction, resulting in improved wear resistance even at higher loads and higher operating temperatures. Our results demonstrated that squeeze casting of the novel Al-Si alloy at high-pressure exhibits a 47% increase in tensile strength, 33% increase in hardness, 10% reduction in coefficient of friction, and 15% reduction in wear loss compared to the GDC counterpart.

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Section: Wear Behaviorsupporting

confidence: 57%

Mechanical and Tribological Behavior of Gravity and Squeeze Cast Novel Al-Si Alloy

Chandra

Krishna

Ravi

et al. 2022

Metals

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“…With increasing current density, extensive delamination and coating failure occurred. In contrast to previous investigations on APS coatings of the same composition, there is no passivation for the investigated test conditions [18]. The average characteristic values for both corrosion types are summarized in Table 5.…”

Section: Corrosion Behaviormentioning

confidence: 79%

“…Thermally sprayed AlCrFeCoNi coatings produced by atmospheric plasma spraying (APS) were investigated by Mu et al in 3.5 wt.% NaCl electrolyte, and were revealed to have high corrosion resistance. The formation of a passive film, which is comprised of Cr and Fe oxides, could be proven despite the relatively heterogeneous condition due to feedstock oxidation during thermal spraying [18]. Investigations of laser cladded coatings in 0.6 M NaCl electrolyte also clearly showed passivation and an improved corrosion resistance in comparison to the stainless steel AISI 304L (EN 1.4306) [19].…”

Section: Introductionmentioning

confidence: 95%

Microstructure and Corrosion Properties of AlCoCrFeNi High-Entropy Alloy Coatings Prepared by HVAF and HVOF

Löbel

Lindner

Mehner

et al. 2021

Thermal Spray 2021: Proceedings From the International Thermal Spray Conference

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High-entropy alloys (HEAs) represent an innovative development approach for new alloy systems. These materials have been found to yield promising properties, such as high strength in combination with sufficient ductility as well as high wear and corrosion resistance. Especially for alloys with a body-centered cubic (bcc) structure, advantageous surface properties have been revealed. However, typical HEA systems contain high contents of expensive or scarce elements. Consequently, applying them as coatings where their use is limited to the surface represents an exciting pathway enabling economical exploitation of their superior properties. Nevertheless, processing conditions strongly influence the resulting microstructure and phase formation, which in turn has a considerable effect on the functional properties of HEAs. In the presented study, microstructural differences between high-velocity oxygen fuel (HVOF) and high-velocity air fuel (HVAF) sprayed coatings of the alloy AlCrFeCoNi are investigated. A metastable bcc structure is formed in both coating processes. Precipitation reactions are suppressed by the rapid solidification during atomization and by the relatively low thermal input during spraying. The coating resistance to corrosive media was investigated in detail, and an improved passivation behavior was observed in the HVAF coatings.

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“…Numerous studies suggest that these metallic alloys have the potential to mitigate wear and corrosion compared to traditional alloys. [1][2][3] HEAs are characterized by their multicomponent compositions (five or more elements) DOI: 10.1002/adem.202101713 High entropy alloys (HEAs) represent a new class of advanced metallic alloys that exhibit unique structural features and promising properties. The potential benefit of HEAs, in conjunction with established thermal spray manufacturing technologies, can provide a practical approach to mitigate wear and corrosion.…”

Section: Introductionmentioning

confidence: 99%

“…Numerous studies suggest that these metallic alloys have the potential to mitigate wear and corrosion compared to traditional alloys. [ 1–3 ] HEAs are characterized by their multicomponent compositions (five or more elements) mixed in equimolar or close to equimolar concentrations, enabling them to form a single‐phase solid solution. [ 4 ] However, the formation of intermetallics together with solid solution phases was also reported for the HEAs.…”

Section: Introductionmentioning

confidence: 99%

Effect of Microstructure on Wear and Corrosion Performance of Thermally Sprayed AlCoCrFeMo High‐Entropy Alloy Coatings

2022

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mixed in equimolar or close to equimolar concentrations, enabling them to form a single-phase solid solution. [4] However, the formation of intermetallics together with solid solution phases was also reported for the HEAs. [5,6] The alloys exhibit an inherently high configurational entropy effect owing to compositionally complex mixing, which promotes the solid solution phases in the form of face-centered cubic (FCC) and/or body-centered cubic (BCC) phases. [6] Other core effects, such as sluggish diffusion, distorted lattice, and cocktail effect, favor HEAs to have outstanding properties, including excellent strength, [7] significant toughness, [8] and better strain hardening ability [9] with remarkable tribological characteristics, including superior wear and corrosion resistance. [6,[9][10][11] Various studies had been employed to produce HEAs by arc melting, [12,13] spark plasma sintering, [14] laser technology, [15] microwave processing, [5,16] additive manufacturing, [17,18] and thermal spraying. [19,20] Among the techniques, thermal spray manufacturing is a promising and well-established technology, which is capable of using a broad range of feedstocks (including alloys, ceramics, and polymers) for producing thick coatings for use in developing protective surface layers. [21] The impact of thermal spraying of HEA coatings on microstructure, mechanical, and wear properties has been studied previously. [22,23] For instance, Wang et al. [24] reported excellent hardness for the AlCoCrFeNi HEA coatings developed via atmospheric plasma spraying due to hard BCC and ordered B2 phases. Another study by Meghwal et al. [22] reported high hardness of around 4 GPa for AlCoCrFeNi due to the formation of Al-rich oxide phases. Still a noticeable decrease in the corrosion performance was found compared to 316L stainless steel under seawater conditions. However, the high-temperature heat source in thermal spraying can result in undesirable phase transformations, residual stresses, and oxide contaminations. [23] In addition, the oxide inclusions along with voids such as pores and cracks are detrimental for protective performance against electrochemical damage. To probe such microstructural inhomogeneities, deposition techniques that operate with low-temperature heat sources are desirable.Cold spraying is a branch of thermal spray technologies that received attention for structural repair coatings for various

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Frictional Wear and Corrosion Behavior of AlCoCrFeNi High-Entropy Alloy Coatings Synthesized by Atmospheric Plasma Spraying

Cited by 45 publications

References 40 publications

Mechanical and Tribological Behavior of Gravity and Squeeze Cast Novel Al-Si Alloy

Mechanical and Tribological Behavior of Gravity and Squeeze Cast Novel Al-Si Alloy

Microstructure and Corrosion Properties of AlCoCrFeNi High-Entropy Alloy Coatings Prepared by HVAF and HVOF

Effect of Microstructure on Wear and Corrosion Performance of Thermally Sprayed AlCoCrFeMo High‐Entropy Alloy Coatings

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