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Influence of HVOF spraying parameters on microstructure and mechanical properties of FeCrMnCoNi high-entropy coatings (HECs)

  • Metals & corrosion
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Abstract

The study aimed to investigate the impact of high velocity oxy-fuel (HVOF) spraying parameters on the inflight particle temperature, velocity, and microstructure of FeCrMnCoNi high-entropy coatings (HECs). The sprayed coatings exhibited a typical lamellar structure with a single solid solution FCC phase and minor oxides. Ex-situ characterization of the coatings was conducted using X-ray diffraction, Raman spectroscopy, and high-resolution scanning electron microscope (HR-SEM) to analyze the phase composition, microstructure, and surface morphology. The findings revealed that fuel-rich flames with a higher feed rate resulted in coatings with low porosity and oxidation as well as high deposition efficiency due to the high velocity and low particle temperatures. Additionally, the transverse scratch tests were conducted to determine the cohesive/adhesive nature of the coatings, and the results demonstrated that the cohesive strength between the splats was influenced by the porosity and area fraction of the oxides. Coatings deposited with oxygen-rich conditions showed maximum hardness, but low cohesive strength compared to coatings sprayed using fuel-rich conditions due to higher oxides formation during spraying. The microstructural changes, phase compositions, and microhardness of the coatings were correlated with the scratch resistance of the HECs developed using three distinct spraying conditions. These results suggest that FeCrMnCoNi HECs hold significant potential for surface protection in various industrial and aerospace applications. Moreover, the findings point toward new material design strategies to attain desired microstructure with enhanced mechanical properties.

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Acknowledgements

The study was a collaborative effort between two groups from Concordia University and McGill University in Canada. The authors would like to express their gratitude to Dr. Fadhel Ben Ettouil for his contributions to the experimental work. The authors also thank Dr. Lise Guichaoua and Mr. Nicholas Brodusch at the Facility for Electron Microscopy Research of McGill University for their assistance with advanced characterization techniques and Dr. Sadegh Mahdipor for helping with the procurement of powders. The authors are grateful for the financial support provided by the Natural Sciences and Engineering Research Council (NSERC) Project Number CRDPJ 530409-18 and the Consortium for Research and Innovation in Aerospace in Québec (CRIAQ) Project Number MANU-1719.

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Authors and Affiliations

  1. Department of Mechanical, Industrial and Aerospace Engineering, Concordia University, Montreal, Canada

    Payank Patel, Navid Sharifi, Amit Roy & Christian Moreau

  2. Department of Mining and Materials Engineering, McGill University, Montreal, Canada

    Payank Patel, Venkata Naga Vamsi Munagala, Amit Roy, Sima A. Alidokht, Maya Harfouche & Richard R. Chromik

  3. Pratt & Whitney, 400 Main Street, East Hartford, CT, 06118, USA

    Mary Makowiec

  4. Department of Chemical and Materials Engineering, Concordia University, Montreal, Canada

    Pantcho Stoyanov

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  1. Payank Patel
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Patel, P., Munagala, V.N.V., Sharifi, N. et al. Influence of HVOF spraying parameters on microstructure and mechanical properties of FeCrMnCoNi high-entropy coatings (HECs). J Mater Sci 59, 4293–4323 (2024). https://doi.org/10.1007/s10853-024-09476-w

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