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Microstructure and Tribological Properties of FeCoCrNi High-Entropy Alloy Coatings Fabricated by Atmospheric Plasma Spraying

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Abstract

This work aims to investigate microstructure and wear resistance of FeCoCrNi high-entropy alloy (HEA) coatings prepared by atmospheric plasma spraying (APS) at different spray powers. The density of the coatings is proportional to the spray power in the range of 15-25 kW. The room-temperature wear resistance of FeCoCrNi HEA coating sprayed under 25 kW power was the best with friction coefficient, wear rate and wear track depth to be (0.61 ± 0.02), (5.32 ± 0.02) × 10−5 mm3/(N·m) and (88.1 ± 10) μm, respectively. Abrasive wear, adhesive wear and plastic deformation were identified as the main wear mechanisms. Nano-mechanical properties of in situ formed oxides were much higher than those of metallic phases of HEA coating and feedstock. The friction coefficient, wear track depth and width, wear rate and wear mass loss of coated samples at 25 kW were first increased with temperature and then falling down at higher temperature. Main oxidation wear, supplemented with abrasive wear, adhesive wear and fatigue wear, was occurred during high temperature (≥ 400 °C) wear test. The wear resistance of HEA coatings was improved at high temperature attributed to solid lubrication from continuous oxide films formed on the worn surfaces of HEA coatings and Si3N4 balls.

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Acknowledgments

This work was supported by National Natural Science Foundation of China (Grant No. 51701072, and Grant No. 52011530147), Natural Science Foundation of Hunan Province of China (Grant No. 2021JJ50025), Key Research and Development Program of Hunan Province of China (2022GK2030), Youth Innovation Foundation of Jihua Laboratory (X201211XJ200), Military and Civilian Integration Industry Development Special Foundation of Hunan Province (Grant No. 2016B116J1).

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Authors and Affiliations

  1. Hunan Provincial Key Defense Laboratory of High Temperature Wear-Resisting Materials and Preparation Technology, Hunan University of Science and Technology, Xiangtan, 411201, China

    Y. M. Wang, X. L. Wu, C. L. Li & P. Zhou

  2. Hunan Provincial Key Laboratory of Advanced Materials for New Energy Storage and Conversion, Hunan University of Science and Technology, Xiangtan, 411201, China

    Y. M. Wang, X. L. Wu, C. L. Li & P. Zhou

  3. School of Management Engineering, Jiangsu Urban and Rural Construction Vocational College, Changzhou, 213147, China

    L. Xie

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YW carried out main work of this paper including experimental design, experimental data processing, original draft preparation and acting as corresponding author during submitting and revision. LX focused on technical guidance during APS and coating sample preparation. XW was devoted to reference inquiry and manuscript revision. CL completed part of experiments including nano-indentation test, friction and wear test. PZ undertook sample analysis and test including SEM and XRD etc.

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Wang, Y.M., Xie, L., Wu, X.L. et al. Microstructure and Tribological Properties of FeCoCrNi High-Entropy Alloy Coatings Fabricated by Atmospheric Plasma Spraying. J. of Materi Eng and Perform 32, 3475–3486 (2023). https://doi.org/10.1007/s11665-022-07331-0

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