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Microstructural and Tribological Behavior of Thermal Spray CrMnFeCoNi High Entropy Alloy Coatings

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Abstract

High entropy alloys (HEAs) are characterized as alloys containing five or more principal elements in equal or close to equal atomic percentage. HEAs as bulk materials and coatings are considered a potential candidate for high-temperature applications owing to their superior combination of mechanical and thermal properties. In the present study, the CrMnFeCoNi HEA coatings were developed using high-velocity oxygen fuel (HVOF) and annealed at 800 °C for 2 h. The microstructure and wear behavior of the as sprayed and annealed HEA coatings were systematically evaluated on rough and polished surfaces. The wear behavior of these HEA coatings against an alumina (Al2O3) ball was tested at room temperature. Ex situ characterization was performed using XRD and Raman spectroscopy for phase analysis, SEM-EDS for cross-section microscopy and phase compositions of the HEA coatings. Both the as sprayed and annealed coatings comprised the FCC solid solution phase with the formation of oxides. The tribological results showed equivalent behavior of as sprayed and heat-treated coatings on the polished surfaces. Rough surfaces, on the other hand, revealed significantly higher wear rates compared to the polished surfaces due to third body abrasion during sliding. A strong emphasis was placed on correlating the interfacial processes to the tribological behavior.

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Acknowledgment

The work was conducted in collaboration between two groups of Concordia University and McGill University, Canada. The authors sincerely acknowledge the support of Dr. Fadhel Ben Ettouil and Mr. Saeed Garmeh in experiments of the reported work. The authors express their sincere gratitude to Dr. Vamsi Mungala for his support during experimental work and Dr. Sadegh Mahdipoor for helping in procurement of powders. The authors would also like to acknowledge the financial support from 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, QC, Canada

    Payank Patel, Navid Sharifi, Amit Roy & Christian Moreau

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

    Payank Patel, Sima A. Alidokht, Amit Roy & Richard R. Chromik

  3. Pratt and Whitney, East Hartford, CT, USA

    Kelly Harrington

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

    Pantcho Stoyanov

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This article is part of a special topical focus in the Journal of Thermal Spray Technology on High Entropy Alloy and Bulk Metallic Glass Coatings. The issue was organized by Dr. Andrew S.M. Ang, Swinburne University of Technology; Prof. B.S. Murty, Indian Institute of Technology Hyderabad; Distinguished Prof. Jien-Wei Yeh, National Tsing Hua University; Prof. Paul Munroe, University of New South Wales; Distinguished Prof. Christopher C. Berndt, Swinburne University of Technology. The issue organizers were mentored by Emeritus Prof. S. Ranganathan, Indian Institute of Sciences.

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Patel, P., Alidokht, S.A., Sharifi, N. et al. Microstructural and Tribological Behavior of Thermal Spray CrMnFeCoNi High Entropy Alloy Coatings. J Therm Spray Tech 31, 1285–1301 (2022). https://doi.org/10.1007/s11666-022-01350-y

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