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Effect of Nanostructure on Wear and Corrosion Behavior of HVAF-Sprayed Eutectic High-Entropy Alloy Coatings

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Abstract

Adopting multi-principal high entropy alloys (HEAs) as wear/corrosion-resistant coatings is a frontier in the field of surface engineering. The eutectic high entropy alloy (EHEA) exhibited excellent mechanical properties, and its dual-phase, lamellar nanostructure effectively prohibited pitting corrosion, making the alloy a potential candidate for wear/corrosion-resistant coatings served in the complicated environments. In the presented study, a dense and non-oxidized CoCrFeNiTaAl EHEA was coated on 304 stainless steel (SUS 304) substrate by a high-velocity air fuel (HVAF) thermal spraying process. The microstructure, corrosion resistance, as well as high temperature wear resistance of the coating were analyzed. The coating consisted of a deformation zone and a solidified zone. The deformation zone had the same structure as the original powders of the hypo-eutectic structure, and the solidified zone exhibited a single-phase solid solution structure. The EHEA coating exhibited an excellent combination of pitting corrosion and room-temperature wear resistance. The wear mechanism of EHEA coatings was abrasive, and oxidation wear at room temperature and 100 °C, while adhesive and oxidation wears occurred at elevated temperatures. The wear resistance decreases as temperature increases.

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Acknowledgments

This research was supported by the Regional Innovation and Development Joint Fund of National Natural Science Foundation of China (No. U20A20236), National Natural Science Foundation of China (No. 51731006, NO.5210110643), Natural Science Foundation of Hunan Province (No. 2020JJ4738), Natural Science Foundation of Shandong Province (No. ZR2020QD081, NO. ZR2020ME130, NO. ZR2020ME131), Green Innovation Science and Technology Plan of Colleges and Universities in Shandong Province (No. 2020KJA014), Open Sharing Fund for the Large-scale Instruments and Equipment of Central South University and 2020 open projects (KLATM202004) of Key Laboratory of Advanced Technologies of Materials, Ministry of Education China, Southwest Jiaotong University.

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Authors and Affiliations

  1. State Key Laboratory of Powder Metallurgy, Central South University, Changsha, 410083, China

    Shuyu Liu, Yingbo Peng, Yong Zhang, Wei Zhang, Yanni Tan, Qingyuan Ma & Yang Lan

  2. College of Engineering, Nanjing Agricultural University, Nanjing, 210031, China

    Yingbo Peng

  3. Qingdao Branch of Naval Aeronautical University, Qingdao, 266041, China

    Yong Zhang, Weijie Fan & Andong Wang

  4. Hunan Provincial Key Laboratory of High Efficiency and Precision Machining of Difficult-to-Cut Material, Hunan University of Science and Technology, Xiangtan, 411201, China

    Yueming Wang

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  1. Shuyu Liu
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Correspondence to Wei Zhang.

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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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Liu, S., Peng, Y., Zhang, Y. et al. Effect of Nanostructure on Wear and Corrosion Behavior of HVAF-Sprayed Eutectic High-Entropy Alloy Coatings. J Therm Spray Tech 31, 1252–1262 (2022). https://doi.org/10.1007/s11666-022-01342-y

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