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Microstructure and Mechanical Properties of the Plasma-Sprayed and Cold-Sprayed Al0.5CoCrFeNi2Ti0.5 High-Entropy Alloy Coatings

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Abstract

In this study, Al0.5CoCrFeNi2Ti0.5 high-entropy alloy (HEA) powders were prepared by the gas atomization method. The sieved powders with particle sizes of 10-60 and 60-120 µm gas-atomized powders were chosen for further analysis and coatings’ application processes. The as-obtained powders possessed spherical shape and uniform element distribution with an initial FCC structure with a minor BCC phase. The as-atomized powders were annealed at 1000 °C temperature for varying durations and characterized to determine their stable state properties. After annealed at 10000 °C, the metastable BCC phase disappeared and Al0.5CoCrFeNi2Ti0.5 transformed into solid-solution FCC matrix with minor BCC precipitates. The Vickers hardness of the plasma-sprayed coatings showed an increasing trend from 285.3 to 396.7 HV as the current was raised from 500 to 750 A, respectively. Cold-sprayed coatings were performed on both carbon steel and aluminum alloy AA 6061, and their properties were analyzed. The obtained hardness of 426.6 HV was about 10% higher than the plasma-sprayed coatings. Plasma-sprayed coating properties can be varied with plasma power and size of the powder particles. Mechanical locking effect enhanced the bond strength in cold-sprayed AA 6061 compared to carbon substrate. Improved mechanical properties in this alloy were due to precipitation hardening after titanium addition.

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Acknowledgment

Authors acknowledge the support from the Ministry of Science and Technology of Taiwan under Project No. 107-2218-E-011-017 and the support by the Research Center for Intelligent Medical Devices, Ming Chi University of Technology. This work was financially supported by the “High Entropy Materials Center” from The Featured Areas Research Center Program within the framework of the Higher Education Sprout Project by the Ministry of Education (MOE) and from Project MOST 109-2634-F-007-024 by the Ministry of Science and Technology (MOST) in Taiwan. Thanks for Plus Metal Tech., Co. supporting in conducting plasma and cold spraying processes.

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Taiwan University of Science and Technology, Taipei, 10607, Taiwan

    Rotich Sammy Kiplangat, Tzu-Tang Lin, Ngetich Gilbert Kipkirui & Shih-Hsun Chen

  2. High Entropy Materials Center, National Tsing Hua University, Hsinchu, 30013, Taiwan

    Shih-Hsun Chen

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  1. Rotich Sammy Kiplangat
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Contributions

Rotich Sammy Kiplangat was involved in writing—original draft, investigation. Tzu-Tang Lin performed writing—review & editing and investigation. Ngetich Gilbert Kipkirui contributed to investigation and data curation. Shih-Hsun Chen did supervision, methodology and resources.

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Correspondence to Shih-Hsun Chen.

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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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Kiplangat, R.S., Lin, TT., Kipkirui, N.G. et al. Microstructure and Mechanical Properties of the Plasma-Sprayed and Cold-Sprayed Al0.5CoCrFeNi2Ti0.5 High-Entropy Alloy Coatings. J Therm Spray Tech 31, 1207–1221 (2022). https://doi.org/10.1007/s11666-022-01356-6

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