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Microstructural Characterization and Tribological Properties of Atmospheric Plasma Sprayed High Entropy Alloy Coatings

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Abstract

Two different types of high entropy alloy thick coatings (HEAs), namely, AlCrCoFeNiTi and FeCrCoNiW0.3 + 5 at.% C were fabricated using atmospheric plasma spray (APS) on stellite substrate and compared for their various properties. Fine spherical powder particles used for fabrication resulted in homogeneous and surface defect-free (like cracks or voids) coatings with a negligible amount of porosity. The surface roughness and dilution level of both the coatings were found to be 8.56 µm, 7.23 µm, and 3.71%, 3.55% for AlCrCoFeNiTi and FeCrCoNiW0.3 + 5 at.% C alloy, respectively, demonstrating a strong metallurgical bonding between the coatings and substrate. A lamellar microstructure along with precipitates was observed from the microstructural investigation of both coatings. The AlCrCoFeNiTi coating comprised of two BCC phases (A2 and B2) and FeCrCoNiW0.3 + 5 at.% coating consisted of FCC phase with Cr and W rich carbides. The microhardness of AlCrCoFeNiTi alloy coating exhibited 2.16 times higher hardness (761 ± 14 HV0.2) and 4.28 times lower wear rate (2.8 × 10−7 mm3/ Nm) than the substrate. BCC phases, good metallurgical bonding between the matrix and substrate, and defect-free microstructure attributed to the improved wear performance of the aforementioned alloy coating.

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Acknowledgement

This work was supported by the Indian Space Research Organization (ISRO) (Grant no. ISRO/RES/3/844/19-20). The authors thank the central instrumentation facility (CIF), the Indian Institute of Technology Jammu (IIT Jammu) for providing the necessary characterization facility.

Funding

This study was funded by Indian Space Research Organization (ISRO) (Grant no. ISRO/RES/3/844/19-20).

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Authors and Affiliations

  1. Laboratory for Advanced Manufacturing and Processing, Indian Institute of Technology Jammu, Jammu, India

    Himanshu Kumar & S. Shiva

  2. Process Intensification and Nanoscale Advanced Materials Laboratory, Department of Chemical Engineering, Indian Institute of Technology Jammu, Jammu, India

    Gaurav A Bhaduri

  3. Indian Space Research Organization Propulsion Complex, Mahendragiri, India

    S. G. K. Manikandan

  4. Department of Metallurgical and Materials Engineering, Indian Institute of Technology Madras, Chennai, India

    M. Kamaraj

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  1. Himanshu Kumar
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  2. Gaurav A Bhaduri
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Correspondence to S. Shiva.

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Author S. Shiva has received research grants from Indian Space Research Organization (ISRO). The authors declare that they have no conflict of interest.

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Kumar, H., Bhaduri, G.A., Manikandan, S.G.K. et al. Microstructural Characterization and Tribological Properties of Atmospheric Plasma Sprayed High Entropy Alloy Coatings. J Therm Spray Tech 31, 1956–1974 (2022). https://doi.org/10.1007/s11666-022-01422-z

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