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Erosion Behavior of Cold-Sprayed Coatings Made of CoCrFeMnNi HEA and Tungsten Carbide Nanoparticles in a Nickel Matrix

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Abstract

The study investigated the performance of CoCrFeMnNi high entropy alloy and tungsten carbide–nickel coatings under alumina particle impingement. The coatings were applied to 2205 duplex stainless steel substrates by cold spray using nitrogen. For the composite coatings, the amount of WC nanoparticles entrapped in the Ni matrix was estimated as 42.5 ± 8 vol.%. A cold-sprayed interlayer of 316 stainless steel promoted CoCrFeMnNi HEA deposition. Post-process annealing was performed on the coatings. After 3 hours of holding time, x-ray diffraction examination revealed no tungsten decarburization in the WC/Ni-Ni coating. Annealing peak temperatures for the WC/Ni–Ni and high entropy alloy coatings were 600 and 550 °C, respectively. The effect of SS316 annealing on subsequent HEA deposition and coating’s erosion behavior was also investigated. Microhardness tests showed the HEA coating outperforming the WC/Ni-Ni. The coatings were subjected to impact erosion using alumina particles at three different approach angles: 30°, 60°, and 90°. To compare the different materials, average erosion values were calculated expressed in volume loss per grams of erodent. The as-sprayed WC/Ni–Ni was the most effective against 60° impingement angle, while HEA coatings demonstrated promising under impacts at 30° and 90°. Overall, the 30° impact orientation was identified as the most critical condition. Eroded surfaces were examined using optical microscopy (OM) and scanning electron microscopy (SEM).

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Acknowledgments

The authors express their appreciation to SchuF Valve Technology GmbH and ESA for their financial support (Grant: 4000137618/22/NL/GLC/idb). Special thanks are extended to Trinity College Dublin's CRANN Advanced Microscopy Laboratory (AML) for their valuable assistance in microscopy characterization and analysis. This project received additional backing from the EU Commission Recovery and Resilience Facility through the Science Foundation Ireland Future Digital Challenge Grant Number 22/NCF/FD/10827. Support was also provided by Science Foundation Ireland under Grant 18/EPSRC-CDT-3581 and the Engineering and Physical Sciences Research Council (EPSRC) Grant EP/S023259/1.

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  1. Department of Mechanical, Trinity College Dublin, The University of Dublin, Manufacturing & Biomedical Engineering, Dublin, Ireland

    Giacomo Cappelli, Arnoldas Sasnauskas, Shuo Yin & Rocco Lupoi

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This article is an invited paper selected from presentations at the 2023 International Thermal Spray Conference, held May 22–25, 2023, in Québec City, Canada, and has been expanded from the original presentation. The issue was organized by Giovanni Bolelli, University of Modena and Reggio Emilia (Lead Editor); Emine Bakan, Forschungszentrum Jülich GmbH; Partha Pratim Bandyopadhyay, Indian Institute of Technology, Karaghpur; Šárka Houdková, University of West Bohemia; Yuji Ichikawa, Tohoku University; Heli Koivuluoto, Tampere University; Yuk-Chiu Lau, General Electric Power (Retired); Hua Li, Ningbo Institute of Materials Technology and Engineering, CAS; Dheepa Srinivasan, Pratt & Whitney; and Filofteia-Laura Toma, Fraunhofer Institute for Material and Beam Technology.

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Cappelli, G., Sasnauskas, A., Yin, S. et al. Erosion Behavior of Cold-Sprayed Coatings Made of CoCrFeMnNi HEA and Tungsten Carbide Nanoparticles in a Nickel Matrix. J Therm Spray Tech 33, 471–488 (2024). https://doi.org/10.1007/s11666-023-01710-2

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