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Cold Spray Additive Manufacturing of CoCrFeNiMn High-Entropy Alloy: Process Development, Microstructure, and Mechanical Properties

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Abstract

High-entropy alloys (HEAs) represent a new alloy design paradigm that involves simultaneous mixing of multiple elements in an equimolar or near-equimolar composition to form multi-principal solid solutions with unusual mechanical properties. In this work, CoCrFeNiMn HEA deposits with a near-full density were successfully prepared by a solid-state cold spray additive manufacturing process. In particular, cold spray process conditions such as carrier gas temperature and pressure, particle velocity, and particle size were studied to identify the effective cold spray process window. The as-deposited CoCrFeNiMn HEA deposits are featured by highly heterogeneous and significantly refined grain structures that lead to enhanced micro-hardness compared with conventional cast counterparts. The effects of heat treatment conditions on the microstructure and mechanical properties of the cold-sprayed CoCrFeNiMn HEA deposits are also discussed in order to understand their thermal stability.

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Acknowledgments

W.C. is grateful for the support from the US National Science Foundation (CMMI-1927621) and the U.S. Army Research Laboratory under Cooperative Agreement Award No. HQ0034-15-2-0007. The authors would like to thank Yuchen Li in the Department of Civil and Environmental Engineering, University of Massachusetts Amherst for his assistance during the nanoindentation experiments.

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  1. Department of Mechanical and Industrial Engineering, University of Massachusetts, Amherst, MA, 01003, USA

    Shuai Feng, Shuai Guan, Jie Ren, Shengbiao Zhang & Wen Chen

  2. U.S. Army Research Laboratory, Aberdeen Proving Ground, MD, 21005, USA

    William A. Story, Wieslaw Kapalczynski, Aaron T. Naardi, Victor K. Champagne & Matthew J. Siopis

  3. Solvus Global LLC, Worcester, MA, 01605, USA

    Alino Te, Joseph Heelan, Caitlin Walde & Aaron Birt

  4. Worcester Polytechnic Institute, Worcester, MA, 01609, USA

    Matthew A. Gleason, Kyle L. Tsaknopoulos & Danielle L. Cote

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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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Feng, S., Guan, S., Story, W.A. et al. Cold Spray Additive Manufacturing of CoCrFeNiMn High-Entropy Alloy: Process Development, Microstructure, and Mechanical Properties. J Therm Spray Tech 31, 1222–1231 (2022). https://doi.org/10.1007/s11666-022-01374-4

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