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Volume 18
Issue 12
10.3390/ma18122799
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Article

Spark Plasma Sintering and Electrospark Deposition of High Entropy Alloys with Elemental Variation

by
Ciprian Alexandru Manea
1,
Laura Elena Geambazu
1,*,
Ileana Mariana Mateș
2,3,*,
Delia Pătroi
1,
Gabriela Beatrice Sbârcea
1,
Dorinel Tălpeanu
1,
Jan Přikryl
4,
Gifty B. Oppong
4 and
Augustin Semenescu
2,5
1
National Institute for R&D in Electrical Engineering ICPE-CA Bucharest, Splaiul Unirii 313, 030138 Bucharest, Romania
2
Faculty of Material Science and Engineering, National University for Science & Technology POLITEHNICA of Bucharest, 313 Splaiul Independentei, 060042 Bucharest, Romania
3
Central Military Emergency University Hospital “Dr. Carol Davila”, Calea Plevnei 134, 010825 Bucharest, Romania
4
Gerosion ehf, Árleynir 2-8, IS-112 Reykjavik, Iceland
5
Academy of Romanian Scientists, 3 Ilfov St., 050044 Bucharest, Romania
*
Authors to whom correspondence should be addressed.
Materials 2025, 18(12), 2799; https://doi.org/10.3390/ma18122799 (registering DOI)
Submission received: 8 May 2025 / Revised: 7 June 2025 / Accepted: 11 June 2025 / Published: 13 June 2025
(This article belongs to the Section Metals and Alloys)
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Abstract

A novel processing route of producing CrFeNiMo, Co0.5CrFeNiMo, and Al0.5CrFeNiMo high-entropy alloy coatings was proposed in this work. Pre-alloyed HEAs were consolidated by spark plasma sintering (SPS) in order to fabricate electrodes for electrospark deposition (ESD) coatings on carbon steel substrates. Investigations were performed to observe aspects such as phase composition and stability, contamination level, homogeneity, elemental distribution, and microstructural integrity. The results indicated phase stability and lower porosity when increasing the SPS temperature by 50 °C for all cases, with tetragonal distortion related to the HEAs’ severe lattice distortion core effect. The coating surface analysis indicated that a continuous and compact coating was obtained, correlated with the ESD layering count, but microfissures were present after 6 layers were applied due to the reduced ductility combined with rapid cooling under Ar atmosphere. The chemical integrity of both the sintered samples and the coatings was preserved during the processing, revealing a uniform elemental distribution with no contaminations or impurities present. The results indicated successful HEA sintering and deposition, highlighting the potential of the combined SPS-ESD process for high-performance material fabrication with possible applications in aggressive environments.
Keywords: HEA; spark plasma sintering; electrospark deposition; coatings HEA; spark plasma sintering; electrospark deposition; coatings
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MDPI and ACS Style

Manea, C.A.; Geambazu, L.E.; Mateș, I.M.; Pătroi, D.; Sbârcea, G.B.; Tălpeanu, D.; Přikryl, J.; Oppong, G.B.; Semenescu, A. Spark Plasma Sintering and Electrospark Deposition of High Entropy Alloys with Elemental Variation. Materials 2025, 18, 2799. https://doi.org/10.3390/ma18122799

AMA Style

Manea CA, Geambazu LE, Mateș IM, Pătroi D, Sbârcea GB, Tălpeanu D, Přikryl J, Oppong GB, Semenescu A. Spark Plasma Sintering and Electrospark Deposition of High Entropy Alloys with Elemental Variation. Materials. 2025; 18(12):2799. https://doi.org/10.3390/ma18122799

Chicago/Turabian Style

Manea, Ciprian Alexandru, Laura Elena Geambazu, Ileana Mariana Mateș, Delia Pătroi, Gabriela Beatrice Sbârcea, Dorinel Tălpeanu, Jan Přikryl, Gifty B. Oppong, and Augustin Semenescu. 2025. "Spark Plasma Sintering and Electrospark Deposition of High Entropy Alloys with Elemental Variation" Materials 18, no. 12: 2799. https://doi.org/10.3390/ma18122799

APA Style

Manea, C. A., Geambazu, L. E., Mateș, I. M., Pătroi, D., Sbârcea, G. B., Tălpeanu, D., Přikryl, J., Oppong, G. B., & Semenescu, A. (2025). Spark Plasma Sintering and Electrospark Deposition of High Entropy Alloys with Elemental Variation. Materials, 18(12), 2799. https://doi.org/10.3390/ma18122799

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