Search Results (7)

This paper discusses a comparative micromechanical and tribological analysis of laser-cladded equiatomic FeNiCr coatings reinforced with TiC and NbC particles. Two types of coatings, FeNiCr-TiC (3 wt.% TiC) and FeNiCr-NbC (3 wt.% NbC), were deposited onto an AISI 1040 steel substrate by means of short-pulsed laser cladding. The chemical composition, microstructure, and micromechanical and tribological characteristics of the coatings were systematically investigated via optical and scanning electron microscopy, Raman spectroscopy, and mechanical and tribological tests. The average thicknesses and compositional transition zones of the coatings were 600 ± 20 μm and 150 ± 20 μm, respectively. Raman spectroscopy revealed that both coatings are primarily composed of a single FCC γ-phase (γ-FeNiCr). The FeNiCr + 3 wt.% TiC coating exhibited an additional TiC phase dispersed within the γ-FeNiCr matrix. In contrast, the FeNiCr + 3 wt.% NbC coating displayed a more homogeneous distribution of finely dispersed NbC phase throughout the composite, leading to enhanced mechanical behavior. Micromechanical characterization showed that the FeNiCr + 3 wt.% NbC coating possessed higher average microhardness (3.8 GPa) and elastic modulus (180 GPa) compared to the FeNiCr + 3 wt.% TiC coating, which had values of ~3.2 GPa and ~156 GPa, respectively. Both coatings significantly exceeded the AISI 1040 steel substrate in tribological performance. The FeNiCr + 3 wt.% TiC and FeNiCr + 3 wt.% NbC coatings exhibited substantial reductions in both weight loss (37% and 41%, respectively) and wear rate (33% and 42%, respectively) compared to the substrate material. These findings indicate that more finely dispersed NbC particles are better suited for hardening laser-cladded equiatomic FeNiCr-NbC coatings, making them advanced candidates for industrial applications. Full article

The non-equiatomic Al_0.32CrFeTi_0.73(Ni_1.50−xMo_x) (x = 0, 0.23) high-entropy alloy (HEA) coatings were prepared by the high-velocity oxygen fuel (HVOF) method. The microstructures and corrosion behaviors of the HVOF-prepared coatings were investigated. The corrosion behaviors were characterized by polarization, EIS and Mott-Schottky tests under a 3.5 wt.% sodium chloride aqueous solution open to air at room temperature. The Al_0.32CrFeTi_0.73Ni_1.50 coating is a simple BCC single-phase solid solution structure compared with the corresponding poly-phase composite bulk. The structure of the Al_0.32CrFeTi_0.73Ni_1.27Mo_0.23 coating, combined with the introduction of the Mo element, means that the (Cr,Mo)-rich sigma phase precipitates out of the BCC solid solution matrix phase, thus forming Cr-depleted regions around the sigma phases. The solid solution of large atomic-size Mo element causes the lattice expansion of the BCC solid solution matrix phase. Micro-hole and micro-crack defects are formed on the surface of both coatings. The growth of both coatings’ passivation films is spontaneous. Both passivation films are stable and Cr₂O₃-rich, P-type, single-layer structures. The Al_0.32CrFeTi_0.73Ni_1.50 coating has better corrosion resistance and much less pitting susceptibility than the corresponding bulk. The corrosion type of the Mo-free coating is mainly pitting, occurring in the coating’s surface defects. The Al_0.32CrFeTi_0.73Ni_1.27Mo_0.23 coating with the introduction of Mo element increases pitting susceptibility and deteriorates corrosion resistance compared with the Mo-free Al_0.32CrFeTi_0.73Ni_1.50 coating. The corrosion type of the Mo-bearing coating is mainly pitting, occurring in the coating’s surface defects and Cr-depleted regions. Full article

The main objective of this study was to develop a high-entropy alloy (HEA) derived from the Co_xCrFeNiTi HEA system (x = 0.5, 1) for protective coatings using the magnetron sputtering method. In order to produce the high-entropy alloy targets required for the magnetron sputtering process, mechanically alloyed metallic powders were consolidated via spark plasma sintering (SPS). The microstructural analysis results of the HEA mixture presented morphology changes after 30 h of alloying, with the particles presenting uniform polygonal shapes and dimensions. Subsequently, 316L stainless steel (SS) specimens were coated via magnetron sputtering, comparing their composition with that of the sputtering targets used for deposition to establish stoichiometry. Microstructural analyses of the SPSed HEAs revealed no defects and indicated a uniform elemental distribution across the surface. Furthermore, the CoCrFeNiTi equiatomic alloy exhibited a nearly stoichiometric composition, both in the coating and the sputtering target. The XRD analysis results indicated that amorphous coatings were obtained for both Co_0.5CrFeNiTi and the CoCrFeNiTi HEA, and nanoindentation tests indicated that the CoCrFeNiTi HEA coating presented a hardness of 596 ± 22 HV, compared to the 570 ± 19 HV measured for Co_0.5CrFeNiTi, suggesting an improved wear resistance. Full article

Equiatomic medium-entropy alloy (MEA) FeNiCr-B₄C (0, 1, and 3 wt.% B₄C) coatings were deposited onto an AISI 1040 steel substrate using pulsed laser cladding. Based on an SEM microstructural analysis, it was found that the cross-sections of all the obtained specimens were characterized by an average coating thickness of 400 ± 20 μm, a sufficiently narrow (100 ± 20 μm) “coating–substrate” transition zone, and the presence of a small number of defects, including cracks and pores. An XRD analysis showed that the formed coatings consisted of a single face-centered cubic (FCC) γ-phase and the space group Fm-3m, regardless of the B₄C content. However, additional TEM analysis of the FeNiCr coating with 3 wt.% B₄C revealed a two-phase FCC structure consisting of grains (FCC-1 phase, Fm-3m) up to 1 µm in size and banded interlayers (FCC-2 phase, Fm-3m) between the grains. The grains were clean with a low density of dislocations. Raman spectroscopy confirmed the presence of B₄C carbides inside the FeNiCr (1 and 3 wt.% B₄C) coatings, as evidenced by detected peaks corresponding to amorphous carbon and peaks indicating the stretching of C-B-C chains. The mechanical characterization of the FeNiCr-B₄C coatings specified that additions of 1 and 3 wt.% B₄C resulted in a notable increase in microhardness of 16% and 38%, respectively, with a slight decrease in ductility of 4% and 10%, respectively, compared to the B₄C-free FeNiCr coating. Thus, the B₄C addition can be considered a promising method for strengthening laser-cladded MEA FeNiCr-B₄C coatings. Full article

Oxygen-carbon-contained CrMnFeCoNi coatings were electrodeposited in an organic solvent of DMF-CH₃CN (N,N-dimethylformamide-acetonitrile) containing chlorides of chromium, manganese, iron, cobalt, and nickel, with or without supporting electrolyte lithium perchlorate (LiClO₄). The coatings’ composition, structure, hardness, and electrocatalytic properties were examined. The presence of lithium in coatings obtained with LiClO₄ showed it unsuitable as a supporting electrolyte in this fabrication process. Without LiClO₄, oxygen-carbon-contained CrMnFeCoNi coatings were obtained at constant potentials at −2.0, −2.5, and −3.0 V (vs. SSE) by enhancing the concentrations of the target metal ions in the solution. These coatings were mainly amorphous with nanocrystals, which were comprised of >50 atom% oxygen atoms, >7 atom% carbon atoms, and near equiatomic Cr, Mn, Fe, Co, and Ni, showing a high level of hardness and advanced electrocatalytic activity in the oxygen evolution reaction. Full article

To improve the AlCoCrFeNi high entropy alloys’ (HEAs’) toughness, it was coated with different amounts of Cu then fabricated by the powder metallurgy technique. Mechanical alloying of equiatomic AlCoCrFeNi HEAs for 25 h preceded the coating process. The established powder samples were sintered at different temperatures in a vacuum furnace. The HEAs samples sintered at 950 °C exhibit the highest relative density. The AlCoCrFeNi HEAs model sample was not successfully produced by the applied method due to the low melting point of aluminum. The Al element’s problem disappeared due to encapsulating it with a copper layer during the coating process. Because the atomic radius of the copper metal (0.1278 nm) is less than the atomic radius of the aluminum metal (0.1431 nm) and nearly equal to the rest of the other elements (Co, Cr, Fe, and Ni), the crystal size powder and fabricated samples decreased by increasing the content of the Cu wt%. On the other hand, the lattice strain increased. The microstructure revealed that the complete diffusion between the different elements to form high entropy alloy material was not achieved. A dramatic decrease in the produced samples’ hardness was observed where it decreased from 403 HV at 5 wt% Cu to 191 HV at 20 wt% Cu. On the contrary, the compressive strength increased from 400.034 MPa at 5 wt% Cu to 599.527 MPa at 15 wt% Cu with a 49.86% increment. This increment in the compressive strength may be due to precipitating the copper metal on the particles’ surface in the nano-size, reducing the dislocations’ motion, increasing the stiffness of produced materials. The formability and toughness of the fabricated materials improved by increasing the copper’s content. The thermal expansion has increased gradually by increasing the Cu wt%. Full article

Cold gas spraying was used to make a coating from an equiatomic CrFeNiMn high-entropy alloy. This four-component alloy was chosen because it is Co-free, thus allowing application in nuclear industries as a possible replacement of currently used stainless steel coatings. The feedstock material was gas atomized powder with a particle size distribution from 20 to 45 µm. A number of parameters were tested, such as the powder feed rate and gas feed pressure, in order to obtain as dense a coating as possible with nitrogen as the process gas. Spraying was performed using a gas preheating temperature of 1000 °C, gas feed pressure ranging from 50 to 60 bar, and two powder feeding rates. The coating thicknesses ranging from 230 to 490 µm and porosities ranging from 3% to 10% were obtained depending on the powder feed rate and gas feed pressure. The hardness of the cross-section of the coating was usually lower than that of the surface. The highest coating hardness obtained was above 300 HV_0.3 for both the surface and the cross-section. The as-atomized powder consisted of a face-centered cubic (FCC) phase with a minute amount of body-centered cubic (BCC) phase, which was no longer detectable in the coatings. The microstructure of the coating was highly stressed due to the high degree of deformation occurring in cold gas spraying. The deformation leads to strain hardening and induces a pronounced texture in the coating. The {111} planes tend to align along the coating surface, with deformation and texturing concentrating mainly on particle boundaries. A high-entropy alloy (HEA) coating was successfully sprayed for the first time using nitrogen as a process gas. The coating has the potential to replace stainless steel coatings in nuclear industry applications. Full article