Structure and corrosion behavior of FeCoCrNiMo high-entropy alloy coatings prepared by mechanical alloying and plasma spraying

FeCoCrNiMox composite powders were prepared using the mechanical alloying technique and made into high-entropy alloy(HEA)coatings with the face-centered cubic phase using plasma spraying to address the element segregation problem in HEAs and pre-pare uniform HEA coatings.Scanning electron microscopy,transmission electron microscopy,and X-ray diffractometry were employed to characterize these coatings’microstructure and phase composition.The hardness,elastic modulus,and fracture toughness of coatings were tested,and the corrosion resistance was analyzed in simulated seawater.Results show that the hardness of the coating is HV0.1606.15,the modulus of elasticity is 128.42 GPa,and the fracture toughness is 43.98 MPa·m^(1/2).The corrosion potential of the coating in 3.5wt%NaCl solution is-0.49 V,and the corrosion current density is 1.2×10^(−6)A/cm^(2).The electrochemical system comprises three parts:the electrolyte,the adsorption and metallic oxide films produced during immersion,and the FeCoNiCrMo HEA coating.Over in-creasingly long periods,the corrosion reaction rate increases first and then decreases,the corrosion product film comprising metal oxides reaches a dynamic balance between formation and dissolution,and the internal reaction of the coating declines.

Influences of Milling Time and NbC on Microstructure of AlCoCrFeNi_(2.1)High Entropy Alloy by Mechanical Alloying

AlCoCrFeNi_(2.1)eutectic high entropy alloy(EHEA)and AlCoCrFeNi_(2.1)-x NbC(x=2.5wt%,5.0wt%,7.5wt%,and 10wt%)high entropy alloy(HEAs)were prepared by mechanical alloying(MA).The effects of milling time and NbC content on the alloying behavior and grain size of the AlCoCrFeNi_(2.1)EHEA were investigated.The experimental results show that the AlCoCrFeNi_(2.1)EHEA primarily consists of order BCC(B2)and face-centered-cubic(FCC)phases,while the AlCoCrFeNi_(2.1)-x NbC(x=2.5wt%,5.0wt%,7.5wt%,and 10wt%)HEAs are composed of B2,FCC,and NbC phases.With the increase of milling time,the powder goes through three stages,irregularity,cold welding fracture and spheroidization.The particle size of AlCoCrFeNi_(2.1)EHEA powder shows a trend of first increasing and then decreasing.Therein,the particle size presents a normal distribution during 0-50 h alloying.With the addition of NbC,the AlCoCrFeNi_(2.1)-x NbC HEAs powders are significantly refined.And the degree of grain refinement gradually increases with the increase of NbC content.

Rapid synthesis of Ti(C,N) powders by mechanical alloying and subsequent arc discharging

Ti（C,N） powders were synthesized by mechanical alloying （MA） from a mixture of pure titanium and graphite under a nitrogen atmosphere in a planetary mill.Effects of arc discharging on phase transformation and microstructure of MA powders milled for 1-7 h were explored.The results show that Ti（C,N） powders were prepared after mechanical milling for 1 h and subsequent arc discharge treatment,whereas the synthesis reaction did not occur in 7 h by mechanical milling alone.The ions produced during arc discharging interacted with powder particles and accelerated the diffusion of atoms and the nucleation on the surface of the as-milled powder,which results in fast synthesis of Ti（C,N） powders.The formation mechanisms of the two synthesis processes are self-propagating reactive synthesis.

Effect of mechanical alloying and sintering process on microstructure and mechanical properties of Al-Ni-Y-Co-La alloy

Al86Ni7Y4.5Co1La1.5 （mole fraction, %） alloy powder was produced by argon gas atomization process. After high-energy ball milling, the powder was consolidated by vacuum hot press sintering and spark plasma sintering （SPS） under different process conditions. The microstructure and morphology of the powder and consolidated bulk sample were examined by X-ray diffraction （XRD）, scanning electron microscopy （SEM） and transmission electron microscopy （TEM）. It is shown that amorphous phase appears when ball milling time is more than 100 h, and the bulk sample consolidated by SPS can maintain amorphous/ nanocrystalline microstructure but has lower relative density. A compressive strength of 650 MPa of Al86Ni7Y4.5Co1La1.5 nanostructured samples is achieved by vacuum hot extrusion （VHE）.

Mechanical alloying and phase transformation in Fe-Si alloy

The Fe-Si mechanical alloying and its transformation are investigated to evaluate whether mechanical alloying is a useful process for producing Fe-Si alloy. The mechanical alloying process of Fe-Si powders is studied by SEM（ scanning electron microscopy）, EDS（energy dispersive spectrometer）and XRD（X-ray diffraction）. The results show that the ball milling process first makes tough Fe powder a lump structure and brittle Si powder a small particle, and then as the mill power increases, the tough powder of iron with a lamellar structure forms and the Si particles lies on or between the Fe lamellas. Finally, the Fe and Si powders are mechanically alloyed through atom diffusion. So the Fe and Si powders can be alloyed by 15 h ball milling at a speed of 400 r/min and with a ball-to-powder ratio of 40 ： 1. After heating at 1 243 K for 1 h, the milled powders transform to α-FeSi2, and after heating at 1 243 K for 1 h, then cooling to 1 073 K for 1 h, the milled powders transform to β-FeSi2. Therefore, the monophase α-FeSi2 or β-FeSi2 can be obtained by heat treatment of mechanically alloyed Fe-Si powders.

Pressure sintering of W-15wt.%Cu alloys prepared by mechanical alloying as a subsequent densification treatment method

The sintered W-15wt.%Cu alloys fabricated by mechanical alloying were re-sintered under pressure to increase the density and improve the properties of these alloys. The pressure was applied vertically along the axis of the sintered sample. Properties such as density, hardness, and bending strength were measured. The microstructures of the sintered bodies were observed. The results showed that the subsequent pressure sintering could increase the density of the sintered W-15wt.%Cu alloys. Their hardness, bending strength, and some other physical properties were also improved by this subsequent densification treatment.

Effects of rare earth La on the microstructure and melting property of(Ag-Cu_(28))-30Sn alloys prepared by mechanical alloying

To obtain novel intermediate temperature alloy solders with a melting temperature of 400-600°C,nominal（Ag-Cu28）-30Sn alloys without or with a trace addition（0.5 or 1.0 wt.%） of rare earth（RE） element La were prepared by mechanical alloying.The aim of this research is to investigate the effects of the addition of La on the microstructures,alloying process and melting properties of（Ag-Cu28）-30Sn alloys.The results show that the addition of La produces no new phase.A trace amount of La addition can effectively refine the grain size,but the excessive addition of 1.0 wt.% La inhibits the alloying process.The influence of La on the melting temperatures of solder alloys is negligible.However,the trace addition of 0.5 wt.% La can distinctly reduce the fusion zone and improve the melting property of（Ag-Cu28）-30Sn alloys.

Structural characteristics and magnetic properties of bulk nanocrystalline Fe_(84)Zr_2Nb_4B_(10) alloy prepared by mechanical alloying and spark plasma sintering consolidation

Magnetic properties of Fe84Zr2Nb4B10 sample were investigated. The sample was produced from nanocrystalline powders made by the mechanical alloying (MA) and consolidation using the spark plasma sintering (SPS) technique. Effects of milling time on phase transformation, structural characteristics, and magnetic properties of powders were examined by X-ray diffraction (XRD), scanning electron microscopy (SEM), and physical property measure system (PPMS), respectively. Results show that nanostructured α-Fe supersaturated solid solution is obtained in the final MAed products. The saturation magnetization (Ms) increased with increasing milling time and became constant at 130 h, but the coercivity (Hc) increased firstly and then decreased. The consolidated bulk sample exhibited a high density of 6.893 g·cm-3, there was no phase change during SPS process, and the saturation magnetization and susceptibility of the SPSed bulk sample improved in comparison with the milled powders. The variation of magnetic parameters can be explained by nano-scale effect and Herzer model.

SYNTHESIS OF INTERMETALLICS BY MECHANICAL ALLOYING

Mechanical alloying (MA), a solid-state powder processing method, is a 'far from equilibrium' synthesis technique which allows development of novel crystal structures and microstructures, leading to enhanced physical and mechanical properties. The ability to synthesize a variety of alloy phases including supersaturated solid solutions, nanocrystalline structures, amorphous phases and intermetallic compounds themselves is discussed. No extension of solubility using MA has been observed in the intermetallics studied. Nanostructured grains were observed in all compositions. Long time milling generally resulted in amorphous phase formation in large part because of the increase in grain boundary energy/mole with reduced grain size; good agreement with the Miedema model for amorphization was obtained in the Al-Fe system. Generally an anneal was required to form the intermetallic after MA; however,intermetallics with a large negative enthalpy of formation were detected in the MA condition. A study of the hot isostatic pressing of γ-TiAl powders produced by MA demonstrated that full density can be achieved at least 400℃ below the normal temperature required for conventional powder, that is 725℃ or below. Nanometered sized grains (≤100nm)were observed after HIP'ing up to 850℃.

Microstructure and properties of ultra-fine tungsten heavy alloys prepared by mechanical alloying and electric current activated sintering

The microstructure and properties of the 93W-4Ni-2Co-1Fe(mass fraction,%) tungsten heavy alloys prepared by mechanical alloying and electric current activated sintering from mixed elemental powders were investigated.After 15 h milling,the average W grain size in the powders is decreased to 120 nm.For the powders milled for 15 h,the density,hardness and transverse rupture strength of the alloys sintered only by an intensive pulse electric current are the maximum.When the total sintering time keeps constant,the properties of the sintered alloys can be obviously improved by optimizing the sintering time of pulse-and constant-currents.A bulk ultrafine alloy with an average W grain size of about 340 nm can be obtained by sintering 15 h-milled powders in a total sintering time of 6 min.The corresponding sintered density,hardness and transverse rupture strength reach 16.78 g /cm3,HRA84.3 and 968 MPa,respectively.

Evaluation of the microstructure,thermal and mechanical properties of Cu/SiC nanocomposites fabricated by mechanical alloying

Nano-sized silicon carbide(SiC:0wt%,1wt%,2wt%,4wt%,and 8wt%)reinforced copper(Cu)matrix nanocomposites were manufactured,pressed,and sintered at 775 and 875℃in an argon atmosphere.X-ray diffraction(XRD)and scanning electron microscopy were performed to characterize the microstructural evolution.The density,thermal expansion,mechanical,and electrical properties were studied.XRD analyses showed that with increasing SiC content,the microstrain and dislocation density increased,while the crystal size decreased.The coefficient of thermal expansion(CTE)of the nanocomposites was less than that of the Cu matrix.The improvement in the CTE with increasing sintering temperature may be because of densification of the microstructure.Moreover,the mechanical properties of these nanocomposites showed noticeable enhancements with the addition of SiC and sintering temperatures,where the microhardness and apparent strengthening efficiency of nanocomposites containing 8wt%SiC and sintered at 875℃were 958.7 MPa and 1.07 vol%^(−1),respectively.The electrical conductivity of the sample slightly decreased with additional SiC and increased with sintering temperature.The prepared Cu/SiC nanocomposites possessed good electrical conductivity,high thermal stability,and excellent mechanical properties.

Microstructure Design of High-Entropy Alloys Through a Multistage Mechanical Alloying Strategy for Temperature-Stable Megahertz Electromagnetic Absorption

Developing megahertz(MHz)electromagnetic wave(EMW)absorption materials with broadband absorption,multi-temperature adaptability,and facile preparation method remains a challenge.Herein,nanocrystalline FeCoNiCr_(0.4)Cu_(0.2) high-entropy alloy powders(HEAs)with both large aspect ratios and thin intergranular amorphous layers are constructed by a multistage mechanical alloying strategy,aiming to achieve excellent and temperature-stable permeability and EMW absorption.A single-phase face-centered cubic structure with good ductility and high crystallinity is obtained as wet milling precursors,via precisely controlling dry milling time.Then,HEAs are flattened to improve aspect ratios by synergistically regulating wet milling time.FeCoNiCr_(0.4)Cu_(0.2) HEAs with dry milling 20 h and wet milling 5 h(D20)exhibit higher and more stable permeability because of larger aspect ratios and thinner intergranular amorphous layers.The maximum reflection loss(RL)of D20/SiO_(2) composites is greater than-7 dB with 5 mm thickness,and EMW absorption bandwidth(RL<-7 dB)can maintain between 523 and 600 MHz from-50 to 150℃.Furthermore,relying on the“cocktail effect”of HEAs,D20 sample also exhibits excellent corrosion resistance and high Curie temperature.This work provides a facile and tunable strategy to design MHz electromagnetic absorbers with temperature stability,broadband,and resistance to harsh environments.

Alloying behavior and characterization of(CoCrFeNiMn)_(90)M_(10)(M=Al,Hf)high-entropy materials fabricated by mechanical alloying

The alloying behavior and microstructures of the(CoCrFeNiMn)_(90)M_(10)(M=Al,Hf)high-entropy alloy(HEA)powders fabricated by mechanical alloying were studied.The CoCrFeNiMn)_(90)Al_(10) powders have duplex solid-solution structures.In contrast,nanocrystalline HfNi_(3) anchoring in amorphous structures is found in the(CoCrFeNiMn)_(90)Hf_(10) powders.The(CoCrFeNiMn)_(90)Al_(10) powders show better ferromagnetic behaviors,mainly explained by the facilitated motion of the magnetic domain induced by the coherent interface between duplex phases.Combined with our previous work,the rules of forming solid-solution and amorphous phase in as-milled HEA powders are preliminarily proposed.It is found that,compared with the as-cast HEA reported previously,the variation range of mixing enthalpy with atomic size difference of the solid-solution formed in as-milled HEA powders is broader.Moreover,the variation ranges between mixing enthalpy and entropy with atomic size difference of the amorphous phase in HEA powder become wider than those of high-entropy bulk metallic glass.

Microstructure, thermal properties, and corrosion behaviors of FeSiBAlNi alloy fabricated by mechanical alloying and spark plasma sintering

An equiatomic FeSiBAlNi amorphous high-entropy alloy （HEA） was fabricated by mechanical alloying （MA）. A fully amorphous phase was obtained in the FeSiBAlNi HEA after 240 h of MA. The bulk FeSiBAlNi samples were sintered by spark plasma sintering （SPS） at 520 and 1080℃ under a pressure of 80 MPa. The sample sintered at 520℃ exhibited an amorphous composite structure comprising solid-solution phases （body-centered cubic （bcc） and face-centered cubic （fee） phases）. When the as-milled amorphous HEA was consoli- dated at 1080℃, another fcc phase appeared and the amorphous phase disappeared. The sample sintered by SPS at 1080℃ exhibited a slightly higher melting temperature compared with those of the as-milled alloy and the bulk sample sintered at 520℃. The corrosion behav- iors of the as-sintered samples were investigated by potentiodynamic polarization measurements and immersion tests in seawater solution. The results showed that the HEA obtained by SPS at 1080℃ exhibited better corrosion resistance than that obtained by SPS at 520℃.

Influence of B source materials on the synthesis of TiB_2-Al_2O_3 nanocomposite powders by mechanical alloying

An Al2O3-TiB2 nanocomposite was successfully synthesized by ball milling of Al, TiO2 and two B source materials of B2O3 （system （1）） and H3BO3 （system （2））. Phase identification of the milled samples was examined by Xray diffraction. The morphology and microstructure of the milled powders were monitored by scanning electron microscopy and transmission electron microscopy. It was found that the formation of this composite was completed after 15 and 30 h of milling time in systems （1） and （2）, respectively. More milling energy was required for the formation of this composite in system （2） due to the lubricant properties of HaBO3 and also its decomposition to HBO2 and B2O3 during milling. On the basis of X-ray diffraction patterns and thermodynamic calculations, this composite was formed by highly exothermic mechanically induced self-sustaining reactions （MSR） in both systems. The MSR mode took place around 9 h and 25 h of milling in systems （1） and （2）, respectively. At the end of milling （15 h for system （1） and 30 h for system （2）） the grain size of about 35-50 nm was obtained in both systems.

Influence of mechanical alloying time on the properties of Fe_3Al intermetallics prepared by spark plasma sintering

The Fe3Al-based intermetallics were prepared by mechanical alloying and spark plasma sintering （SPS）, and the influence of milling time on the properties of materials was investigated. The phase identification was investigated by X-ray, and the surface morphology and fractography were observed by scanning electron microscope （SEM）. The mechanical properties such as bending strength, strain, and microhardness were tested. The results show that Fe reacts with Al completely to form Fe3Al during short SPS processing time. The relative densities of the sintered samples were nearly 100%. The mechanical properties of the sintered samples can be improved along with the milling time. The representative values are the bend strength of 1327 MPa and the microhardness of 434.

Morphology and microstructure characterization of 95W-3.5Ni-1.5Fe powder prepared by mechanical alloying

The mechanism of mechanical solid-state reactions for formation of tungsten heavy alloy powder was discussed. A highenergy ball mill operating at room temperature was used for preparing tungsten heavy alloy powders, starting from elemental tungsten （W）, nickel （Ni）, and iron （Fe） powders. X-ray diffraction （XRD）, particle size analyzer, scanning electron microscopy （SEM）, and transmission electron microscopy （TEM） were used to follow the progress of the mechanical solid-state reaction of W, Ni, and Fe powders. These morphological studies revealed three stages in the milling process. In the first stage, the particle deformation changes the irregular structure of the as-received powder particles to flattened morphology, and the average particle size increases. In the second stage, the powder is sufficiently deformed and the tendency to fracture predominates over welding, and the particle size decreases. With continuous milling, the system reaches steady state, and relatively small and uniform particle size distribution is obtained after 20 h of milling.

Effects of Mechanical Alloying Parameters on the Microstructures of Nanocrystalline Cu-5 wt% Cr Alloy

Nanocrystalline Cu-5 wt%Cr alloy powders were fabricated by mechanical alloying （MA）, The effects of MA processing parameters on the crystallite size, solid solubility, and microstructures of the Cu- 5 wt%Cr alloys were investigated including type and size distribution of the grinding medium and ball-topowder weight ratio （BPR）. The results show that the crystallites were refined effectively and solid solubility of Cr in Cu was extended when heavier ball and higher BPR were adopted. The maximum solubility is extended up to 5.6 at% （namely 4.6 wt%） Cr in Cu by use of a combination of large and small size WC-Co balls with BPR of 30：1. A Cn-5 wt%Cr supersaturated solid solution alloy bulk is obtained by spark plasma sintering the as-milled powders at 900 ℃ for 5 min.

Fabrication of Ti_3AlC_2 ceramic material by mechanical alloying

Ti3AlC2 has the properties of ceramics and metals. These excellent properties indicate that Ti3AlC2 is a very promising material to extensive applications. Ti3AlC2 ceramic material was prepared by mechanical alloying. The effects of milling time and sintering temperature on the fracture, microstmctttre and mechanical properties of Ti3AlC2 ceramic material were analyzed by laser particle analyzer, X-ray diffraction, and scanning electron microscopy. The experimental results showed that Ti3AlC2 had the best comprehensive properties after the composite powder was milled for 3 h and sintered at 1630℃ for 2 h. The relative density, bending strength, and hardness of the sample reached 92.23%, 345.2 MPa, and HRA 34.1, respectively. The fracture surface indicated that the fracture of the material belonged to ductile rapture.

Titanium Aluminides: Science, Technology, Applications and Synthesis by Mechanical Alloying

The production. characteristics. and commercialization of monolithic and composite titanium aluminides are summanzed with emphasis on use in the demanding aerospace industry. The attractive elevated temperature properties combined with alow density make these materials of great interest, but inherently low 'forgiveness', and environmental concerns, must be overcome before widespread use will occur One synthesis method for the production of monolithic titanium aluminides-mechanical alloying- will be discussed in detail