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.

Adhesion property of AlCrNbSiTi high-entropy alloy coating on zirconium:experimental and theoretical studies

Experimental scratch tests and first-principles calculations were used to investigate the adhesion property of AlCrNbSiTi high-entropy alloy(HEA)coatings on zirconium substrates.AlCrNbSiTi HEA and Cr coatings were deposited on Zr alloy substrates using multi-arc ion plating technology,and scratch tests were subsequently conducted to estimate the adhesion property of the coatings.The results indicated that Cr coatings had better adhesion strength than HEA coatings,and the HEA coatings showed brittleness.The special quasi-random structure approach was used to build HEA models,and Cr/Zr and HEA/Zr interface models were employed to investigate the cohesion between the coatings and Zr substrate using first-principles calculations.The calculated interface energies showed that the cohesion between the Cr coating and the Zr substrate was stronger than that of the HEA coating with Zr.In contrary to Al or Si in the HEA coating,Cr,Nb,and Ti atoms binded strongly with Zr substrate.Based on the calculated elastic constants,it was found that low Cr and high Al content decreased the mechanical performances of HEA coatings.Finally,this study demonstrated the utilization of a combined approach involving first-principles calculations and experimental studies for future HEA coating development.

Micro-aluminum powder with bi-or tri-component alloy coating as a promising catalyst:Boosting pyrolysis and combustion of ammonium perchlorate

A novel design of micro-aluminum(μAl)powder coated with bi-/tri-component alloy layer,such as:Ni-P and Ni-P-Cu(namely,Al@Ni-P,Al@Ni-P-Cu,respectively),as combustion catalysts,were introduced to release its huge energy inside Al-core and promote rapid pyrolysis of ammonium perchlorate(AP)at a lower temperature in aluminized propellants.The microstructure of Al@Ni-P-Cu demonstrates that a three-layer Ni-P-Cu shell,with the thickness of~100 nm,is uniformly supported byμAl carrier(fuel unit),which has an amorphous surface with a thickness of~2.3 nm(catalytic unit).The peak temperature of AP with the addition of Al@Ni-P-Cu(3.5%)could significantly drop to 316.2℃ at high-temperature thermal decomposition,reduced by 124.3℃,in comparison to that of pure AP with 440.5℃.It illustrated that the introduction of Al@Ni-P-Cu could weaken or even eliminate the obstacle of AP pyrolysis due to its reduction of activation energy with 118.28 kJ/mol.The laser ignition results showed that the ignition delay time of Al@Ni-P-Cu/AP mixture with 78 ms in air is shorter than that of Al@Ni-P/AP(118 ms),decreased by 33.90%.Those astonishing breakthroughs were attributed to the synergistic effects of adequate active sites on amorphous surface and oxidation exothermic reactions(7597.7 J/g)of Al@Ni-P-Cu,resulting in accelerated mass and/or heat transfer rate to catalyze AP pyrolysis and combustion.Moreover,it is believed to provide an alternative Al-based combustion catalyst for propellant designer,to promote the development the propellants toward a higher energy.

Effects of substrate temperature and deposition time on the morphology and corrosion resistance of FeCoCrNiMo0.3 high-entropy alloy coating fabricated by magnetron sputtering

The effects of substrate temperature and deposition time on the morphology and corrosion resistance of FeCoCrNiMo0.3 coating fabricated by magnetron sputtering were investigated by scanning electron microscopy and electrochemical tests.The FeCoCrNiMo0.3 coating was mainly composed of the face-centered cubic phase.High substrate temperature promoted the densification of the coating,and the pitting resistance and protective ability of the coating in 3.5wt%NaCl solution was thus improved.When the deposition time was prolonged at 500℃,the thickness of the coating remarkably increased.Meanwhile,the pitting resistance improved as the deposition time increased from 1 to 3 h;however,further improvement could not be obtained for the coating sputtered for 5 h.Overall,the pitting resistance of the FeCoCrNiMo0.3 coating sputtered at 500℃for 3 h exceeds those of most of the reported high-entropy alloy coatings.

Superior corrosion resistance-dependent laser energy density in(CoCrFeNi)95Nb5 high entropy alloy coating fabricated by laser cladding

(CoCrFeNi)95Nb5 high entropy alloy(HEA)coatings were successfully fabricated on a substrate of Q235 steel by laser cladding technology.These(CoCrFeNi)95Nb5 HEA coatings possess excellent properties,particularly corrosion resistance,which is clearly superior to that of some typical bulk HEA and common engineering alloys.In order to obtain appropriate laser cladding preparation process parameters,the effects of laser energy density on the microstructure,microhardness,and corrosion resistance of(CoCrFeNi)95Nb5 HEA coating were closely studied.Results showed that as the laser energy density increases,precipitation of the Laves phase in(CoCrFeNi)95Nb5 HEA coating gradually decreases,and diffusion of the Fe element in the substrate intensifies,affecting the integrity of the(CoCrFeNi)95Nb5 HEA.This decreases the microhardness of(CoCrFeNi)95Nb5 HEA coatings.Moreover,the relative content of Cr2O3,Cr(OH)3,and Nb2O5 in the surface passive film of the coating decreases with increasing energy density,causing corrosion resistance to decrease.This study demonstrates the controllability of a high-performance HEA coating using laser cladding technology,which has significance for the laser cladding preparation of other CoCrFeNi-system HEA coatings.

High-temperature tribological properties of Ni-P alloy coatings deposited by electro-brush plating

High-temperature tribological properties of Ni-P alloy coatings processed by electro-brush plating on 20CrMo steel have been investigated. A baU-on-disc configuration was employed and 4 mm diameter Si3N4 balls were used as static counterpart. All the wear tests were carried out at 450℃ for 180 rain without lubricants. The electro-brush plating Ni-P coating is amorphous in as-deposited condition, and it becomes polycrystalline with the formation of Ni and Ni3P after heat treatment at 450℃for 1 h. The friction coefficient of the Ni-P coating is just 50% of that of the 20CrMo steel at the friction temperature of 450℃. A mild adhesive wear mechanism was found for the electro-brush plating Ni-P coating tested at 450℃, whereas for the 20CrMo steel at the same temperature a mixed adhesive and abrasive wear mechanism was observed.

Microstructure and wear resistance of AlCrFeNiMo_(0.5)Si_(x) high-entropy alloy coatings prepared by laser cladding

In recent years,the coating prepared by laser cladding has attracted much attention in the field of wear research.In this work,AlCrFeNiMo_(0.5)Si_(x)(x=0,0.5,1.0,1.5,2.0)high-entropy alloy coatings were designed and prepared on Q235 steel by laser cladding.The effect of Si content on microstructure,microhardness and wear resistance of the coatings was studied in detail.The results indicate that the AlCrFeNiMo_(0.5)Si_(x) highentropy alloy coatings show an excellent bonding between substrate and the cladding layer.The AlCrFeNiMo_(0.5)Si_(x) coatings are composed of nano-precipitated phase with BCC structure and matrix with ordered B2 structure.With the addition of Si,the white phase(Cr,Mo)_(3)Si with cubic structure appears in the interdendritic,and the morphology of the coating(x=2.0)transforms into lamellar eutectic-like structures.The addition of Si enhances the microhardness and significantly improves the wear resistance of the coatings.As x increases from 0 to 2.0,the average hardness of the cladding zone increases from 632 HV to 835 HV,and the wear rate decreases from 1.64×10^(-5) mm^(3)·(N·m)^(-1) to 5.13×10^(-6) mm^(3)·(N·m)^(-1).When x≥1.5,the decreasing trend of the wear rate gradually slows down.The wear rates of Si1.5 and Si2.0 coatings are 5.85×10^(-6) mm^(3)·(N·m)^(-1) and 5.13×10^(-6) mm^(3)·(N·m)^(-1),respectively,which is an order of magnitude lower than that of Q235 steel.

Effect of Rare Earth on Microstructure and Corrosion Resistance of Pulse Reversal Current Electrodeposition Ni-Co Alloy Coatings

The effect of adding RE to plating bath on microstructure and corrosion resistance of Ni-Co alloy coatings prepared by pulse reversal current electrodeposition was studied by means of SEM/EDS, electrochemical analysis and corrosion mass loss etc. The results show that adding proper RE to plating solution can promote the microstructure of coatings compacter, the surface smoother and the crystal finer, and improve the corrosion resistance. The coatings exhibite the highest corrosion resistance when the concentration of RE reaches 0.25 g·L -1. The reason of increasing corrosion resistance by adding RE was also investigated.

STUDIES OF LOW-CONCENTRATION CHROMATE PASSIVE FILM FOR ZINC-BASED ALLOY COATED STEEL WIRES

The corrosion resistance of a low concentration chromate passive film for zinc based alloy coated steel wires was assessed by salt spray and electrochemical corrosion tests. XPS and AES analyses showed that the composition of such chromate passive film was S 5 5, Na 3 4, C 11 8, Ti 7 9, O 41 6, Cr 13 7, Zn 16 0.

Fracture Behaviour of Laser Clad Fe-and Ni-base Alloy Coatings on a Cast Iron under SEMI Loading

Laser cladding technique has been applied to renovate some partially-damaged (or worn) components with Fe, Ni, Co-base alloys, hence to improve their hardness values and wear resistance successfully in previous reports. But for some punching or shearing cast iron dies damaged or worn in automobile manufacture, the renovated surfaces also bear some impact loading. Therefore, a small-energy and multi-impact (SEMI) test was designed to investigate the fracture behaviour of renovated cast iron dies achieved by laser cladding of Fe and Ni-base alloys under SEMI loading to meet above requirement. observations show that the fracture took place in the substrate near to the substrate/coating interface rather than at the interface. The tempering temperature has a great influence on the cycles to fracture of laser-clad samples under SEMl loading, i.e. the low tempering temperature of 300℃ gives a maximum cycle to fracture, while a higher tempering temperature of 400℃ has a minimum. Furthermore, the fracture mechanism has also been discussed in present study

Effects of C/B4 C ratio on microstructure and property of Fe-based alloy coatings reinforced with in situ synthesized TiB2 -TiC

The Fe-based alloy coatings reinforced with in situ synthesized TiB2-TiC were prepared on Q235 steel by reactive plasma cladding using Fe901 alloy, Ti, B4C, and graphite （C） powders us raw materials. The effects of C/B4C weight percentage ratio （0 - 1. 38 ） on the microstructure , microhardness , and wet sand abrasion resistance of the coatings were investigated. The results show that the coatings consist of （ Fe, Cr ） solid solution, TiC, TiB2, Ti8C5 , and Fe3 C phases. The decrease of C/B4 C ratio is propitious to the formation of TiB2 and Tis C5. Increasing the C/B4 C ratio can help to refine the microstructure of the coatings. However, the microhardness of the middle-upper of the coatings and the wet sand abrasion resistance of the coatings degenerate with the increase of C/B4C ratio. The coating exhibits the best wet sand abrasion resistance at C/BaC =0 and its average mass loss rate per unit wear distance is 0. 001 2%/m. The change of the wet sand abrasion resistance of the coatings with the C/B4C ratio can be mainly attributed to the combined action of the changes of microhardness and the volume percentage of the ceramic reinforcements containing titanium in the coatings.

Effect of Y_(2)O_(3) on microstructure and properties of CoCrFeNiTiNb high entropy alloy coating on Ti-6Al-4V surface by laser cladding

The effects of Y_(2)O_(3) on the microstructure, microhardness, wear resistance, high-temperature oxidation resistance, hot corrosion resistance, and electrochemical corrosion behaviour of CoCrFeNiTiNb high entropy alloy coatings formed on Ti-6Al-4V alloy surfaces were studied. The results show that the addition of Y_(2)O_(3) changes the proportion of the phase but does not change its type. The average grain size is only 1/4.7 of that of the high entropy alloy(HEA) coating, and the fine-grained strengthening leads to increases in the microhardness and wear resistance of 21.8% and 26.9%, respectively. The addition of Y_(2)O_(3) enhances the denseness and bonding properties of the oxide and corrosion product layers, reducing the oxidation and hot corrosion rates by 60.3% and 40.3%, respectively. The addition of Y_(2)O_(3) doubles the corrosion resistance which is attributed to the refinement of the grains, the increased proportion of HCP and TiN, and the weakening of galvanic coupling corrosion.

Design and characterization of a novel Cu_(2.3)Al_(1.3)Ni_(1.7)SnCr_(0.3) multi-principal element alloy coating on magnesium alloy by laser cladding

The evaporation and dilution of substrate seriously limit the performance of laser cladding coatings on magnesium alloys.In order to overcome the above shortcomings,a multi-step ultrasonic assisted laser remelting technology was proposed to improve the performance of the coating.In this work,a novel Cu_(2.3)Al_(1.3)Ni_(1.7)SnCr_(0.3) multi-principal element alloy coating(MPEAC)was prepared on the surface of mag-nesium alloy.Characterization techniques such as transmission electron microscopy(TEM),electron back scatter diffraction(EBSD)and scanning electron microscopy(SEM)were employed to characterize the microstructure and phase composition of the coatings.And the phase structure and morphology at the interface between the coating and the substrate were also studied via focus ion beam(FIB)and TEM method.In addition,the corrosion and wear resistance ability of the coatings were monitored by potentiodynamic polarization(PDP),and electrochemical impedance spectroscopy(EIS),hardness and friction tests.The results show that Cu_(2.3)Al_(1.3)Ni_(1.7)SnCr_(0.3) MPEAC with ultrasonic assisted is composed of FCC phase and eutectic phases(Cu_(10)Sn_(3) and Cu_(2)Ni_(3)Sn_(3)).Due to the forced convection generated by ultrasonic waves,some Cu and Ni phases are precipitated around Cu_(2)Ni_(3)Sn_(3) phases,which is beneficial to enhance the corrosion resistance.Because of the grain refinement effect caused by ultrasonic,the wear resistance of the coating is also improved.Furthermore,ultrasonic vibration can effectively weaken and eliminate the texture density of the Cu_(2.3)Al_(1.3)Ni_(1.7)SnCr_(0.3) MPEAC fabricated by laser cladding.

Anomalous microstructure and tribological evaluation of AlCrFeNiW_(0.2)Ti_(0.5)high-entropy alloy coating manufactured by laser cladding in seawater

To evaluate the potential of high entropy alloys for marine applications,a new high entropy alloy coating of AlCrFeNiW_(0.2)Ti_(0.5)was designed and produced on Q235 steel via laser cladding.The microstructure,microhardness and tribological performances sliding against YG6 cemented carbide,GCr15 steel and Si_(3)N_(4)ceramic in seawater were studied in detail.The AlCrFeNiW_(0.2)Ti_(0.5)coating showed an anomalous’sunflower-like’morphology and consisted of BCC and ordered B2 phases.The microhardness was approximately 692.5 HV,which was 5 times higher than substrate.The coating showed more excellent tribological performances than Q235 steel and SUS304,a typical material used in seawater environment,sliding against all three coupled balls in seawater.Besides,the wear and friction of AlCrFeNiW_(0.2)Ti_(0.5)coating sliding against YG6 in seawater were most mild.The main reason was the generation of Mg(OH)_(2),CaCO_(3),metal oxides and hydroxides and the formation of protective tribo-film on the worn surface of AlCrFeNiW_(0.2)Ti_(0.5)coating in the process of reciprocated sliding.This would effectively hinder the direct contact between the worn surfaces of AlCrFeNiW_(0.2)Ti_(0.5)coating and YG6 ball,resulting in a decrease of friction coefficient and wear rate.Thus the YG6 was an ideal coupled material for AlCrFeNiW_(0.2)Ti_(0.5)coating in seawater,and the coating would become a promising wear-resisting material in ocean environment.

Corrosion behavior of Al_(0.4)CoCu_(0.6)NiSi_(0.2)Ti_(0.25) high-entropy alloy coating via 3D printing laser cladding in a sulphur environment

High-entropy alloys(HEAs) are of great interest in materials science and engineering communities owing to their unique phase structure.HEAs are constructed with five or more principal alloying elements in equimolar or near-equimolar ratios.Therefore,they can derive their performance from multiple principal elements ratherthan a single element.In this work,three-dimensional printing laser cladding was applied to produce an Al_(0.4)CoCu_(0.6)NiSi_(0.2)Ti_(0.25) HEA coating.The experimental results confirmed that the laser cladding could be used to produce a thin coating of 120 μm in thickness.In the high-temperature laser cladding process,some Fe elements diffused from the substrate to the coating,forming a combination of face-centred cubic and body-centred cubic phase structures.The HEA coating metallurgically bonded well with the substrate.Owing to the increased dislocation density and number of grain boundaries,the HEA coating was harder and had a stronger hydrophobicity than X70 steel.The electrochemistry results showed that the HEA coating had better corrosion resistance than X70 steel.Aluminium oxides formed on the surface of the HEA coating had a certain protective effect.However,because of the laser cladding,the HEA coating generated cracks.In future work,the laser cladding technology will be improved and heat treatment will be implemented to prevent formation of cracks.

Effects of Al contents on microstructure and properties of hot-dip Zn-Al alloy coatings on hydrogen reduced hot-rolled steel without acid pickling

A new hot-dip galvanizing method was employed on hot-rolled low carbon steel.The effects of Al contents on microstructure,micro-hardness and corrosion resistance of Zn-Al alloy coatings were systematically investigated.Phase composition,microstructure and element distribution in Zn-Al alloy coatings were analyzed using X-ray diffraction（XRD）and electron probe micro analysis（EPMA）,respectively.It is found that Al content（0.6-6.0 wt.%）in galvanizing zinc affects surface quality and adhesion between coatings and matrix in the newly developed method.In addition,with increasing Al content,micro-hardness significantly increased due to the increase in Zn-Al eutectoid phases.Potentiodynamic polarization and electrochemical impedance spectroscopy（EIS）also revealed that increase in Al plays a noticeable role in improving the corrosion resistance of Zn-Al alloy coatings.

Influence of laser re-melting and vacuum heat treatment on plasma-sprayed FeCoCrNiAl alloy coatings

FeCoCrNiAl high entropy alloy coatings were prepared by supersonic air-plasma spraying.The coatings were post-treated by vacuum heat treatment at 600 and 900°C,and laser re-melting with 300 W,respectively,to study the influence of different treatments on the structure and properties of the coatings.The phase constitution,microstructure and microhardness of the coatings after treatments were investigated using X-ray diffraction,scanning electron microscopy and energy dispersive spectrometry.Results showed that the as-sprayed coatings consisted of pure metal and Fe-Cr.The AlNi;phase was obtained after the vacuum heat treatment process.A body-centered cubic structure with less AlNi;could be found in the coating after the laser re-melting process.The average hardness values of the as-sprayed coating and the coatings with two different temperature vacuum heat treatments and with laser re-melting were 177,227,266 and 682 HV,respectively.This suggests that the vacuum heat treatment promoted the alloying process of the coatings,and contributed to the enhancement of the coating wear resistance.The laser re-melted coating showed the best wear resistance.

High-frequency electropulse deposition of microcrystallized MGH754 ODS alloy coatings

A simple but more efficient technique—high-frequency electropulse deposition—was developed to produce microcrystallized MGH754 ODS alloy coatings on the 1Cr18Ni9Ti stainless steel substrate. The coating has a very fine grain size of 30–300 nm and metallurgical bonding with the substrate. Isothermal oxidation in air at 1 000°C for 100 h shows that micro-crystallisation and dispersed oxide particles promote the selective oxidation of Cr greatly to form a protective and continuous Cr2O3 scale and also improve the scale spallation resistance dramatically, thus increasing the oxidation resistance of 1Cr18Ni9Ti.

Investigation on a Non-cyanide Plating Process of Ni-P Coating on Magnesium Alloy AZ91D

In this research we presented a non-cyanide plating process of Ni-P alloy coating on Mg alloy AZ91D. By applying a new process flow of electroless nickel plating in which zinc coating is used as transition of Ni-P coating on Mg alloy AZ91D, the process of copper transition coating plated in the cyanides bath can be replaced. A new bath composed of NiSO4 was established by orthogonal test. The results show that zinc transition coating can increase the adhesion and protect the Mg alloy substrate from the bath corrosion. The optimal plating bath composition is NiSO4·6H2O 20 g/L, NaH2PO2·H2O20g/L and C6H8O7·H2O 2.5 g/L, and optimal bath acidity and optimal plating temperature are pH 4.0 and 95℃, respectively. The present process flow is composed of ultrasonic cleaning→alkaline cleaning→acid pickling→activation→double immersing zinc→electroplating zinc→electroless nickel plating→passivation treatment. The present non-cyanide process of electroless nickel plating is harmless to our surroundings and Ni-P coating on Mg alloy AZ91D produced by present process possesses good adhesion and corrosion resistance.

Preparation and properties of Al-Mn alloy coatings in NaCl-KCl-AlCl_3-CeCl_3 molten salts

Al-Mn alloy coatings were electrodeposited on an iron substrate from AlCl3-NaCl-KCl molten salts with anhydrous MnCl2 enhanced by the addition of CeCl3. The microstructure and properties of the Al-Mn alloy coatings were investigated, and scanning electron microscopy, X-ray diffraction, and polarization curves were used to determine the composition, surface morphology, phase structure, and corrosion resistance of the obtained deposits. The results showed that the surface coatings were smooth, and that the crystallites were dense and uniform when 0.22 wt.% CeCl3 was added to the molten salt. An amorphous mixture of Al and Al6Mn was obtained. CeCl3 enhanced the corrosion resistance and increased the hardness of the single amorphous phase alloys. The pitting potential of the coating was approximately -1.1239 V, and its hardness was 390 kgf/mm2.