| GUAN Qi,GONG Wenbiao,LI Yupeng,MENG Qingchen,DONG Junyan,CUI Heng.Microstructure and Properties of High Entropy Alloy Coatings of AlCoCrFeNi Prepared by Plasma Spraying[J],54(11):243-251 |
| Microstructure and Properties of High Entropy Alloy Coatings of AlCoCrFeNi Prepared by Plasma Spraying |
| Received:December 04, 2024 Revised:February 13, 2025 |
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| DOI：10.16490/j.cnki.issn.1001-3660.2025.11.021 |
| KeyWord:atmospheric plasma spraying high entropy alloy coating hardness wear resistance wear mechanism |
| Author | Institution |
| GUAN Qi |
Key Laboratory of Advanced Structural Materials, Ministry of Education,School of Materials Science and Engineering, Changchun University of Technology, Changchun , China |
| GONG Wenbiao |
Key Laboratory of Advanced Structural Materials, Ministry of Education,School of Materials Science and Engineering, Changchun University of Technology, Changchun , China |
| LI Yupeng |
Key Laboratory of Advanced Structural Materials, Ministry of Education,School of Materials Science and Engineering, Changchun University of Technology, Changchun , China |
| MENG Qingchen |
Key Laboratory of Advanced Structural Materials, Ministry of Education,School of Materials Science and Engineering, Changchun University of Technology, Changchun , China |
| DONG Junyan |
State Key Laboratory of Superhard Materials, Jilin University, Changchun , China |
| CUI Heng |
Changchun Railway Vehicles Co., Ltd., Changchun , China |
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| Abstract: |
| The enhancement of wear resistance in aluminum alloys is crucial for their application in industrial environments where high durability and surface integrity are required. In this study, AlCoCrFeNi high-entropy alloy (HEA) coatings are successfully deposited onto 7005 aluminum alloy substrates by atmospheric plasma spraying (APS). This work focuses on the investigation of the microstructure, mechanical properties, and wear resistance of these coatings, aiming to improve the surface performance of aluminum alloys, particularly in applications that demand exceptional wear resistance. The microstructural characteristics of the coatings are extensively studied using scanning electron microscopy (SEM), X-ray diffraction (XRD), and laser confocal microscopy (LSM). The AlCoCrFeNi HEA coatings exhibit a typical lamellar structure, with Fe, Co, Cr, and Ni elements being uniformly distributed across the coatings. In contrast, aluminum (Al) shows a tendency to segregate within the structure. XRD analysis reveals that the as-sprayed powder primarily consists of a body-centered cubic (BCC) phase, while the coatings exhibit a mixed-phase structure, consisting of both BCC and face-centered cubic (FCC) phases. The formation of the FCC phase is attributed to the reaction between aluminum in the HEA powder and oxygen during the APS process, leading to the generation of oxide phases. This phase transformation contributes to the overall improvement in the mechanical and wear properties of the coatings. Mechanical performance evaluations reveals significant enhancements in the hardness and porosity of the HEA coatings. The average hardness of the coatings is measured at 512.2HV, which is a substantial increase compared with the 120.7HV of the base 7005 aluminum alloy. The coatings demonstrate a low porosity of 3.23%, indicating a dense and well-adhered coating structure. These improvements in hardness and porosity suggest that the APS-deposited HEA coatings have a strong mechanical integrity, contributing to their excellent performance in wear resistance. Wear testing is conducted under dry friction conditions to assess the wear behavior of the coatings. The wear rate of the base aluminum alloy is found to be 7.67×10−4 mm³/(N.m), while the HEA coatings demonstrate a significantly lower wear rate of 3.02×10−5 mm³/(N.m), which represents a 96.06% reduction in wear rate compared with the untreated substrate. This significant decrease in wear rate highlights the exceptional wear resistance of the HEA coatings. The wear mechanisms of the HEA coatings are analyzed, and it is found that the coatings primarily experience abrasive wear and oxidative wear under dry friction conditions, with additional contributions from adhesive wear and fatigue wear. The results of this study demonstrate that the AlCoCrFeNi HEA coatings, prepared using APS, not only significantly improve the wear resistance of 7005 aluminum alloys but also offer enhanced mechanical properties such as increased hardness and reduced porosity. These findings suggest that HEA coatings are a promising solution for enhancing the performance of aluminum alloys in industrial applications that demand high wear resistance and durability. The successful implementation of APS for coating aluminum alloys with high-entropy alloys opens up new opportunities for the development of advanced materials suitable for a variety of demanding applications in industries such as aerospace, automotive, and machinery. This research illustrates the potential of HEA coatings to offer superior surface protection and extend the service life of aluminum alloy components subject to wear and mechanical stress, thus contributing to the development of more durable materials for industrial applications. |
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