J. Manuf. Mater. Process. 2024, 8(6), 280; https://doi.org/10.3390/jmmp8060280 - 3 Dec 2024
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In this work, the effect of high-entropy alloy powder preparation on the coatings deposited via high-velocity oxygen fuel sprayings was studied. The powders of FeNiCoCrMo0.5Al1.3 composition were prepared by milling and gas atomization. The structures, porosity, phase composition, and microhardness
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In this work, the effect of high-entropy alloy powder preparation on the coatings deposited via high-velocity oxygen fuel sprayings was studied. The powders of FeNiCoCrMo0.5Al1.3 composition were prepared by milling and gas atomization. The structures, porosity, phase composition, and microhardness of the coatings produced from mechanically alloyed and gas-atomized powders were compared. The influence of milling parameters on the powder phase composition and morphology was studied. Milling at 600 rpm for 1.5 h allowed the production of mechanically alloyed powder with a homogeneous distribution of Fe, Ni, and Al and thin lamellas enriched with Co, Cr, and Mo. Despite the difference in the feedstock powders’ phase compositions, the phase compositions of the coatings deposited from mechanically alloyed and gas-atomized powders are the same consisting of BCC, FCC solutions, and oxide. The amount of FCC solutions and oxide in the coating depends on the size distribution of the sprayed powder. It was found that the phase composition and the properties of the coatings deposited from the mechanically alloyed and gas-atomized powders of similar sizes are similar.
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Figure 1
Figure 1
<p>SEM images of the powder particles: (<b>a</b>,<b>e</b>)—blended, (<b>b</b>,<b>f</b>)—milled for 0.5 h, (<b>c</b>,<b>g</b>)—milled for 1.5 h, and (<b>d</b>,<b>h</b>)—gas-atomized.</p> Full article ">Figure 2
<p>EDS line scan element distribution in dependence on the milling parameter: (<b>a</b>) blended at 300 rpm for 0.5 h; (<b>b</b>) milled at 600 rpm for 0.5 h; (<b>c</b>) milled at 600 rpm for 1.5 h.</p> Full article ">Figure 3
<p>X-ray diffraction patterns of the powders (<b>a</b>) and the lattice parameters of the phases (<b>b</b>).</p> Full article ">Figure 4
<p>Optical microscopy images of the coatings deposited from: blended powder (<b>a</b>), milled powder (<b>b</b>), gas-atomized powder with a size of 50 µm (<b>c</b>), and gas-atomized powder with a size of 25 µm (<b>d</b>).</p> Full article ">Figure 5
<p>Porosity of the coatings produced from the different powders.</p> Full article ">Figure 6
<p>Element mapping data of the coating deposited from the powder prepared via different methods.</p> Full article ">Figure 7
<p>X-ray diffraction patterns of the coatings (<b>a</b>) and the lattice parameters of the phases (<b>b</b>).</p> Full article ">Figure 8
<p>Fraction of oxide (<b>a</b>) and FCC (<b>b</b>) in the coatings deposited from milled and gas-atomized powders.</p> Full article ">Figure 9
<p>Microhardness of the coatings (<b>a</b>) and the coatings surface after salt fog chamber test for 672 h (<b>b</b>).</p> Full article ">
<p>SEM images of the powder particles: (<b>a</b>,<b>e</b>)—blended, (<b>b</b>,<b>f</b>)—milled for 0.5 h, (<b>c</b>,<b>g</b>)—milled for 1.5 h, and (<b>d</b>,<b>h</b>)—gas-atomized.</p> Full article ">Figure 2
<p>EDS line scan element distribution in dependence on the milling parameter: (<b>a</b>) blended at 300 rpm for 0.5 h; (<b>b</b>) milled at 600 rpm for 0.5 h; (<b>c</b>) milled at 600 rpm for 1.5 h.</p> Full article ">Figure 3
<p>X-ray diffraction patterns of the powders (<b>a</b>) and the lattice parameters of the phases (<b>b</b>).</p> Full article ">Figure 4
<p>Optical microscopy images of the coatings deposited from: blended powder (<b>a</b>), milled powder (<b>b</b>), gas-atomized powder with a size of 50 µm (<b>c</b>), and gas-atomized powder with a size of 25 µm (<b>d</b>).</p> Full article ">Figure 5
<p>Porosity of the coatings produced from the different powders.</p> Full article ">Figure 6
<p>Element mapping data of the coating deposited from the powder prepared via different methods.</p> Full article ">Figure 7
<p>X-ray diffraction patterns of the coatings (<b>a</b>) and the lattice parameters of the phases (<b>b</b>).</p> Full article ">Figure 8
<p>Fraction of oxide (<b>a</b>) and FCC (<b>b</b>) in the coatings deposited from milled and gas-atomized powders.</p> Full article ">Figure 9
<p>Microhardness of the coatings (<b>a</b>) and the coatings surface after salt fog chamber test for 672 h (<b>b</b>).</p> Full article ">
