First report of agglomerated and sintered carbide-high-entropy alloy composite thermal spray coating

IF 5.6 2区材料科学 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY Scripta Materialia Pub Date : 2025-02-08 DOI:10.1016/j.scriptamat.2025.116591

Ecio Bosi , Ashok Meghwal , Mehdi Hourmand , Surinder Singh , Michael Boschen , Anthony Roccisano , Colin Hall , Steven Matthews , Paul Munroe , Christopher C. Berndt , Andrew Siao Ming Ang

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Abstract

A novel cemented carbide composite coating was developed using high-velocity oxygen fuel (HVOF) spraying with an agglomerated and sintered WC-20 wt.% CoCrFeNi high-entropy alloy (HEA) powder. The coating exhibited a complex microstructure of WC, W₂C, W, Cr₂O₃, spinel oxide, and two FCC phases. CALPHAD simulations provided insights into phase stability but were not fully accurate due to decarburization during deposition. Nano- and micro-indentation revealed hardness variability between the carbide-rich and FCC phases, attributed to decarburization and dissolution mechanisms. The WC-20CoCrFeNi coating demonstrated superior hardness and wear resistance compared to HEAs but did not exceed those of conventional cemented carbide thermal spray coatings. Electrochemical testing revealed enhanced seawater corrosion resistance for the WC-20CoCrFeNi coating than both HEAs and conventional cemented carbides. This study highlights the potential of HEAs as binder materials in cemented carbides processed via agglomeration and sintering, offering a promising balance of properties for engineering applications.

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团聚烧结碳化物-高熵合金复合热喷涂涂层首次报道

以wc - 20wt .% CoCrFeNi高熵合金（HEA）粉末为基体，采用高速氧燃料（HVOF）喷涂技术制备了一种新型硬质合金复合涂层。涂层呈现出WC、W2C、W、Cr2O3、氧化尖晶石和两种FCC相的复杂微观结构。CALPHAD模拟提供了对相稳定性的深入了解，但由于沉积过程中的脱碳，并不完全准确。纳米和微压痕显示了富碳化物相和FCC相之间的硬度变化，这归因于脱碳和溶解机制。WC-20CoCrFeNi涂层的硬度和耐磨性优于HEAs涂层，但不超过常规硬质合金热喷涂涂层。电化学测试表明，WC-20CoCrFeNi涂层的耐海水腐蚀性能优于HEAs和常规硬质合金。这项研究强调了HEAs作为通过团聚和烧结加工的硬质合金粘结材料的潜力，为工程应用提供了一个有前途的性能平衡。

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来源期刊

Scripta Materialia 工程技术-材料科学：综合

CiteScore

11.40

自引率

5.00%

发文量

581

审稿时长

34 days

期刊介绍： Scripta Materialia is a LETTERS journal of Acta Materialia, providing a forum for the rapid publication of short communications on the relationship between the structure and the properties of inorganic materials. The emphasis is on originality rather than incremental research. Short reports on the development of materials with novel or substantially improved properties are also welcomed. Emphasis is on either the functional or mechanical behavior of metals, ceramics and semiconductors at all length scales.