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Development of Single-Stage TiNbMoMnFe High-Entropy Alloy Coating on 304L Stainless Steel Using HVOF Thermal Spray

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Abstract

Stainless steels are considered to be corrosion resistant; however, the performance of the material is affected under long-term or extreme conditions. The development of high-entropy alloys (HEAs) has opened avenues to enhance a useful life even under extreme environmental conditions. However, the fabrication of HEAs involves multiple-stage (milling, compaction, sintering, and inert environment) manufacturing processes. The present study explores the single-stage process development of a TiNbMoMnFe high-entropy alloy (HEA) coating on 304L stainless steel substrate using a high-velocity oxy-fuel (HVOF) thermal spray technique. Prior to HVOF coating, the feedstock powders were milled for 5, 10, and 15 h, respectively. The coated surfaces were analyzed for morphology, wettability, microstructure, corrosion resistance, presence of different phases and their distribution. Scanning electron microscopy (SEM), microhardness tester, 3D optical profilometry, and x-ray diffraction (XRD) were used to get different metallurgical and mechanical characteristics. The results indicated that 15-h milled powder-coated substrate exhibited higher corrosion resistance than the other coatings as well as the 304L stainless steel substrate. Chemically stable BCC phase was observed in 15-h milled powder-coated substrates. Moreover, the microhardness, surface roughness, and hydrophobicity of the coated surface were also improved with an increased milling rate. Thus, corrosion resistance of HEA coating can be optimized by a good selection of milling time of powder feedstock.

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Acknowledgments

The authors are grateful to BRNS, India (Project no. 34/14/01/2018-BRNS) for giving financial assistance for the HVOF coating unit and SERB, DST (CRG/2021/000754) for other financial support. The authors are also thankful to the Central Research Facility (CRF) and Nanoscale Research Facility (NRF) provided by the IIT Delhi, New Delhi, India.

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  1. Centre for Automotive Research and Tribology, Indian Institute of Technology Delhi, New Delhi , Delhi, 110016, India

    N. V. Abhijith & Deepak Kumar

  2. Centre for Biomedical Engineering, Indian Institute of Technology Delhi, New Delhi, 110016, India

    Dinesh Kalyansundaram

  3. Department of Biomedical Engineering, All India Institute of Medical Sciences, New Delhi, 110029, India

    Dinesh Kalyansundaram

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Correspondence to Deepak Kumar.

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This article is part of a special topical focus in the Journal of Thermal Spray Technology on High Entropy Alloy and Bulk Metallic Glass Coatings. The issue was organized by Dr. Andrew S.M. Ang, Swinburne University of Technology; Prof. B.S. Murty, Indian Institute of Technology Hyderabad; Distinguished Prof. Jien-Wei Yeh, National Tsing Hua University; Prof. Paul Munroe, University of New South Wales; Distinguished Prof. Christopher C. Berndt, Swinburne University of Technology. The issue organizers were mentored by Emeritus Prof. S. Ranganathan, Indian Institute of Sciences.

The original online version of this article was revised: This article was originally published without the following Acknowledgments.

The authors are grateful to BRNS, India (Project no. 34/14/01/2018-BRNS) for giving financial assistance for the HVOF coating unit and SERB, DST (CRG/2021/000754) for other financial support. The authors are also thankful to the Central Research Facility (CRF) and Nanoscale Research Facility (NRF) provided by the IIT Delhi, New Delhi, India.

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Abhijith, N.V., Kumar, D. & Kalyansundaram, D. Development of Single-Stage TiNbMoMnFe High-Entropy Alloy Coating on 304L Stainless Steel Using HVOF Thermal Spray. J Therm Spray Tech 31, 1032–1044 (2022). https://doi.org/10.1007/s11666-021-01294-9

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