Corrosion behaviour of thermally sprayed Mo added AlCoCrNi high entropy alloy coating

Corrosion behaviour of thermally sprayed Mo added AlCoCrNi high entropy alloy coating

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Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr

Corrosion behaviour of thermally sprayed Mo added AlCoCrNi high entropy alloy coating A. Vallimanalan ⇑, S.P. Kumaresh Babu, S. Muthukumaran, M. Murali, Vivek Gaurav, R. Mahendran Department of Metallurgical and Materials Engineering, NIT, Trichy, Tamil Nadu, India

a r t i c l e

i n f o

Article history: Received 19 September 2019 Accepted 23 September 2019 Available online xxxx Keywords: High entropy alloy HVOF AlCoCrMoNi Thermal spray coating Corrosion

a b s t r a c t AlCoCrNi alloy was modified by adding Mo to increase its corrosion resistance. Mo was successfully added to the alloy using mechanical milling. All the five constituents of the alloy were milled in a high-energy planetary ball-mill for 20 h. The effective concentration of Mo in the alloy was 10%. At equal intervals, samples were taken for phase formation studies using X-ray diffractional analysis (XRD). The micro-structural characterization was carried out to confirm the homogeneity of the alloy using Field emission scanning electron microscopy (FESEM). The resultant high entropy alloy (HEA) powder was thermally sprayed over a 316l substrate using High-velocity Oxy-fuel (HVOF) technique. Corrosion characteristics of the coating were studied using potentio-dynamic polarization (PDP) test under standard condition. The corrosion properties of the coating were compared with conventional NiCrSiB corrosion resistant coating. The AlCoCrMoNi HEA system offers better resistance to corrosion than NiCrSiB coating. Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International conference on Materials and Manufacturing Methods.

1. Introduction Recent advances in alloy development has introduced a new potential material in the form of high-entropy alloys (HEA). This material is being extensively studied for application in various fields owing to their strength, stability and corrosion resistance. Five or more elements with a particular combination can be classified as HEAs if they meet certain criteria of mixing enthalpy and entropy. AlCoCrNi is a quaternary alloy achieved by removing the Fe content in AlCoCrFeNi HEA. This quaternary alloy has a dualphase with low density. HEA containing Al have been of interest recently with an attempt to understand microstructural changes and mechanical properties. HVOF is one of the many technologies in the thermal-spray framework. Metallic and ceramic powders are fed into HVOF, which reaches up to 1500 °C to melt these powders and carries it to a substrate. The molten powder cools down at the surface of the substrate and bonds with it. The coating achieved through this process protects the substrate from corrosion, erosion, wear and environmental degradation. The combination of HEA and HVOF for surface protection is of interest in various sectors. NiCoFeCrSiAlTi based HEA coating was studied for thermal barrier

⇑ Corresponding author. E-mail address: [email protected] (A. Vallimanalan).

application. The HVOF coating of HEA resulted in better mechanical properties [1]. Another combination of AlTiCrFeCoNi HEA was used for HVOF coating to improve the wear behavior of steel substrate and it was found to improve fracture toughness even at high temperature [2].

2. Materials and methods 2.1. HVOF coating of AlCoCrMoNi HEA and NiCrSiB HIPOJET 2700 HVOF spray equipment of Metallizing Equipment Co. Pvt. Ltd., India was used to coat the 316 steel substrate. Substrate samples in the form of plates (50  50  8 mm) were prepared. The samples were grit blasted, cleaned with acetone and screwed on to a separate thick metallic plate. NiCrSiB alloy powder was also supplied by Metallizing Equipment Co Pvt Ltd., India. The elements Al, Co, Cr, Mo and Ni (Sigma-Aldrich, 99.5% purity) were taken in powder form with average particle size of 40 mm. They were mechanically alloyed using a high energy planetary ball-mill. Milling was done for 20 h with 5:1 ball to powder ratio. The resultant powder was characterized for phase formation using XRD (Rigaku ultima III diffractometer). Table 1 gives the coating parameters used for HVOF coating. Both the powders were coated with same parameters. The test surfaces of the coatings were pol-

https://doi.org/10.1016/j.matpr.2019.09.149 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International conference on Materials and Manufacturing Methods.

Please cite this article as: A. Vallimanalan, S. P. Kumaresh Babu, S. Muthukumaran et al., Corrosion behaviour of thermally sprayed Mo added AlCoCrNi high entropy alloy coating, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.149

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ished to 600 grit prior to testing. Coating thickness of around 300 mm was achieved. Potentiodynamic polarization test was conducted on both the coatings using ACM Gill electrochemical workstation (model 1762). ASTM standard G59 was followed to conduct the test.

Table 1 Coating Parameters for HVOF. Oxygen flow

270 SLPM

LPG flow Air flow Nitrogen flow Spray distance Powder feed rate Particle velocity

50–55 SLPM 550 SLPM 20 SLPM 7 in. 40 g/min 300–350 m/s

3. Result and discussion 3.1. Powder XRD characterization

Table 2 Enthalpy of Mixing between elements of HEA system. Al 19 10 5 –22

19 Co 4 5 0

10 4 Cr 0 7

5 5

–22 0 7 7 Ni

0 Mo 7

The solid-solution formation for the present HEA was predicted using parameters like entropy of mixing, enthalpy of mixing, electron negativity difference and atomic size. Table 2 consolidates the enthalpy of mixing between elements of the current HEA system. XRD pattern of as-prepared powder taken at 2 h, 5 h, 10 h, 15 h and 20 h is shown in Fig. 1. The Willamson-Hall equation was used to calculate crystallite size of the developed HEA and its lattice strain as shown in Table 3.

Fig. 1. XRD of HEA as-prepared powders at different intervals. Table 3 Lattice strain and Crystallite size of HEA system. System

Lattice strain

Crystallite size

AlCoCrMoNi

0.0032

30 nm

Fig. 3. Cross-Section of HEA coating on SS316 L substrate.

Fig. 2. FESEM micrographs of HEA as-prepared powders at (a) 5 h (b) 10 h (c) 15 h (d) 20 h.

Please cite this article as: A. Vallimanalan, S. P. Kumaresh Babu, S. Muthukumaran et al., Corrosion behaviour of thermally sprayed Mo added AlCoCrNi high entropy alloy coating, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.149

A. Vallimanalan et al. / Materials Today: Proceedings xxx (xxxx) xxx

The porosity of the coating was measured to be around 1.03%. The bond strength was 68Mpa. The top surface contains certain cracks where the unmelted particles were present and spalled off [8–10]. The mechanical properties of the coating are summarized in Table 4.

Table 4 Mechanical properties of the coated substrate. Property

Value

Hardness Surface roughness Porosity Bond strength

665 VHN 7.73 Ra 1.03% 68 Mpa

3

3.4. Corrosion studies The data obtained from the potentiodynamic polarization test conducted using the ACM Gill electrochemical workstation are used to draw the Tafel plot of Potential, Ecorr vs log of Current Density [11,12]. The Icorr for AlCoCrMoNi and AlCoCrMo0.5Ni and NiCrSiB coatings are shown in Fig. 4. From the above Tafel Plot, Ecorr, Icorr values are calculated using the Cathodic and Anodic Tafel slopes bc and ba respectively. The corrosion rates are calculated from icorr values. Corrosion rate calculated are given in Table 5. From Table 5 it is inferred that the corrosion resistance is significantly higher for HEA coating as compared to NiCrSiB coating. 4. Conclusion AlCoCrMo0.5Ni HEA was successfully synthesized using mechanical alloying. A BCC solid solution is obtained with XRD peaks at [2 1 1] and [0 1 1]. The as-prepared powder was found to be homogenous. The synthesized HEA was successfully produced over SS316L substrate through HVOF process. The coating protects the surface with superior corrosion resistance as compared to conventional NiCrSiB HVOF coating. References

Fig. 4. Tafel plot of HVOF Coated AlCoCrMoxNi and NiCrSiB coating.

Table 5 Corrosion rate of AlCoCrMoxNi and NiCrSiB coating. Coating

AlCoCrMoNi

AlCoCrMo0.5 Ni

NiCrSiB

Corrosion Rate (mm/year)

0.00276

0.00438

0.018

Initially, the peaks can be observed for all the elements at 2 h. After 5 h, few peaks vanish, indicating the start of solid-solution formation. Al and Cr seem to diffuse into Co, Mo and Ni conforming partial solid solution. The crystallite size reduces due to high lattice strain. This is confirmed by reduced intensity of the peaks [3,4]. Further milling of the powders has resulted in diffusion of Al, Cr and Ni into Co and Mo. At 20 h of milling, BCC peak is seen at (2 1 1) and (0 1 1) with complete solid solution formation of HEA. 3.2. Microstructural evolution of developed HEA. Fig. 2(a–d) shows the microstructure of milled HEA system at 5 h, 10 h, 15 h and 20 h respectively. At the initial stage, the powders are stage cold-weld together. Hence, larger particles are formed [6]. After extension of milling this agglomeration is crushed and smaller particles are obtained. Solid solution formation occurs as a process of equilibrium between crushment and fragmentation [5–7]. 3.3. Coating characterization The SEM micrograph of cross-section of the HEA coating is shown in Fig. 3. The coating is dense with a thickness of 250 mm.

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Please cite this article as: A. Vallimanalan, S. P. Kumaresh Babu, S. Muthukumaran et al., Corrosion behaviour of thermally sprayed Mo added AlCoCrNi high entropy alloy coating, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.149