Tailoring High-Entropy Alloy Powders for Thermal Spray Processing

High-entropy alloys (HEAs), particularly the CoCrFeNi-based system, have gained significant attention for their exceptional toughness and resistance to wear and corrosion. However, processing these complex alloys through traditional melting methods can often lead to undesirable phase changes or oxidation. Thermal spray technology offers a unique solution by depositing materials in a solid state, allowing the CoCrFeNi-based alloy to retain its superior properties without the heat-related degradation typical of other coating methods.

This talk examines the performance and microstructural evolution of CoCrFeNi-based HEA powders during the thermal spray process. We explore how the splats deformation, resulting in coatings or deposits that can be suitable for industrial applications. By analyzing the correlations between material phase, deposition parameters and the resulting mechanical behavior, this research demonstrates how HEAs can be designed for thermal spray processing. The findings provide a pathway for utilizing HEAs to create more durable and reliable surface solutions for the future of engineering.