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<p>This study focused on the fabrication of AlCrCoCuFeNi high-entropy alloy (HEA) coating on an AISI 304L stainless steel substrate using tungsten inert gas (TIG) arcing. The equiatomic HEA composition was deposited and characterized for its microstructure, hardness and wear resistance. Thermo-Calc (CALPHAD) simulations were used to generate the phase diagram and perform thermodynamic assessments. Coatings produced with higher arc current exhibited refined equiaxed dendrites. X-ray diffraction (XRD) analysis confirmed the presence of a single-phase FCC structure alongside BCC phases while energy-dispersive X-ray spectroscopy (EDX) revealed a uniform elemental distribution. The highest recorded hardness was 440 HV<sub>0.5</sub>, marking an 87&#xa0;pct increase compared to the substrate. The TIG-melted HEA coatings demonstrated enhanced wear resistance and superior hardness, making them highly suitable for demanding mechanical applications.</p>

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In-Situ Synthesis of AlCrCoCuFeNi High-Entropy Alloy Coating on AISI 304L Stainless Steel Substrate by TIG Arcing Process

  • 期刊论文

  • 发表日期：

    2025年12月17日

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  • Ansari Mohd Farhan Mohd Saleem,
  • Ramkishor Anant

摘要

This study focused on the fabrication of AlCrCoCuFeNi high-entropy alloy (HEA) coating on an AISI 304L stainless steel substrate using tungsten inert gas (TIG) arcing. The equiatomic HEA composition was deposited and characterized for its microstructure, hardness and wear resistance. Thermo-Calc (CALPHAD) simulations were used to generate the phase diagram and perform thermodynamic assessments. Coatings produced with higher arc current exhibited refined equiaxed dendrites. X-ray diffraction (XRD) analysis confirmed the presence of a single-phase FCC structure alongside BCC phases while energy-dispersive X-ray spectroscopy (EDX) revealed a uniform elemental distribution. The highest recorded hardness was 440 HV0.5, marking an 87 pct increase compared to the substrate. The TIG-melted HEA coatings demonstrated enhanced wear resistance and superior hardness, making them highly suitable for demanding mechanical applications.