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<p>The Al<sub>x</sub>CoCrFeNi high entropy alloys coatings were prepared on the surface of 40CrMnMoA alloy steel, a material commonly used in drilling tool, via high velocity oxygen fuel spraying. This study investigated the effect of Al content on the microstructure, phase composition, and hardness of the coatings. The impact wear resistance with different counterpart materials was evaluated using a low-energy impact wear tester. The results indicated that increasing the Al content leads to progressive microstructural refinement and densification of the coatings. Accordingly, the surface roughness and grain size decreased, while the microhardness, nanohardness, and elastic modulus gradually increased. All coatings exhibited a typical BCC phase structure, and no additional new diffraction peaks were observed. As the Al content increased, the diffraction peaks of Al<sub>x</sub>CoCrFeNi high entropy alloys coatings gradually shifted to lower angles. Under impact by a GCr15 bearing steel ball, the impact force, the rebound velocity, and energy absorption rate of the coating are significantly lower than those under the impact by a Si<sub>3</sub>N<sub>4</sub> ceramic ball. As the Al content increased, the impact wear response under the GCr15 bearing steel ball gradually decreased. At low Al contents, the wear mechanism was mainly characterized by severe adhesive and oxidative wear, while at higher Al contents, the wear mechanism shifts to slight adhesive and oxidative wear. For the Si<sub>3</sub>N<sub>4</sub> ceramic balls, the wear mechanism under the same coating remained unchanged, but the degree of impact wear reaction became more intense, indicating that under the same conditions, compared to impact by a GCr15 bearing steel ball, the impact wear response of the Si<sub>3</sub>N<sub>4</sub> ceramic balls was relatively more severe. In summary, increasing the Al content in Al<sub>x</sub>CoCrFeNi high entropy alloy coatings gradually refines the microstructure, enhances hardness and elastic modulus, and improves impact wear resistance. This study demonstrates that adjusting Al content is an effective strategy for optimizing the performance of HVOF sprayed high entropy alloy coatings, offering a promising approach to extending the service life of drilling tools under complex impact wear conditions.</p>

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Kinetic Response and Damage Behavior of AlxCoCrFeNi High Entropy Alloys Coating Produced by HVOF Spraying

  • 期刊论文

  • 发表日期：

    2026年7月16日

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  • Qiang Da,
  • Jia-jie Kang,
  • Guo-zheng Ma,
  • Yong-kuan Zhou,
  • Zhi-qiang Fu,
  • Li-na Zhu,
  • Ding-shun She,
  • Hai-dou Wang

摘要

The AlxCoCrFeNi high entropy alloys coatings were prepared on the surface of 40CrMnMoA alloy steel, a material commonly used in drilling tool, via high velocity oxygen fuel spraying. This study investigated the effect of Al content on the microstructure, phase composition, and hardness of the coatings. The impact wear resistance with different counterpart materials was evaluated using a low-energy impact wear tester. The results indicated that increasing the Al content leads to progressive microstructural refinement and densification of the coatings. Accordingly, the surface roughness and grain size decreased, while the microhardness, nanohardness, and elastic modulus gradually increased. All coatings exhibited a typical BCC phase structure, and no additional new diffraction peaks were observed. As the Al content increased, the diffraction peaks of AlxCoCrFeNi high entropy alloys coatings gradually shifted to lower angles. Under impact by a GCr15 bearing steel ball, the impact force, the rebound velocity, and energy absorption rate of the coating are significantly lower than those under the impact by a Si3N4 ceramic ball. As the Al content increased, the impact wear response under the GCr15 bearing steel ball gradually decreased. At low Al contents, the wear mechanism was mainly characterized by severe adhesive and oxidative wear, while at higher Al contents, the wear mechanism shifts to slight adhesive and oxidative wear. For the Si3N4 ceramic balls, the wear mechanism under the same coating remained unchanged, but the degree of impact wear reaction became more intense, indicating that under the same conditions, compared to impact by a GCr15 bearing steel ball, the impact wear response of the Si3N4 ceramic balls was relatively more severe. In summary, increasing the Al content in AlxCoCrFeNi high entropy alloy coatings gradually refines the microstructure, enhances hardness and elastic modulus, and improves impact wear resistance. This study demonstrates that adjusting Al content is an effective strategy for optimizing the performance of HVOF sprayed high entropy alloy coatings, offering a promising approach to extending the service life of drilling tools under complex impact wear conditions.