Influence of aluminum addition on the microstructure and tribomechanical behavior of HVOF-sprayed AlxFeCrMnCoNi high entropy coatings (HECs)
Bibliographic record
Abstract
High-entropy alloys (HEAs) have gained significant attention due to their exceptional mechanical and thermal properties; however, their performance assessment as coatings still remains an active area of research. This study investigates the effects of aluminum (Al) addition on the microstructural and tribological behavior of thermally sprayed Al x FeCrMnCoNi coatings. Specifically, Al was added in amounts of 5 wt% and 10 wt% to the base FeCrMnCoNi composition to synthesize Al x FeCrMnCoNi HEA powders using mechanical mixing followed by a solid-state reaction process. Among these, the powder with 10 wt% Al was chosen for deposition using the high-velocity oxy-fuel (HVOF) thermal spray technique to produce AlFeCrMnCoNi high-entropy coatings (HECs). The addition of Al to the FeCrMnCoNi system promoted the formation of duplex (BCC + FCC) phases within the final coating, enhancing its microhardness. Transverse scratch testing revealed cohesive failure of the coatings, with splat delamination occurring at a critical load of 4 N. The tribological performance of the AlFeCrMnCoNi HECs was evaluated under dry sliding conditions up to 350 °C using an Al₂O₃ counter ball. Across all testing temperatures, abrasion was identified as the primary wear mechanism. However, at 350 °C, tribo-chemical reactions contributed significantly to the wear behavior, resulting in the lowest friction coefficient and wear rate observed under the given conditions. Strong emphasis was placed on understanding interfacial phenomena and their correlation with wear behavior to support the design and evaluation of advanced HECs.
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How this classification was reachedexpand
Full frame distilled prediction
Teacher imitationNot calibrated prevalence, not ground truth. Human validation pending. Learned from the 10,348 direct Codex labels and 10,348 direct Gemma labels. Candidate is the union of thresholded teacher heads; consensus is their intersection. These outputs are machine_predicted_unvalidated and are not human labels or direct frontier model labels.
Codex and Gemma teacher scores by category
| Category | Codex | Gemma |
|---|---|---|
| Metaresearch | 0.000 | 0.000 |
| Meta-epidemiology (narrow) | 0.000 | 0.000 |
| Meta-epidemiology (broad) | 0.000 | 0.000 |
| Bibliometrics | 0.000 | 0.000 |
| Science and technology studies | 0.000 | 0.000 |
| Scholarly communication | 0.000 | 0.000 |
| Open science | 0.000 | 0.000 |
| Research integrity | 0.000 | 0.000 |
| Insufficient payload (model declined to judge) | 0.000 | 0.000 |
Machine scores (provisional)
The two teacher heads of the student model, read on this work. A score orders the frame for review; it never asserts a category, and the validation status ships verbatim with every row.
Baseline scores from an immature model (maturity gate not passed, 7 training rounds). Scores rank; they never assert a category.
score_only:v0-immature-baseline · verbatim from the scoring run: score_only means the number may rank works, and no category label ships from itClassification
machine, unvalidatedMachine predicted; a candidate call from one teacher head, not a consensus.
How this classification was reached, model by model and score by score, is at the end of the page under "How this classification was reached".