Performance evaluation of thermally sprayed Zr-added high entropy alloy coatings
Bibliographic record
Abstract
This study explores the development of multifunctional high-entropy alloy (HEA) coatings by adding Zirconium (Zr) at concentrations of 5, 10, and 15 wt% into an equiatomic AlCoCrFeMo system. Aimed at enhancing resistance to erosion and corrosion for applications in aviation, oil and gas, and potential hydrogen storage environments, four coating compositions, namely Base-HEA (0 wt% Zr), HEA 5Zr, HEA 10Zr, and HEA 15Zr, were fabricated via the flame-spraying process. Comprehensive characterization was conducted using scanning electron microscopy (SEM), X-ray diffraction (XRD), microhardness testing, adhesion strength evaluation, solid particle erosion at 30° and 90° impingement angles, and corrosion testing in 3.5 % NaCl solution. XRD revealed the presence of BCC solid solution phases, intermetallics, spinel oxides, and ZrO 2 oxides. SEM micrographs showed both thin and thick lamellar splats in the Zr-added coatings. Hardness increased by 30–50 % with Zr addition, with HEA-15Zr showing the highest value. Adhesion strength improved by 12 % in HEA 15Zr, but decreased by 33 % and 15 % in HEA-5Zr and HEA 10Zr, respectively. Erosion testing indicated that HEA-10Zr exhibited 24 % and 21 % improved erosion resistance at 30° and 90°, respectively, due to a favorable hardness–toughness balance. Corrosion resistance measured in saline water at room temperature was also enhanced by 14 % and 88 % for HEA-10Zr and HEA-15Zr coatings as compared to the Base-HEA coating, due to Zr addition. This might be attributed to the formation of passive protective ZrO 2 and Al 2 O 3 oxide films. Among all the compositions, the HEA-10Zr coating demonstrated the optimal combination of hardness, adhesion, erosion resistance, and corrosion protection, making it a strong candidate for use in demanding erosion- and corrosion-prone service environments. • Multifunctional Zr-added AlCoCrFeMo HEA coatings at 5, 10, and 15 wt% were developed using flame spraying, including Base-HEA (0 wt% Zr), HEA 5Zr, HEA 10Zr, and HEA 15Zr. • Zr-added AlCoCrFeMo HEA coatings exhibited an increase in hardness by 30 % to 50 % compared to the Base-HEA coating. • Adhesion strength of the HEA-15Zr coating improved by 12 % compared to the Base-HEA coating. • Erosion testing showed that HEA-10Zr had 24 % and 21 % lower mass loss at 30° and 90° erosion impact angles, respectively, compared to the Base-HEA coating. • Zr-added AlCoCrFeMo HEA coatings exhibited reduced corrosion rates by 14 % and 88 % for HEA-10Zr and HEA-15Zr coatings compared to the Base-HEA coating.
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How this classification was reachedexpand
Full frame machine prediction
Teacher imitationNot calibrated prevalence, not ground truth. Human validation pending. The Gemma side is a direct model label for every work in the frame, read from the title-only record. The Codex side is a classifier learned from the 10,348 direct Codex labels and calibrated to design-weighted sample rates; fields without enough sample support carry no Codex call. Candidate is the union of the two sides; consensus is their intersection. These outputs are machine_predicted_unvalidated and are not human labels.
Distilled classifier scores by category (both heads)
| Category | Codex | Gemma |
|---|---|---|
| Metaresearch | 0.000 | 0.001 |
| 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) | 0.001 | 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 source (direct Gemma or distilled Codex), 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".