Cyclic Oxidation Properties of the Near Nanocrystalline AlCrFeCoNi High-Entropy Alloy Coatings Applied by Atmospheric Plasma Spraying Technique

Microcrystalline and near nanocrystalline AlCrFeCoNi high-entropy alloy (HEA) coatings were applied on Inconel 718 superalloy using air plasma spraying (APS) process. High-temperature oxidation behavior of the microcrystalline and near nanocrystalline AlCrFeCoNi HEA coated superalloy were examined at 110°C under the air atmosphere for 50 cycles under cyclic heating and cooling (1 h for each cycle). The oxidation kinetics of both nanocrystalline and microcrystalline coated superalloy was accordingly analyzed by weight change measurement. It was noticed that the uncoated and coated followed the parabolic rate law of the oxidation. X-ray diffraction (XRD), field emission scanning electron microscopy (FESEM), energy dispersive X-ray analysis (EDS), and elemental mapping techniques were used to analyze the oxidized coated and uncoated samples. In the HEA coated superalloy, Fe, Ni, Co, and Al were oxidized in the inter-splat region, whereas the splats which consist mainly of Ni and Cr remained unoxidized. Because of the formation of compact and adhesive thin NiO, CoO oxides, and spinels together with the Al2O3 oxide scale on the surface of the coating during oxidation, the developed nanocrystalline HEA coating shows better oxidation resistance than the microcrystalline HEA coating.