Laser-induced topology optimized amorphous nanostructure and corrosion electrochemistry of supersonically deposited Ni30Cr25Al15Co15Mo5Ti5Y5 HEA coating based on AIMD

doi:10.1016/j.jmst.2021.07.043

Abstract

Abstract:

A novel Ni₃₀Cr₂₅Al₁₅Co₁₅Mo₅Ti₅Y₅ high-entropy alloy (HEA) coating was irradiated to optimize its internal structure via laser after supersonic particle deposition (SPD). Owing to the high energy density of the laser and large temperature gradient, the crystallization process of the molecules and atoms in the coating was restrained and supercooling occurred. Experimental results showed that a considerable number of nano-crystal grains precipitated and amorphous structures were formed because of the random orientation of the crystals. The baseline of differential scanning calorimetry scans obtained for the coating started to shift at the Tg of 939.37 ℃ and a step was observed. Multiple dispersion peaks and lattice fringes indicated that the nucleation of the irradiated laser-induced topology optimized (LTO) coating was incomplete. The laser-induced topology optimizing treatment led to quasi-isotropy in the SPD coating. Furthermore, the LTO coating exhibited a residual stress of 18.4 MPa, stress-strain response, and fatigue limit of 265 MPa. Hence, the LTO coating exhibited higher performance than the unirradiated SPD coating. The Nyquist and Bode electrochemical impedance spectra of the LTO coating, including two relaxation processes, indicated that the corrosion process steadily recovered to the equilibrium state. This implies that the uniform oxidation passivation layer on the surface of the LTO coating insulated the material from the corrosive medium, protecting the substrate from further corrosion, thus enhancing the structural security of the material for use in super-intense laser facility applications.

Key words: Ultrasonic atomization spin method (UASM), Laser-induced topology optimized (LTO), Amorphous nanostructure, High-entropy alloy (HEA), Ab-initio molecular dynamics (AIMD)

Xue Yan, Cheng Zhang, Yangshuai Li, Youjian Yi, Ziruo Cui, Bingyuan Han. Laser-induced topology optimized amorphous nanostructure and corrosion electrochemistry of supersonically deposited Ni₃₀Cr₂₅Al₁₅Co₁₅Mo₅Ti₅Y₅ HEA coating based on AIMD[J]. J. Mater. Sci. Technol., 2022, 106: 257-269.

Figures/Tables 20

Table 1. Chemical composition of P355GH structural steel (wt.%).

Mn	Si	Cr	Cu	Ni	Mo	Nb	Ti	V	Impurity	Fe
1.10-1.7	≤ 0.60	≤ 0.30	≤ 0.30	≤ 0.30	≤ 0.08	≤ 0.04	≤ 0.03	≤ 0.02	≤ 0.257	Bal.

Table 2. Chemical composition of HEA powder (wt.%).

Ni	Cr	Al	Co	Mo	Ti	Y
30.00	25.00	15.00	15.00	5.0	5.00	5.00

Fig. 1. Powder preparation, and SPD and laser-induced topology optimization method: (a) flowchart of UASM powder preparation; (b) SPD system; (c) technological process of laser-induced topology optimizing.

Table 3. SPD parameters.

Parameters	Values
Air Pressure (PSI)	80-90
C₃H₈ Pressure (PSI)	60-75
Ar Pressure (MPa)	30-40
H₂ Flowrate (L/min)	30-40
Powder Speed (r/min)	5-10
Spray Speed (mm/s)	1000-2000
Spray Distance (mm)	200-250

Table 4. Parameters employed in the laser-induced topology optimization process.

Parameters	Values
Focal length (mm)	400
Defocusing amount (nm)	+600
Laser wavelength (nm)	1070 ± 5
Spot diameter (mm)	3
Particle size (mesh)	200-600
Laser-surface distance (mm)	900
Scanning speed (mm/s)	2
Overlap ratio (%)	50
Gas velocity (L/min)	6
Fiber core diameter (μm)	100
Laser power (W)	1200-1800

Fig. 2. Ab-initio molecular dynamics model of the SPD and LTO-HEA coatings: (a, b) line and ball and stick model of the SPD unit cell; (c, d) line model ball and stick model of the SPD supercell; (e, f) line and ball and stick model of the SPD+LTO supercell; (g) Forcite dynamics energies; (h) Forcite dynamics temperature.

Table 5. Crystal structure parameters of the Ni30Cr25Al15Co15Mo5Ti5Y5 HEA coating.

Atom	X	y	z	U_iso	Occ.
Ni	0.1045	0.065	0.045	0.0178	1
Cr	0.1045	0.581	0.381	0.0134	1
Al	0.1045	0.35847	0.0658	0.0376	1
Co	0.378	0.0006	0.1847	0.0458	1
Mo	0.151	0.0088	0.9474	0.0263	1
Ti	0.0683	0.6884	0.378	0.0761	1
Y	0.157	0.2867	0.845	0.0573	1

Fig. 3. Corrosion electrochemistry model and simulation of the SPD and SPD+LTO-HEA coatings: (a) passivated LTO-HEA coating model; (b) corrosion electrochemistry model of SPD supercell; (c) corrosion electrochemistry line model of the SPD+LTO supercell; (d) corrosion electrochemistry ball and stick model of the SPD+LTO supercell.

Fig. 4. Morphology and size distribution of spherical Ni30Cr25Al15Co15Mo5Ti5Y5 powders: (a) Powder morphology; (b) Adherent particles; (c) Size distribution of the alloy powders.

Fig. 5. Microstructure of the Ni30Cr25Al15Co15Mo5Ti5Y5 HEA coating fabricated via SPD: (a) SEM morphology; (b) AFM image; (c) EDS spectra; (d) SPD-HEA coating interface; (e) EDS line-scan across interface.

Table 6. EDS analysis results of the SPD-HEA coating (wt.%).

Ni	Cr	Al	Co	Mo	Ti	Y	Fe	O
31.45	23.67	10.37	15.04	5.43	4.89	4.75	3.26	1.14

Fig. 6. Microstructure of the SPD+LTO Ni30Cr25Al15Co15Mo5Ti5Y5 HEA coating: (a) SEM morphology; (b) AFM images; (c) EDS spectra; (d) LTO-HEA coating interface; (e) EDS line-scan.

Table 7. EDS analysis results of the LTO-HEA coating (wt.%).

Ni	Cr	Al	Co	Mo	Ti	Y	Fe	O
30.94	22.87	10.91	14.63	5.72	4.04	4.85	5.37	0.67

Table 8. AFM analysis parameters of the SPD and LTO coatings.

Coatings	S_a /nm	S_q /nm	S_sk	S_ku	S_y /nm	S_z /nm
SPD	831.5	124.2	0.52	4.95	1512	672
LTO	113.7	62.5	0.08	0.79	204	78

Fig. 7. EBSD grain analysis of the substrate and LTO and SPD-HEA coatings: (a) EBSD system; (b) EBSD probe; (c) Substrate; (d) SPD coating; (e) LTO coating; (f) Substrate distribution; (g) SPD coating distribution; (h) LTO coating distribution.

Fig. 9. DSC and XRD phase and TEM images of the coating grains along with a selected-area electron diffraction pattern: (a) DSC thermal analysis of LTO coatings; (b) XRD data of SPD and LTO coatings; (c) SPD bright-field TEM; (d) LTO bright-field TEM; (e) LTO high-resolution lattice fringe image.

Fig. 10. XPS analysis of the SPD+LTO Ni30Cr25Al15Co15Mo5Ti5Y5 HEA coating: (a) XPS full spectra (b) Al; (c) Cr; (d) Fe; (e) Co; (f) Ni.

Fig. 11. Mechanical properties and fatigue damage of the substrate and SPD and LTO-HEA coatings: (a) residual stress of substrate; (b) residual stress of SPD coating; (c) residual stress of LTO coating; (d) Stress vs. strain responses; (e) mechanical parameters; (f) fatigue damage vs. stress curves.

Fig. 12. Corrosion electrochemistry of the SPD+LTO Ni30Cr25Al15Co15Mo5Ti5Y5 HEA coating: (a) electrochemical corrosion of SPD coating; (b) electrochemical corrosion of LTO coating; (c) polarization curves; (d) Nyquist impedance spectra; (e) Bode spectra of SPD coating; (f) Bode spectra of LTO coating.

Table 9. Technological parameters of electrochemical corrosion testing.

	E_corr/V	i_corr/mA/cm²	R_SP/Ω	E_pass/V	log(i_pass)/mA/cm²	b_c/mV/dec.	b_a/mV/dec.	V_corr/mm/a
Al-Ni coating	-0.727	6.300	-	-	-	-0.0933	0.0682	0.0248
AlNiCoCrY₂O₃ coating	-0.762	1.400	2095	-0.566 ± 0.05	-4.514 ± 0.01	-0.1431	0.1240	0.0045
Substrate	-0.890	-4.092	-	-	-	-0.101	0.071	0.0582
SPD coating	-0.757	-5.215	1076	-	-	-0.073	0.166	0.0257
LTO coating	-0.258	-8.0011	4059	0.0447 ± 0.01	-6.177 ± 0.50	-0.057	0.0793	0.0032

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Laser-induced topology optimized amorphous nanostructure and corrosion electrochemistry of supersonically deposited Ni₃₀Cr₂₅Al₁₅Co₁₅Mo₅Ti₅Y₅ HEA coating based on AIMD

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