Microstructure evolution and oxidation behavior of in-situ oxide-dispersion-strengthened AlCoCrFeNi2.1 composite coatings manufactured by high-speed laser cladding

doi:10.1016/j.jmst.2025.05.017

Abstract

Abstract: To develop thermal barrier coatings (TBCs) that protect against high-temperature oxidation, it is critical to explore and develop new bonded coating materials and fabrication techniques. Here, oxide-dispersion-strengthened (ODS) AlCoCrFeNi_2.1 composite coatings were formed using high-speed laser cladding (HSLC), of which long-term oxidation behavior at 1000, 1100, and 1200 °C was studied. The results showed that the ODS AlCoCrFeNi_2.1 composite coatings exhibited better oxidation resistance than the conventional NiCoCrAlY coatings and some other high-entropy alloy (HEA) coatings at 1000 and 1100 °C. This was because Y₂Hf₂O₇ nanoparticles decreased the thermally-grown oxide (TGO) growth rate and thermal expansion mismatch stresses, and increased the coating/TGO interfacial toughness. The composite coating rapidly failed after only 200 h of oxidation at 1200 °C, primarily due to the formation of coarse Al₂Y₄O₉ oxide aggregates within the TGO, which caused the rapid transport of Fe, Cr, Hf, Y, Al, and O atoms. Moreover, the formation of Y₂Hf₂O₇ nanoparticles within the composite coating was induced by regulating the Marangoni convection intensity in the melt pool during HSLC. This report provides a candidate for the next-generation, low-cost, oxidation-resistant bonded coatings.

Key words: High-entropy alloys, High-temperature oxidation, ODS AlCoCrFeNi_2.1 composite coatings, Bonded coatings, High-speed laser cladding

Peng Wang, Xianglin Zhou, Zhipei Chen, Yu Shi, Yudong Liang, Mina Zhang, Jian Sun, Zhiyong Yu, Peixin Xu, Xianglong Wang, Xinggang Li. Microstructure evolution and oxidation behavior of in-situ oxide-dispersion-strengthened AlCoCrFeNi_2.1 composite coatings manufactured by high-speed laser cladding[J]. J. Mater. Sci. Technol., 2026, 244: 1-19.

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Microstructure evolution and oxidation behavior of in-situ oxide-dispersion-strengthened AlCoCrFeNi_2.1 composite coatings manufactured by high-speed laser cladding

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