Microwave synthesized complex concentrated alloy coatings: Plausible solution to cavitation induced erosion-corrosion

Surface phenomenon such as cavitation erosion-corrosion limits the working life and durability of the fluid machines through significantly altering the efficiency. Surface modification is an apparent and economical route for improving the sustainability of these components. Recently developed complex concentrated alloys (CCAs) or high entropy alloys (HEAs) possess exceptional properties owing to high configurational entropy. We developed CCA coatings on the stainless steel using a facial and effective microwave processing technique. The effect of Al molar fraction in AlCoCrFeNi (x = 0.1-3) CCAs on ultrasonic cavitation erosion-corrosion was investigated in 3.5% NaCl solution. For comparison, cavitation erosion and electrochemical corrosion behavior of the pre- and post-tested samples was also performed. Detailed microstructure and mechanical characterization of the developed coatings were also preformed using different analytical techniques. The equimolar CCA coating showed apical degradation resistance under both pure erosion and erosion-corrosion conditions. The observed behavior is attributed to high strain hardening, optimal hardness, fracture toughness, and utmost stability of the passive layer. The phenomenal conjugation of these properties was associated with highest configurational entropy for equimolar composition resulting in sluggish diffusion, and severe lattice straining. Compared to pits, striations and cracks characterizing the morphology of the degraded stainless steel, the equimolar and AlCoCrFeNi CCAs showed TTS (tearing topograph surface) as the dominant failure mode characterized by presence of microplastic deformation. The degradation of the AlCoCrFeNi CCA occurred mainly through brittle failure mode. The difference in failure mechanism is related to the mechanical properties and underlying microstructure.