In-situ XRD Residual Stress and XAS High-Temperature Oxidation Analyses of HVOF-Sprayed AlCoCrFeNi High-Entropy Alloy Coatings using Synchrotron Radiation Techniques

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Somprasong Ruannut, s6609094860019@email.kmutnb.ac.th, King Mongkut's University of Technology North Bangkok; Assoc. Prof. Dr. Peerawatt Nunthavarawong, Peerawatt.n@tggs.kmutnb.ac.th, King Mongkut's University of Technology North Bangkok; Torsak Boonthai, torsak.b@email.kmutnb.ac.th, King Mongkut's University of Technology North Bangkok; Dr. Chatree Saiyasombat, chatree@slri.or.th, Synchrotron Light Research Institute Nakhon Ratchasima; 

High-entropy alloys (HEAs) are attractive candidates for thermal spray coatings due to their exceptional structural stability, hardness, and oxidation resistance under extreme environments. In this study, AlCoCrFeNi coatings were deposited onto AISI 420 stainless steel substrates using the high-velocity oxy-fuel (HVOF) process. The residual stress magnitude of as-sprayed coatings was characterized by synchrotron X-ray diffraction (SXRD) using the sin²ψ method, revealing compressive residual stress of approximately –108.8 MPa, which enhances fatigue resistance under cyclic loading. Furthermore, in-situ high-temperature Cr K-edge X-ray absorption spectroscopy (XAS) was employed to track oxidation behaviour up to 1000 °C. At elevated temperatures between 900–1000 °C, a distinct energy shift, along with changes in pre-edge and white-line features, was observed, indicating spectral evolution associated with chromium. Subsequent XRD analysis confirmed the formation of chromium carbide phases following high-temperature exposure, indicating phase transformation under high temperature. These findings demonstrate that HVOF-sprayed AlCoCrFeNi HEA coatings offer enhanced thermal and mechanical performance, offering promising performance for high-temperature industrial applications.

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Erscheinungsdatum

March 2026

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