FeCoCrNiAlTi HEA Coating for Wear-Resistant Laser Cladding

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Solution Overview

Problem

Current methods for preparing high-entropy alloy (HEA) coatings using laser cladding lack clarity on suitable raw materials and processes, particularly for achieving high hardness and wear resistance on heavy load-bearing and offshore components.

Innovation Solution

A FeCoCrNiAl0.5Ti0.5 HEA alloy is developed, and a plasma rotating electrode process is used to fabricate the HEA powder. This powder is then used in laser cladding to produce a coating with specific chemical compositions and processing parameters, ensuring high hardness and wear resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If laser cladding technology is used to prepare HEA coatings, then automatic preparation process and metallurgical binding between coating and substrate are achieved, but the types and specific components of HEAs suitable for laser cladding are not yet clearly understood

Engineering Contradiction:
Improveautomatic preparation processVSAvoidclarity on suitable raw materials and processes
Core Design Contradiction:
Ease of manufactureVSLoss of information

Solution Approach 1:

The patent specifies precise compositional parameters for the HEA coating (Fe: 15-25%, Co: 15-25%, Ni: 15-25%, Cr: 15-25%, Al: 5-15%, Ti: 5-15%) and laser cladding parameters (laser power 1800-2400W, scanning speed 300-800mm/min, powder feeding speed 4-6rpm) to resolve the uncertainty about suitable HEA components for laser cladding

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent introduces HEA powder with specific composition ranges as an intermediary material that enables laser cladding process to achieve desired coating properties, bridging the gap between laser cladding technology and HEA coating application

Inventive Principle:
Principle #24Intermediary (Mediator)

2Strength

If HEA coatings are prepared on surfaces of stamping dies and offshore components, then high hardness and wear resistance are achieved, but the components suffer from cyclic softening, surface etching pits, and micro-cracks during actual service

Engineering Contradiction:
ImprovehardnessVSAvoidresistance to cyclic softening, surface etching pits, and micro-cracks
Core Design Contradiction:
StrengthVSReliability

Solution Approach 1:

The patent creates a composite structure by applying HEA coating on substrate surfaces, combining the high hardness and wear resistance of HEA materials with the structural integrity of the substrate, thereby resolving the contradiction between achieving high hardness and maintaining reliability under cyclic loading and corrosion conditions

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent applies HEA coating specifically on the surfaces of stamping dies and offshore components that require high hardness and wear resistance, while the bulk substrate maintains its original properties, achieving local enhancement of performance without compromising overall reliability

Inventive Principle:
Principle #3Local quality

3Device complexity

If conventional alloys with single or two principal elements are used, then the alloy design is simple, but the entropy value of the alloy system is low and the properties are not excellent

Engineering Contradiction:
Improvealloy design complexityVSAvoidentropy value and properties
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The patent changes the compositional parameters from conventional single or two-principal-element alloys to high-entropy alloy system with five or more elements (Fe, Co, Ni, Cr, Al, Ti) each at 5-25% atomic percentage, thereby increasing the entropy value and achieving excellent properties while maintaining controlled design complexity

Inventive Principle:
Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The resulting HEA coating exhibits microhardness of 700 to 770 HV0.2, which is 2.3 to 2.5 times that of the substrate, and an average wear rate of 5.21×10−5 mm3/(N·m) to 9.18×10−5 mm3/(N·m), making it suitable for heavy load-bearing and large impact components.

Implementation Method 1

using a plasma rotating electrode process to fabricate the HEA powder

Methodology Applied
Scientific EffectPlasma: Plasma

Implementation Method 2

laser cladding to prepare an HEA coating

Methodology Applied
Scientific EffectLaser: Laser

Data Source

PatentUS12264385B2High-entropy alloy coating and preparation method and use thereof
Publication Date: 2025.04.01 GUANGDONG INST OF NEW MATERIALS
  • US12264385B2 patent drawing
  • US12264385B2 patent drawing
  • US12264385B2 patent drawing

AI summary

Disclosed are a high-entropy alloy (HEA) coating and a preparation method and use thereof. Laser cladding is conducted with an HEA powder to obtain the HEA coating, where the HEA is a FeCoCrNiAl0.5Ti0.5 alloy, and the HEA includes the following chemical components in atomic percentage: Al: 10.01% to 12.30%, Co: 18.1% to 22.5%, Cr: 18.05% to 20.12%, Fe: 18.77% to 21.02%, Ni: 19.21% to 20.99%, and Ti: 8.43% to 11.5%. The HEA material with high hardness and wear resistance provided by the present disclosure is suitable for laser cladding of a surface of a precision mold, an offshore component, or a drilling rod. A powder is prepared from the above alloy components and then prepared into a corresponding HEA coating with high strength, high hardness, and prominent wear resistance through laser cladding. The material has prominent weldability and is a special nickel-based HEA material suitable for laser additive manufacturing.