Wear behavior of different SiC and WC reinforced high entropy alloys deposited by the spark emmission procedure on a AISI 1010 steel
-
Ersan Mertgenç
Assoc. Prof. Ersan Mertgenç holds a bachelor’s degree in Mechanical Engineering. He received his master’s and doctoral degrees from Afyon Kocatepe University in 2004 and 2015, respectively. He serves as an Associate Professor in the Department of Railway Systems at Afyon Kocatepe University’s Afyon Vocational School. His areas of expertise are materials and metallurgical engineering. He works in the fields of alloys, coatings, wear, and corrosion.
and
Yusuf Kayalı
Prof. Dr. Yusuf Kayalı holds a bachelor’s degree in Mechanical Engineering. He received his master’s and doctoral degrees from Afyon Kocatepe University in 2006 and 2011, respectively. He serves as a professor in the Department of Metallurgy and Materials Engineering, Faculty of Technology, Afyon Kocatepe University. He works in the fields of heat treatment, coating, wear, and corrosion.
Abstract
In this study, CrMnFeCoNi (HEA) coating electrodes containing different proportions of reinforcement elements were produced by arc melting reverse vacuum system and the steel surface was coated by electro-spark deposition (ESD) method. According to the obtained data; while the microstructures for unreinforced HEA consisted of FCC structure, M7C3, M23C6 and phases belonging to reinforcement elements were detected together with FCC structure in SiC and WC reinforcement. Good bonding was detected at the matrix-coating interface and layer thicknesses varied between 18 µm and 60 µm, and micro hardnesses varied between 256 HV and 578 HV. According to the wear tests, the steel wear rate decreased up to 32 times depending on the reinforcement element ratio and type.
Award Identifier / Grant number: 122.M.148
About the authors
Assoc. Prof. Ersan Mertgenç holds a bachelor’s degree in Mechanical Engineering. He received his master’s and doctoral degrees from Afyon Kocatepe University in 2004 and 2015, respectively. He serves as an Associate Professor in the Department of Railway Systems at Afyon Kocatepe University’s Afyon Vocational School. His areas of expertise are materials and metallurgical engineering. He works in the fields of alloys, coatings, wear, and corrosion.
Prof. Dr. Yusuf Kayalı holds a bachelor’s degree in Mechanical Engineering. He received his master’s and doctoral degrees from Afyon Kocatepe University in 2006 and 2011, respectively. He serves as a professor in the Department of Metallurgy and Materials Engineering, Faculty of Technology, Afyon Kocatepe University. He works in the fields of heat treatment, coating, wear, and corrosion.
-
Research ethics: Not applicable.
-
Informed consent: Not applicable.
-
Author contributions: All authors have accepted responsibility for the entire content of this manuscript and approved its submission.
-
Use of Large Language Models, AI and Machine Learning Tools: None declared.
-
Conflict of interest: The authors state no conflict of interest.
-
Research funding: This study was supported by TUBİTAK-Scientific and Research Project Commission (Project No. 122.M.148).
-
Data availability: Not applicable.
References
[1] V. Balaji and M. Anthony Xavior, “Review article – Development of high entropy alloys (HEAs): Current trends,” Heliyon, vol. 10, no. 7, p. e26464, 2024. https://doi.org/10.1016/j.heliyon.2024.e26464.Search in Google Scholar PubMed PubMed Central
[2] P. Patel et al.., “Microstructural and tribological behavior of thermal spray CrMnFeCoNi high entropy alloy coatings,” J. Therm. Spray Tech., vol. 31, pp. 1285–1301, 2022. https://doi.org/10.1007/s11666-022-01350-y.Search in Google Scholar
[3] H. Xie et al.., “Wear-resistance of high-entropy alloy coatings and high-entropy alloy-based composite coatings prepared by the laser cladding technology: A review,” Adv. Eng. Mater., vol. 25, no. 21, p. 2300426, 2023. https://doi.org/10.1002/adem.202300426.Search in Google Scholar
[4] H. Song, S. Lee, and K. Lee, “Thermodynamic parameters, microstructure, and electrochemical properties of equiatomic TiMoVWCr and TiMoVNbZr high-entropy alloys prepared by vacuum arc remelting,” Int J Refract Metals Hard Mater, vol. 99, no. 9, p. 105595, 2021. https://doi.org/10.1016/j.ijrmhm.2021.105595.Search in Google Scholar
[5] B. Chanda and J. Das, “Evolution of microstructure homogeneity and mechanical properties in nano-/ultrafine eutectic CoCrFeNiNbx (0.45 ≤ x ≤ 0.65) high entropy alloy ingots and cast rods,” J. Alloys Compd., vol. 901, no. 1, p. 163610, 2022. https://doi.org/10.1016/j.jallcom.2022.163610.Search in Google Scholar
[6] W. Yuan, R. Li, Z. Chen, J. Gu, and Y. Tian, “A comparative study on microstructure and properties of traditional laser cladding and high-speed laser cladding of Ni45 alloy coatings,” Surf. Coat. Technol., vol. 405, no. 11, p. 126582, 2021. https://doi.org/10.1016/j.surfcoat.2020.126582.Search in Google Scholar
[7] H. Hasırcı and K. Karacif, “Hardness and corrosion properties of AA7075 aluminum alloy coated with WC-Co by HVOF,” Mater. Test., vol. 67, no. 10, pp. 1624–1631, 2025, https://doi.org/10.1515/mt-2025-0171.Search in Google Scholar
[8] B. Güney and İ. Mutlu, “Wear and corrosion resistance of Cr2O3 %-40%TiO2 coating on gray cast-iron by plasma spray technique,” Mater. Res. Express, vol. 6, no. 9, p. 096577, 2019, https://doi.org/10.1088/2053-1591/ab2fb7.Search in Google Scholar
[9] E. Mertgenç, “Effect on wear properties of coating the surface of 904L super austenitic stainless steel by APS with white/grey Al2O3,” Trans. Inst. Met. Finish., vol. 100, no. 6, pp. 342–347, 2022, https://doi.org/10.1080/00202967.2022.2061465.Search in Google Scholar
[10] Bayar and M. Ulutan, “Surface modification of atmospheric plasma sprayed cermet coatings by plasma transferred arc method,” Trans. Inst. Met. Finish., vol. 97, no. 6, pp. 298–304, 2019, https://doi.org/10.1080/00202967.2019.1668123.Search in Google Scholar
[11] A. N. S. Appiah et al.., “Microstructure and performance of NiCrBSi coatings prepared by modulated arc currents using powder plasma transferred arc welding technology,” Appl. Surf. Sci., vol. 648, no. 12, p. 159065, 2024. https://doi.org/10.1016/j.apsusc.2023.159065.Search in Google Scholar
[12] E. Mertgenç, H. Yavuz, and M. Özçatal, “Diffusion kinetics and Rockwell-C adhesion properties in thermochemical pack chroming of HEAs,” Thermochim. Acta, vol. 749, no. 7, p. 180027, 2025. https://doi.org/10.1016/j.tca.2025.180027.Search in Google Scholar
[13] U. Mishigdorzhiyn, Y. Chen, N. Ulakhanov, and H. Liang, “Microstructure and wear behavior of tungsten hot-work steel after boriding and boroaluminizing,” Lubricants, vol. 8, no. 3, 2020, https://doi.org/10.3390/lubricants8030026.Search in Google Scholar
[14] E. Mertgenç, “Diffusion kinetics of borided of low entropy soft magnetic FeCo alloy,” Mater. Test., vol. 66, no. 12, pp. 2078–2086, 2024, https://doi.org/10.1515/mt-2024-0153.Search in Google Scholar
[15] S. Talas, E. Mertgenç, and B. Gökçe, “ESD coating of copper with TiC and TiB 2 based ceramic matrix composites,” IOP Conf Ser Mater Sci Eng, vol. 146, no. 1, p. 012005, 2016. https://doi.org/10.1088/1757-899X/146/1/012005.Search in Google Scholar
[16] F. Habibi and A. Samadi, “In-situ formation of ultra-hard titanium-based composite coatings on carbon steel through electro-spark deposition in different gas media,” Surf. Coat. Technol., vol. 478, no. 2, p. 130472, 2024. https://doi.org/10.1016/j.surfcoat.2024.130472.Search in Google Scholar
[17] E. Mertgenç, “Wear and corrosion behavior of TiC and WC coatings deposited on high-speed steels by electro-spark deposition,” Open Chem., vol. 21, no. 1, 2023, https://doi.org/10.1515/chem-2023-0187.Search in Google Scholar
[18] J. Wu et al.., “Synergistic effects of ultrasonic rolling textures and PTFE-PPS/SiO2 coatings on dry friction and wear properties of GCr15 steel surfaces,” Adv. Eng. Mater., vol. 25, no. 21, 2023, https://doi.org/10.1002/adem.202301108.Search in Google Scholar
[19] S. Frangini and A. Masci, “A study on the effect of a dynamic contact force control for improving electrospark coating properties,” Surf. Coat. Technol., vol. 204, nos. 16–17, 2010, https://doi.org/10.1016/j.surfcoat.2010.02.006.Search in Google Scholar
[20] S. J. Algodi, A. T. Clare, and P. D. Brown, “Modelling of single spark interactions during electrical discharge coating,” J. Mater. Process. Technol., vol. 252, no. 2, pp. 760–772, 2018. https://doi.org/10.1016/j.jmatprotec.2017.10.029.Search in Google Scholar
[21] M. Brochu, J. G. Portillo, J. Milligan, and D. W. Heard, “Development of metastable solidification structures using the electrospark deposition process,” The Open Surface Science Journal, vol. 3, no. 1, 2014, https://doi.org/10.2174/1876531901103010105.Search in Google Scholar
[22] M. R. Zamani, H. Mirzadeh, M. Malekan, I. Weißensteiner, and M. Roostaei, “Unveiling the strengthening mechanisms of as-cast micro-alloyed CrMnFeCoNi high-entropy alloys,” J. Alloys Compd., vol. 957, no. 9, p. 170443, 2023. https://doi.org/10.1016/j.jallcom.2023.170443.Search in Google Scholar
[23] Q. Ye et al.., “Microstructure and corrosion properties of CrMnFeCoNi high entropy alloy coating,” Appl. Surf. Sci., vol. 396, no. 2, pp. 1420–1426, 2017. https://doi.org/10.1016/j.apsusc.2016.11.176.Search in Google Scholar
[24] N. Li et al.., “Microstructure, formation mechanism and property characterization of Ti + SiC laser cladded coatings on Ti6Al4V alloy,” Mater. Charact., vol. 148, no. 2, pp. 43–51, 2019. https://doi.org/10.1016/j.matchar.2018.11.032.Search in Google Scholar
[25] J. Li et al.., “Additive manufacturing of high-strength CrMnFeCoNi high-entropy alloys-based composites with WC addition,” J Mater Sci Technol, vol. 35, no. 11, pp. 2430–2434, 2019. https://doi.org/10.1016/j.jmst.2019.05.062.Search in Google Scholar
[26] L. Yutao, F. Hanguang, M. Tiejun, W. Kaiming, Y. Xiaojun, and L. Jian, “Microstructure and wear resistance of AlCoCrFeNi-WC/TiC composite coating by laser cladding,” Mater. Charact., vol. 194, no. 12, p. 112479, 2022. https://doi.org/10.1016/j.matchar.2022.112479.Search in Google Scholar
[27] G. Ma et al.., “The evolution of multi and hierarchical carbides and their collaborative wear-resisting effects in CoCrNi/WC composite coatings via laser cladding,” Mater. Today Commun., vol. 30, no. 1, p. 103223, 2022. https://doi.org/10.1016/j.mtcomm.2022.103223.Search in Google Scholar
[28] D. Dong et al.., “Microstructure and properties of WC-Co/CrMnFeCoNi composite cemented carbides,” Vacuum, vol. 179, no. 9, p. 109571, 2020. https://doi.org/10.1016/j.vacuum.2020.109571.Search in Google Scholar
[29] A. H. Khallaf, M. Bhlol, O. M. Dawood, and O. A. Elkady, “Wear resistance, hardness, and microstructure of carbide dispersion strengthened high-entropy alloys,” J Cent South Univ, vol. 29, no. 11, pp. 3529–3543, 2022, https://doi.org/10.1007/s11771-022-5181-8.Search in Google Scholar
[30] E. J. Pickering, R. Muñoz-Moreno, H. J. Stone, and N. G. Jones, “Precipitation in the equiatomic high-entropy alloy CrMnFeCoNi,” Scr. Mater., vol. 113, no. 4, pp. 106–109, 2016. https://doi.org/10.1016/j.scriptamat.2015.10.025.Search in Google Scholar
[31] N. D. Stepanov, N. Y. Yurchenko, M. A. Tikhonovsky, and G. A. Salishchev, “Effect of carbon content and annealing on structure and hardness of the CoCrFeNiMn-based high entropy alloys,” J. Alloys Compd., vol. 687, no. 34, pp. 59–71, 2016. https://doi.org/10.1016/j.jallcom.2016.06.103.Search in Google Scholar
[32] Ł. Rogal, D. Kalita, A. Tarasek, P. Bobrowski, and F. Czerwinski, “Effect of SiC nano-particles on microstructure and mechanical properties of the CoCrFeMnNi high entropy alloy,” J. Alloys Compd., vol. 708, no. 18, pp. 344–352, 2017. https://doi.org/10.1016/j.jallcom.2017.02.274.Search in Google Scholar
[33] M.-H. Xun, H.-L. Luo, S.-P. Li, and J. Zhang, “Cold deformation behavior and the microscopic mechanisms of a L605 centrifugal cast tube,” Mater. Test., vol. 67, no. 8, pp. 1272–1282, 2025. https://doi.org/10.1515/mt-2024-0544.Search in Google Scholar
[34] Z. Szklarz, J. Lekki, P. Bobrowski, M. B. Szklarz, and Ł. Rogal, “The effect of SiC nanoparticles addition on the electrochemical response of mechanically alloyed CoCrFeMnNi high entropy alloy,” Mater. Chem. Phys., vol. 215, no. 13, pp. 385–392, 2018. https://doi.org/10.1016/j.matchemphys.2018.05.056.Search in Google Scholar
[35] Q. Shen, X. Kong, X. Chen, X. Yao, V. B. Deev, and E. S. Prusov, “Powder plasma arc additive manufactured CoCrFeNi(SiC)x high-entropy alloys: microstructure and mechanical properties,” Mater. Lett., vol. 282, no. 1, p. 128736, 2021. https://doi.org/10.1016/j.matlet.2020.128736.Search in Google Scholar
[36] K. Wieczerzak et al.., “The effect of temperature on the evolution of eutectic carbides and M7C3 → M23C6carbides reaction in the rapidly solidified Fe-Cr-C alloy,” J. Alloys Compd., vol. 698, no. 8, pp. 673–684, 2017. https://doi.org/10.1016/j.jallcom.2016.12.252.Search in Google Scholar
[37] F. Haftlang and H. S. Kim, “A perspective on precipitation-hardening high-entropy alloys fabricated by additive manufacturing,” Mater. Des., vol. 211, p. 110161, 2021. https://doi.org/10.1016/j.matdes.2021.110161.Search in Google Scholar
[38] E. Mertgenc, S. Talas, and B. Gokce, “The wear and microstructural characterization of copper surface coated with TiC reinforced FeAl intermetallic composite by ESD method,” Mater. Res. Express, vol. 6, no. 11, 2019, https://doi.org/10.1088/2053-1591/ab507e.Search in Google Scholar
[39] A. Lešnjak and J. Tušek, “Processes and properties of deposits in electrospark deposition,” Science and Technology of Welding and Joining, vol. 7, no. 6, pp. 391–396, 2002, https://doi.org/10.1179/136217102225006886.Search in Google Scholar
[40] C. Barile, C. Casavola, G. Pappalettera, and G. Renna, “Advancements in electrospark deposition (ESD) technique: A short review,” Coatings, vol. 12, p. 1536, 2022. https://doi.org/10.3390/coatings12101536.Search in Google Scholar
[41] D. W. Heard and M. Brochu, “Development of a nanostructure microstructure in the Al-Ni system using the electrospark deposition process,” J. Mater. Process. Technol., vol. 210, nos. 6–7, pp. 892–898, 2010, https://doi.org/10.1016/j.jmatprotec.2010.02.001.Search in Google Scholar
[42] G. Renna, P. Leo, and C. Casavola, “Effect of ElectroSpark process parameters on the WE43 magnesium alloy deposition quality,” Applied Sciences (Switzerland), vol. 9, no. 20, 2019, https://doi.org/10.3390/app9204383.Search in Google Scholar
[43] Y. Kayali and Ş. Talaş, “Investigation of wear and corrosion behaviour of AISI 316 L stainless steel coated by ESD surface modification,” Protection of Metals and Physical Chemistry of Surfaces, vol. 55, no. 6, pp. 1148–1153, 2019, https://doi.org/10.1134/S2070205119060170.Search in Google Scholar
[44] P. Leo, G. Renna, and G. Casalino, “Study of the direct metal deposition of AA2024 by electrospark for coating and reparation scopes,” Applied Sciences (Switzerland), vol. 7, no. 9, 2017, https://doi.org/10.3390/app7090945.Search in Google Scholar
[45] G. Renna, P. Leo, G. Casalino, and E. Cerri, “Repairing 2024 aluminum alloy via electrospark deposition process: a feasibility study,” Advances in Materials Science and Engineering, vol. 2018, no. 1, pp. 1–11, 2018. https://doi.org/10.1155/2018/8563054.Search in Google Scholar
[46] J. Padgurskas et al.., “Tribological properties of coatings obtained by electro-spark alloying C45 steel surfaces,” Surf. Coat. Technol., vol. 311, no. 3, pp. 90–97, 2017. https://doi.org/10.1016/j.surfcoat.2016.12.098.Search in Google Scholar
[47] P. Chen, S. Li, Y. Zhou, M. Yan, and M. M. Attallah, “Fabricating CoCrFeMnNi high entropy alloy via selective laser melting in-situ alloying,” J. Mater. Sci. Technol., vol. 43, no. 8, pp. 40–43, 2020. https://doi.org/10.1016/j.jmst.2020.01.002.Search in Google Scholar
[48] A. Ostovari Moghaddam, N. A. Shaburova, M. N. Samodurova, A. Abdollahzadeh, and E. A. Trofimov, “Additive manufacturing of high entropy alloys: A practical review,” J. Mater. Sci. Technol., vol. 77, pp. 131–162, 2021. https://doi.org/10.1016/j.jmst.2020.11.029.Search in Google Scholar
[49] Y. L. Wang, L. Zhao, D. Wan, S. Guan, and K. C. Chan, “Additive manufacturing of TiB2-containing CoCrFeMnNi high-entropy alloy matrix composites with high density and enhanced mechanical properties,” Mater. Sci. Eng., A, vol. 825, no. 26, p. 141871, 2021. https://doi.org/10.1016/j.msea.2021.141871.Search in Google Scholar
[50] E. Mertgenç and Y. Kayali, “Diffusion kinetics and boronizing of high entropy alloy produced by TIG melting reverse suction method,” Can. Metall. Q., vol. 62, no. 2, pp. 362–371, 2023. https://doi.org/10.1080/00084433.2022.2082203.Search in Google Scholar
[51] G. Polat, “Enhanced strength of (CoFeNiMn) 100−x Crx (x = 5, 20, 35 at.%) high entropy alloys via formation of carbide phases produced from industrial-grade raw materials,” Mater. Test., vol. 66, no. 4, pp. 503–512, 2024, https://doi.org/10.1515/mt-2023-0363.Search in Google Scholar
[52] M. G. Poletti, G. Fiore, F. Gili, D. Mangherini, and L. Battezzati, “Development of a new high entropy alloy for wear resistance: FeCoCrNiW0.3 and FeCoCrNiW0.3 + 5 at.% of C,” Mater. Des., vol. 115, no. 3, pp. 247–254, 2017. https://doi.org/10.1016/j.matdes.2016.11.027.Search in Google Scholar
[53] D. Jiang, H. Cui, H. Chen, X. Zhao, G. Ma, and X. Song, “Wear and corrosion properties of B4C-added CoCrNiMo high-entropy alloy coatings with in-situ coherent ceramic,” Mater. Des., vol. 210, no. 14, p. 110068, 2021. https://doi.org/10.1016/j.matdes.2021.110068.Search in Google Scholar
[54] B. Xu, Y. Zhou, Y. Liu, S. Hu, and G. Zhang, “Effect of different contents of WC on microstructure and properties of CrMnFeCoNi high-entropy alloy-deposited layers prepared by PTA,” J. Mater. Res., vol. 37, no. 3, pp. 719–727, 2022, https://doi.org/10.1557/s43578-021-00452-7.Search in Google Scholar
[55] Y. Cai et al.., “Fracture and wear mechanisms of FeMnCrNiCo + x(TiC) composite high-entropy alloy cladding layers,” Appl. Surf. Sci., vol. 543, no. 10, p. 148794, 2021. https://doi.org/10.1016/j.apsusc.2020.148794.Search in Google Scholar
[56] D. Sun et al.., “Tribology comparison of laser-cladded CrMnFeCoNi coatings reinforced by three types of ceramic (TiC/NbC/B4C),” Surf. Coat. Technol., vol. 450, no. 22, p. 129013, 2022. https://doi.org/10.1016/j.surfcoat.2022.129013.Search in Google Scholar
© 2025 Walter de Gruyter GmbH, Berlin/Boston
