Production and Characterization of Fine-Grained Multielement AlCoxCrFeNi (x = 1, 0.75, 0.5) Alloys for High-Temperature Applications

In the present work, three different AlCoxCrFeNi (x = 1, 0.75, 0.5) alloys were produced through the mechanical milling of powders and spark plasma sintering. These alloys were characterized in terms of their microstructural, mechanical, and oxidation behaviors. Mechanical milling and spark plasma sintering were chosen to achieve a fine and homogeneous microstructure. Pore-free samples were produced by properly setting the sintering parameters. The unavoidable uptake of oxygen from the powders when exposed to air after milling was advantageously used as a source of oxides, which acted as reinforcing particles in the alloy. Oxidation behavior, studied through TGA tests, showed that decreasing the Co content promotes better oxidation protection due to the formation of a dense, compact Al₂O₃ layer. The alloy containing the lowest amount of Co is considered a good candidate for high-temperature structural applications.