Effect of Powder Preparation of FeNiCoCrMo0.5Al1.3 High-Entropy Alloy on the Phase Composition and Properties of High-Velocity Oxy-Fuel-Sprayed Coatings

In this work, the effect of high-entropy alloy powder preparation on the coatings deposited via high-velocity oxygen fuel sprayings was studied. The powders of FeNiCoCrMo0.5Al1.3 composition were prepared by milling and gas atomization. The structures, porosity, phase composition, and microhardness of the coatings produced from mechanically alloyed and gas-atomized powders were compared. The influence of milling parameters on the powder phase composition and morphology was studied. Milling at 600 rpm for 1.5 h allowed the production of mechanically alloyed powder with a homogeneous distribution of Fe, Ni, and Al and thin lamellas enriched with Co, Cr, and Mo. Despite the difference in the feedstock powders’ phase compositions, the phase compositions of the coatings deposited from mechanically alloyed and gas-atomized powders are the same consisting of BCC, FCC solutions, and oxide. The amount of FCC solutions and oxide in the coating depends on the size distribution of the sprayed powder. It was found that the phase composition and the properties of the coatings deposited from the mechanically alloyed and gas-atomized powders of similar sizes are similar.