Microstructural, Mechanical, and Tribological Characteristics of ZA40 Alloy Reinforced with AlCrCuFeNi High Entropy Alloy: An Experimental Study

Abstract This study investigates the enhancement of ZA40 alloy through reinforcement with AlCrCuFeNi high-entropy alloy (HEA) particles to improve its mechanical and tribological properties. A mechanical milling process was used to produce ZA40-AlCrCuFeNi composite powders with 5, 10, and 20 wt.% HEA content, which were then hot-pressed to create bulk samples. Microstructural analysis showed that HEA particles were uniformly dispersed throughout the ZA40 matrix without any phase separation, confirming a homogeneous distribution. The addition of HEA particles led to a significant increase in both hardness and tensile strength. The ZA20HEA composite demonstrated the highest tensile strength, highlighting the positive impact of increased HEA content. Tribological testing under 5N, 10N, and 20N loads revealed how wear mechanisms evolved with increasing HEA content. At 5N load, the unreinforced ZA40 alloy exhibited delamination, while composites demonstrated a transition to abrasive wear as HEA content increased. At 20N load, abrasive wear became more dominant, with HEA particles contributing to the formation of a protective layer on the surface and embedding into the matrix. The increased HEA content enhanced wear resistance, showcasing the improved performance of the composites. In conclusion, incorporating AlCrCuFeNi HEA into ZA40 alloy significantly enhanced its hardness, tensile strength, and wear resistance. This study demonstrates that HEA-reinforced ZA40 composites are promising for applications that demand high mechanical strength and durability under varying loading conditions.