High-temperature oxidation behavior of CuAlNiCrFe high-entropy alloy bond coats deposited using high-speed laser cladding process

A promising new bond coat using CuAlNiCrFe high-entropy alloy was proposed in this paper. The difference in pre-oxidation conditions between the traditional thermal-sprayed MCrAlY bond coat and CuAlNiCrFe high-entropy alloy bond coat deposited using high-speed laser cladding was investigated. The result confirmed that the CuAlNiCrFe high-entropy alloy bond coat deposited using high-speed laser cladding can complete the pre-oxidation faster and form a continuous α-Al₂O₃ thermally grown oxide (TGO), which shortens the initial oxidation stage, thereby avoiding the formation of other oxides and spinel structures. In the subsequent isothermal oxidation process, the block-like structure of the high-speed laser cladding layer and the sluggish diffusion effect of the high-entropy alloy work together to ensure the slow and continuous supply of aluminum element to TGO layer and obtain a low growth rate. Also, the diffusion between the bonding layer and the substrate is controlled at a low level, and the new CuAlNiCrFe bond coat exhibits excellent oxidation and diffusion resistance. With the consumption of aluminum, the phase structure of the high-entropy alloy bond coat changed from BCC to FCC, but it still maintained a stable simple solid solution structure.