| Abstract | The increasing demand for higher operating temperatures and improved efficiency has highlighted the limitations of conventional bond coat materials, such as MCrAlX, which are prone to oxidation and degradation. This study investigates FeCoNiCrAl high-entropy alloy (HEA) as an alternative bond coat material to enhance thermal barrier system performance. Using the high-velocity oxygen fuel (HVOF) spray technique, FeCoNiCrAl HEA and industry-standard MCrAlX coatings were deposited and evaluated in terms of deposition efficiency, thermally grown oxide (TGO) growth, and oxidation resistance. The results revealed that HEA bond coats achieved a higher deposition efficiency and formed a dense and protective Al2O3 TGO layer, comparable to conventional bond coat alloys. Notably, the HEA bond coat exhibited no mixed oxide formation, even after 150 h of exposure at 1150 °C. Additionally, the TGO thickness remained controlled, demonstrating the superior oxidation resistance of FeCoNiCrAl HEA. These findings suggest that HEA coatings deposited via HVOF spraying offer a promising alternative to traditional MCrAlX bond coats for high-temperature applications. |
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