Self-propagating high-temperature synthesis of AlxCoCrFeNiMoy high-entropy alloys: thermochemical modelling, microstructural evaluation and high temperature oxidation behaviour

In this study, the feasibility of the synthesis of AlxCoCrFeNiMoy (0.5 < x < 3, y = 0.5,1) alloys via cost and energy efficient thermochemical modelling assisted (FactSage (TM)) aluminothermic self-propagating high-temperature synthesis (SHS) method was investigated. In addition, selected SHS alloys were also suction-casted into a bar shape by using a vacuum arc melter and the microstructural changes and oxidation behaviour of selected alloys were investigated. The characterization results demonstrated that AlxCoCrFeNiMoy (0.5 < x < 3, y = 0.5,1) master alloys can be successfully synthesized via thermochemical modelling assisted SHS method with a substantial composition control. The microstructures of the SHS alloys were found to comprise of the FCC-A1, BCC (A2, B2) and sigma phases with varying fractions depending on the composition. Increasing Al content was found to increase the hardness of the alloys from 278 HV to 829 HV for the AlxCoCrFeNiMo0.5 system. For AlxCoCrFeNiMo system, on the other hand, it had an increasing effect from Al0.5 to Al1.0 (from 659 HV to 903 HV) initially and then decreased the hardness to the levels of 773 HV with the further addition of Al. Suction-cast alloys exhibited rather similar microstructures with similar phase constituents and hardness values. As a general trend primer B2 phase fraction was increased due to higher cooling rate. Oxidation studies revealed that the Al3.0Mo0.5 alloy, which has higher B2 content (919 HV), exhibited better oxidation resistance after 100 h of exposure to air at 800 degrees C. Postulated scaling mechanisms, supported with the CALPHAD simulations and Raman analyses, revealed the formation of non-protective spinel oxides and sublimation of volatile MoOx oxides before the stabilization of a protective M2O3 (M = Al,Cr) layer, especially for the AlCoCrFeNiMo alloy.