Exploring the potential of gas atomized high entropy alloys in thermal spray coatings – a comprehensive review

Abstract

Thermal sprayed High Entropy Alloy (HEA) coatings represent a state-of-the-art advancement in materials science, tailored to meet the evolving needs of various industrial applications. The combination of multiple principal elements in HEAs offers exceptional performance compared to traditional alloys. HEA coatings, distinguished by their distinct composition and structure, have remarkable mechanical properties, tribological resistance, thermal stability, and corrosion resistance. Recent research has focused extensively on various fabrication processes and parameters for thermal sprayed HEA coatings, such as Atmospheric Plasma Spraying (APS), High-Velocity Oxy-Fuel (HVOF), cold spraying, flame spraying, plasma spraying, and detonation gun spraying, as well as thorough examinations of their microstructural characterization and their performance. This study summarizes the present status of research, emphasizing the applications of HEA coatings and offering useful insights for academics and developers.