Effect of refractory element addition on high temperature oxidation process of complex concentrated alloy coatings

The sluggish diffusion effect of complex concentrated alloys (CCAs) affords them considerable application potential in the field of high temperatures. In this study, the role of refractory elements in the high temperature oxidation process of denary complex concentrated alloy coatings (CCACs, namely NiCoCrFeAl0.8Si0.1(MoNbTaW)x, where x is 0.025, 0.05, 0.1 and 0.15) prepared via laser cladding was investigated. Four groups of the CCACs with different refractory contents were subjected to 100 h of high-temperature oxidation experiments, and the oxidation products and microscopic characteristics of the samples were observed via XRD and SEM, respectively. Atomic-scale characterisation and analysis of the oxidised samples were performed using TEM and XPS technology to explore the diffusion behaviour of elements in the high-temperature process. Results indicate that the solid solution limit of the CCACs is obtained by regulating the topological instability of the lattice matrix via the addition of refractory elements. Consequently, when 0.1 > x > 0.025, the coating is a body-centred cubic (BCC) + face-centred cubic (FCC); when x = 0.1, the coating maintains a single-phase FCC structure; and when x > 0.1, the coating changes to an FCC + BCC duplex structure. The x0.1 group exhibits the smallest relative strain among all coatings, which is conducive to maintaining the structural stability of the face-centred cubic at high temperatures and delaying atomic migration within the lattice. Furthermore, the oxidation kinetics curve of the CCACs with a single- phase FCC exhibits low Kp values. In a single- FCC lattice, the atom diffusion rate through volume slows down and grain boundary diffusion decreases. Considering the Weibull modulus for the hardness statistical value after coating oxidation, the modulus of single-FCC phase CCACs is also higher than others. This study has the potential to contribute to the application of high-temperature thermal protection for CCACs. •The denary complex concentrated alloy coatings (CCACs) were prepared by laser cladding.•The solid solutioning limit of the CCACs can be adjusted by the topological instability of the lattice.•The diffusion rate of atoms in matrix is the combined action of the volume and the boundary diffusion.•The single-FCC CCACs with higher solid solubility have better oxidation resistance.