Numerical and Experimental Analysis of the Deformation Behavior of CoCrFeNiMn High Entropy Alloy Particles onto Various Substrates During Cold Spraying

Abstract The bonding mechanisms of a wide range metallic materials in cold spraying have been studied, mainly attributed to adiabatic shear instability (ASI) at high strain rates, whereas the impact and deformation behavior entropy alloys (HEAs) onto various substrates has not widely explored. HEAs characterized by excellent strain-hardening ability resistance localization, which can influence their mechanism during spray. In this study, experimental numerical analyses single-particle CoCrFeNiMn commercially pure aluminum (CP Al), alloy (Al6082), stainless steel (SS304), titanium (Ti6Al4V) were carried out. morphology revealed ASI HEA particle, SS304 Ti6Al4V substrates. HEA/SS304 pair showed higher critical velocity compared HEA/Ti6Al4V due lower density thermal conductivity SS304. Mechanical interlocking was observed on CP Al Al6082 localized An empirical equation is influenced particle substrate hardness. This work critically evaluates provides better understanding particle–substrates behavior, expanding its applicability wider