Faculty Publications
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Item An Overview of Mechanical Alloying and Conventional Metallurgical Methods(Springer, 2024) Bhajantri, V.F.; Kanaginahal, G.M.; Jambagi, S.Mechanical alloying (MA) is a powder processing technique that involves the cyclic process of cold welding, fracturing, and rewelding of powder particles within a high-energy ball mill. This method has the ability to create several forms of non-equilibrium phases, such as supersaturated solid solutions, nanocrystalline materials, metallic glasses, high-entropy alloys, and more. Materials with shape memory properties have been utilized in various applications. This article enlightens on MA and other conventional metallurgical methods. The article provides a description of the current and future applications of MA. © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2024.Item Influence of Refractory Elements on Mechanical Properties of High Entropy Alloys(Springer, 2021) Kumar Sinha, A.K.; Soni, V.K.; Chandrakar, R.; Kumar, A.High entropy alloys (HEAs) have become the most popular among the materials scientists and researchers due to their attributes like high strength, hardness and corrosion resistance when compared to conventional alloys. For sprawling use of HEAs in various domains such as aerospace, structural and automobile, it is necessary for researchers to explore more number of HEAs. In this endless endeavour of exploration, researchers have also developed refractory HEAs which possess better mechanical properties when compared to conventional HEAs. But, HEAs (without refractory elements) are more economical than refractory HEAs. This is due to the fact that most of the refractory elements are expensive. The present work focuses on the effect of refractory elements, namely, Mo, W, Ta, Nb, Ti and V on mechanical properties of HEAs. This review also provides an insight into the phase evolution in HEAs due to addition of refractory elements. Moreover, it also unfolds research gaps from past literature, which shows that there is scarcity of literature on dynamic characteristics, fatigue and creep analysis of Hf, Zr, Si and Cr based HEAs. © 2021, The Indian Institute of Metals - IIM.Item Additive manufacturing of an aluminum matrix composite reinforced with nanocrystalline high-entropy alloy particles(Elsevier Ltd, 2017) Karthik, G.M.; Panikar, S.; Janaki Ram, G.D.J.; Kottada, R.S.In the present work, a metal-metal composite consisting of aluminum-magnesium alloy AA5083 matrix and nanocrystalline CoCrFeNi high-entropy alloy reinforcement particles in 12 vol% was successfully friction deposited in multiple layers. The layer interfaces or the reinforcement/matrix interfaces showed no brittle intermetallic formation – thanks to the inert nature as well as the high strength and hardness of the high-entropy alloy reinforcement particles. The composite showed significantly higher tensile and compressive strengths as compared to standard wrought-processed alloy AA5083-H112 and offered a much better combination of strength and ductility when compared to conventional aluminum matrix composites reinforced with ceramic particles. The current study establishes friction deposition as a viable technique for additive manufacturing of novel high-performance composite materials. © 2016 Elsevier B.V.Item Phase Evolution of Novel MoNbSiTiW Refractory High-Entropy Alloy Prepared by Mechanical Alloying(Springer, 2022) Prakash, O.; Chandrakar, R.; Chandraker, S.; Rao, K.R.; Kumar, R.; Kumar, A.; Dubey, V.Refractory high-entropy alloys (RHEAs) are new types of material that have been developed for high-temperature applications. RHEAs should have enhanced high-temperature strength while maintaining a sufficient level of room-temperature toughness. The phase evolution of novel MoNbSiTiW RHEAs was investigated after mechanical alloying (MA) for 35 h. X-ray diffraction (XRD) was used to analyze the phase evolution, and analysis of particle morphologies was done using a scanning electron microscope (SEM) equipped with energy dispersive spectroscopy (EDS). XRD results indicate that NbMoSiTiW RHEAs with up to 10 h of mechanical alloying have a stable solid solution phase with body centered cubic (BCC) structure. Further milling of NbMoSiTiW RHEAs promotes the evolution of intermetallic compounds until 35 h of mechanical alloying. The Williamson-Hall process was incorporated for crystalline size and lattice strain measurement and the results show that, after 35 h of mechanical alloying, the crystalline size decreased from 298 nm to 25 nm, and an enhancement in lattice strain was observed from 0.1% to 0.65%. © 2022, The Minerals, Metals & Materials Society.Item Phase evolution and high-temperature wear behavior of non-equiatomic metastable CoCrNiTiMox HEA coatings fabricated by high-velocity oxy-fuel technique(Elsevier Ltd, 2023) Addepalli, S.N.; Joladarashi, S.; Ramesh, M.R.The current research aims to enhance the tribological performance of maraging steels at high temperatures by surface modification techniques. CoCrNiTiMox (x; molar fraction, x = 0.5, 1.5) high-entropy alloy (HEA) coatings with dense lamellar microstructures were deposited onto maraging steels using high-velocity oxy-fuel spray (HVOF). In order to achieve a uniform distribution of constituent elements for thermal spray deposition, mechanical alloying was employed to synthesize the HEA feedstock. The phases and microstructure of the synthesized HEA powder, as-sprayed coatings, and worn surfaces were examined using X-ray diffraction (XRD) and scanning electron microscopy (SEM). The as-sprayed HEA coatings exhibited metastability, with a BCC phase solid solution, NiTiO3 spinel, and an intermetallic MoNi phase for CoCrNiTiMo0.5 and Co2Mo3 phase for CoCrNiTiMo1.5. The average microhardness of CoCrNiTiMo0.5 and CoCrNiTiMo1.5 HEA coatings were 841 ± 62 HV0.3 and 952 ± 23 HV0.3, respectively. The specific wear rate and friction coefficients of CoCrNiTiMox HEA coatings exhibited a decreasing trend with an increase in temperature, owing to the formation of tribofilms on the worn surface. X-ray diffraction studies revealed the formation of NiMoO4 spinel for CoCrNiTiMo0.5 and MoO2, Co3O4 phases for CoCrNiTiMo1.5 HEA at a wear temperature of 600 °C. The investigation of worn surfaces showed a transformation in wear mechanisms from abrasive wear at room temperature to oxidative wear with mild fatigue at elevated temperatures. © 2023 Elsevier LtdItem Effect of metalloid element on the microstructural and mechanical properties of AlCoCrCuFeNi high-entropy alloys(Taylor and Francis Ltd., 2024) Chandrakar, R.; Chandraker, S.; Kumar, A.; Jaiswal, A.The impact of the metalloid element silicon (Si) addition on the microstructural and mechanical properties of the AlCoCuCrFeNiSix high-entropy alloy system is examined in this paper. The alloys were synthesized using a vacuum arc melting route. X-ray diffraction was used to analyse the current high-entropy alloys’ phase formation to comprehend the alloying process’s behaviour. It is evident from the peak pattern of the X-ray diffraction that the inclusion of Si promotes the growth of body-centred cubic structures. The microhardness and wear resistance were increased by increasing the Si content from 0 to 0.9. Si presence enhances the hardness of the alloys and strengthens the grain boundary. Improved hardness and wear resistance results from the enhanced body-centred cubic-phase formation, which poses a barrier to the dislocation movement and prevents further deformation. Furthermore, the inclusion of Si improved corrosion resistance in potentiodynamic polarization measurements. Excellent compressive strength is possessed by all of the high-entropy alloys with Si addition. © 2024 The Author(s). Published by Informa UK Limited, trading as Taylor & Francis Group.Item Elevated temperature tribological performance of non-equiatomic CoCrNiTiWx high entropy alloy coatings developed by mechanical alloying and high-velocity oxy-fuel spray(Elsevier B.V., 2024) Addepalli, S.N.; Joladarashi, S.; Ramesh, M.R.High entropy alloys (HEA) have applications in multiple fields owing to their exceptional mechanical and physical properties. In the current study, mechanical alloyed CoCrNiTiWx (x; a molar fraction, x = 0.5 and 1.5) HEA feedstock powders were deposited on maraging steel substrate using high-velocity oxy-fuel spray (HVOF). The phase evolution and the microstructure of the milled powders and as-sprayed coatings were analysed by X-ray diffraction (XRD) and scanning electron microscope (SEM). The tribological behaviour of CoCrNiTiW0.5 and CoCrNiTiW1.5 HEA coatings at elevated temperatures was studied extensively using a Pin-on-Disc tribometer. The CoCrNiTiW0.5 and CoCrNiTiW1.5 HEA coatings retained the BCC solid solution phases formed during the milling stage. However, additional oxide and intermetallic phases were formed owing to the in-flight oxidation and high temperatures experienced during the HVOF deposition. The deposited coatings exhibited a lamellar structure and good mechanical bonding with the substrate. The porosities of CoCrNiTiW0.5 and CoCrNiTiW1.5 HEA coatings were found to be 1.69 ± 0.32 % and 1.51 ± 0.37 % respectively.Consequently, the CoCrNiTiW0.5 and CoCrNiTiW1.5 HEA coatings displayed average microhardness values of 863 ± 52 HV0.3 and 1025 ± 39 HV0.3, respectively. Further, the wear rates of coatings exhibited a significant reduction at elevated temperatures, owing to the formation of TiO2, NiCr2O4 oxide tribofilms for CoCrNiTiW0.5, and CoCr2O4, NiWO4, WO3 oxides for CoCrNiTiW1.5. The specific wear rate of CoCrNiTiW0.5 HEA coating dropped by 73.6 % from 22.7 ± 2.6 × 10−6 mm3/N-m to 5.99 ± 1.9 × 10−6 mm3/N-m, while CoCrNiTiW1.5 dropped by 78.8 % from 11.86 ± 3.5 × 10−6 mm3/N-m to 2.51 ± 1.5 × 10−6 mm3/N-m, with a rise in the temperature from RT to 600 °C. Likewise, The frictional coefficients of CoCrNiTiW0.5 HEA dropped from 0.504 ± 0.015 to 0.397 ± 0.005, while CoCrNiTiW1.5 HEA dropped from 0.578 ± 0.025 to 0.471 ± 0.004, with a rise in temperature from RT to 600 °C. At room temperature, the wear mechanisms of the as-sprayed CoCrNiTiWx coatings were dominated by adhesive wear. However, at elevated temperatures, a shift towards oxidative wear was observed. © 2023 Elsevier B.V.Item Laser cladding technology for high entropy alloys: effect and applications(Institute of Physics, 2024) Prakash, O.; Chandrakar, R.; Martin, L.; Verma, J.; Kumar, A.; Jaiswal, A.A multi-component category of an alloy containing very specific properties revolutionized the area of material science and the present engineering era. Laser cladding, a technique for surface coating, enhances surface quality and modifies properties using advanced coating technologies. In current trends, Laser cladding is mainly used in equipment and machine parts for enhancing surface properties, repairing damaged parts and surface coating caused by its advantages such as small heat-affected zone, low substrate damage, low dilution rate and exceptional metallurgical material bonding among coating and used substrate. Laser cladding improves substrates’ mechanical and various functional-specific properties, ensuring a high-quality balance between mechanical and surface attributes. The research society was able to investigate laser-cladding HEAs coatings because of the superior attributes of HEAs compared to ordinary alloys. This paper reviews current developments in laser-cladding HEAs coatings and the application of laser-cladding technology to HEAs materials. The laser cladding high-entropy alloy coatings have potential applications in corrosion, wear, and oxidation resistance, as well as their respective substrates. Cladded coatings composed of HEAs materials are measured to have shown potential applications in recent technology, opening exciting possibilities for the future. The study also discusses current trends and future prospects. © 2024 The Author(s). Published by IOP Publishing Ltd.Item Investigation of phase transformation and mechanical properties of silicon addition on AlCrFeMnNi high entropy alloys(Institute of Physics, 2024) Chandrakar, R.; Chandraker, S.; Kumar, A.; Jaiswal, A.This paper examines the impact of silicon in the AlCrFeMnNi high-entropy alloy system, focusing on both its microstructural and mechanical properties. Alloys with varying silicon content (x = 0, 0.3, 0.6, 0.9 atomic ratio) were synthesized using vacuum arc melting. The phase formation of these high-entropy alloys was analyzed using x-ray diffraction to comprehend the alloying process behaviour. The findings revealed that the solidification of the AlCrFeMnNi alloy occurred in dendritically, with dendrite cores containing Cr, Fe, and Ni, while interdendritic regions were enriched in Al and Ni after adding Silicon. Increasing the silicon content from 0 to 0.9 led to significant improvements in microhardness and wear resistance. This improvement is attributed to the reinforcement of grain boundaries provided by silicon. The formation of an Al and Ni rich B2 phase is crucial in resisting dislocation motion and preventing further deformation. Additionally, the addition of silicon led to improved corrosion resistance, as demonstrated by potentiodynamic polarization measurements. However, a trade-off was observed between compressive strength and ductility: compressive strength increased with higher silicon concentrations, but at the expense of ductility. © 2024 The Author(s). Published by IOP Publishing Ltd.Item Microstructure, Mechanical, and Dry Sliding Wear Performance of Equimolar CoCrNiTiMo and CoCrNiTiW High-Entropy Alloy Coatings(Springer, 2025) Addepalli, S.N.; Joladarashi, S.; Ramesh, M.R.In the present investigation, mechanical alloyed CoCrNiTiMo and CoCrNiTiW equimolar HEA powders were employed as feedstock in the development of dense coatings using high-velocity oxy-fuel technique. The dry sliding wear behavior of uncoated substrate and high-entropy alloy (HEA) coatings were extensively investigated at different temperatures and loads using a pin-on-disk tribometer. The microstructures and phases of the mechanical alloyed powders, deposited coatings, and worn surfaces were thoroughly studied. The mechanical alloyed CoCrNiTiMo and CoCrNiTiW HEAs demonstrated the evolution of two BCC solid solutions. However, the deposited coatings reported the formation of additional phases, including Co3Ti intermetallic and NiTiO3 spinel. The microstructural analysis of CoCrNiTiMo and CoCrNiTiW coatings unveiled a compact lamellar structure characterized by robust mechanical interlocking to the substrate. The CoCrNiTiMo and CoCrNiTiW HEA coatings displayed porosities of 1.12 ± 0.05% and 1.39 ± 0.03%, respectively. Additionally, the microhardness assessments revealed superior values for CoCrNiTiMo and CoCrNiTiW HEA coatings, measuring at 927 ± 45 HV0.3 and 951 ± 38 HV0.3, correspondingly. The wear rate of CoCrNiTiMo HEA coating dropped by 70.5%, from 17.34 ± 2.8 × 10?6 mm3/N-m to 5.1 ± 1.6 × 10?6 mm3/N-m with an increment in the wear testing temperature from ambient to 600 °C. Concurrently, the CoCrNiTiW coating experienced a 76.3% drop in the wear rates from 15.8 ± 3.7 × 10?6 mm3/N-m to 3.73 ± 2.1 × 10?6 mm3/N-m. The significant fall in the wear rates at higher temperatures was accredited to the development of oxide tribofilms. CoCrNiTiMo exhibited discernible oxide phases, including CoMoO4, TiO2, and NiO. In contrast, its counterpart, CoCrNiTiW, generated WO3, CoWO4, and TiO2 oxides at a temperature of 600 °C. The adhesive wear at RT transitioned to predominant oxidative wear with slight fatigue and abrasive wear at high temperatures. © ASM International 2025.