High-entropy alloys (HEAs) represent an innovative development approach for new alloy systems. These materials have been found to yield promising properties, such as high strength in combination with sufficient ductility as well as high wear and corrosion resistance. Especially for alloys with a body-centered cubic (bcc) structure, advantageous surface properties have been revealed. However, typical HEA systems contain high contents of expensive or scarce elements. Consequently, applying them as coatings where their use is limited to the surface represents an exciting pathway enabling economical exploitation of their superior properties. Nevertheless, processing conditions strongly influence the resulting microstructure and phase formation, which in turn has a considerable effect on the functional properties of HEAs. In the presented study, microstructural differences between high-velocity oxygen fuel (HVOF) and high-velocity air fuel (HVAF) sprayed coatings of the alloy AlCrFeCoNi are investigated. A metastable bcc structure is formed in both coating processes. Precipitation reactions are suppressed by the rapid solidification during atomization and by the relatively low thermal input during spraying. The coating resistance to corrosive media was investigated in detail, and an improved passivation behavior was observed in the HVAF coatings.

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