Simulation of deposition mechanism of Fe-Ni-Cr-Co-Al high-entropy alloy nanocrystals by supersonic spraying

Abstract High-Velocity Oxy-Fuel (HVOF) spraying is widely utilized in aerospace and automotive industries for its ability to produce dense coatings with superior adhesion and mechanical properties. In this study, LAMMPS molecular dynamics simulations were performed to construct a microscopic model of the Fe 66 Ni 7 Cr 24 Co 2 Al 1 high-entropy alloy, investigating its thermodynamic properties during supersonic spraying. Concurrently, ABAQUS was employed to simulate the multi-particle deposition process onto a 7075 aluminum alloy substrate. By analyzing the dynamic evolution of temperature and stress fields, the influence of substrate temperature on coating morphology and residual stress distribution was elucidated. Finally, the microstructure and porosity of the alloy were validated through experimental characterization. This research provides a theoretical framework for optimizing supersonic spraying parameters and understanding the fundamental deposition mechanisms of high-entropy alloy coatings.