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Novel CCA Coatings for Enhanced Wear Resistance

Webinars 29 May 2024

As industries demand materials that can withstand harsh environments, materials research has surged forward, not only enhancing the properties of the existing materials but also with the development and discovery of completely new materials. Recently, there's been a significant exploration into 'multi-principal-elements' materials, which blend multiple elements without a dominant one. This exploration has birthed a new class of alloys known as compositionally complex alloys (CCAs), also referred to as high-entropy alloys or medium-entropy alloys. This innovative approach offers a vast compositional space, allowing the design of structural materials with tailored properties such as exceptional tensile strength, ductility, fracture toughness, wear resistance, and corrosion resistance across various temperatures.

As part of FORGE project, novel CCAs have been designed with three key performance targets: CO2 corrosion resistance, H2 embrittlement resistance, and wear resistance. This webinar focuses specifically on the novel CCA that was designed for wear resistance applications. The webinar will delve into three main aspects: (i) the development of parameters for CCA deposition using high-velocity air fuel (HVAF), high-velocity oxygen fuel (HVOF), cold spray (CS), and laser cladding (LC); whilst briefly touching on how the composition was designed (ii) the microstructural evolution and solidification behavior in CCA coatings, and (iii) the performance of CCA coatings against wear in simulated environments.

TWI will present a study on optimising process parameters for depositing the selected CCA onto steel substrates using four coating processes: HVAF, HVOF, CS, and LC. Experimental frameworks have been established to optimise process parameters for each deposition technique, considering key performance indicators such as deposition efficiency, deposition rate, and the microstructure of deposits (including porosity, cracks, interfacial defects/delamination), etc. University of Leicester (ULEIC) will discuss the microstructural evolution observed in novel CCA coatings produced through the four distinct aforementioned processes. Onderzoeks Centrum voor de Aanwending van Staal (OCAS) will address the wear resistance of selected CCA coatings, deposited by LC, CS, and HVAF, through sliding abrasion tests. Additionally, non-coated samples of the substrate(s), the selected CCA composition, and bulk samples of the Cantor alloy are also tested to obtain reference data for comparison.

FORGE project has received funding from the European Union’s Horizon 2020 research and innovation programme (Grant agreement 958457).


Dr. Dibakor Boruah - Senior Project Leader - Surface, Corrosion, and Interface Engineering

Dr. Dibakor Boruah

Senior Project Leader - Surface, Corrosion, and Interface Engineering

Dr Dibakor Boruah, a Senior Project Leader at TWI Ltd, Cambridge, UK. Dibakor's journey with TWI began in 2017 through the NSIRC programme, where he pursued his PhD, focusing on investigating the structural integrity of cold spray deposited Ti6Al4V alloy for repair and additive manufacturing applications. After completing his PhD, Dibakor further expanded his expertise at Ghent University in 2020, where he served as a leading researcher on multiple collaborative projects related to additive manufacturing, funded by the EU and local government. Returning to TWI's surface engineering team in 2022, Dibakor brought with him over seven years of industry-led research experience in materials engineering and advanced manufacturing. Currently, Dibakor serves as the Technical Manager of the EU-funded collaborative project FORGE, while also spearheading or contributing to various projects related to cold spray and thermal spray processes.

Dr. Deepak Sharma - Research Associate

Dr. Deepak Sharma

Research Associate
Materials Innovation Centre (MATIC)

Dr. Deepak Sharma is a Research Associate at the Materials Innovation Centre (MatIC; a partnership between the University of Leicester and TWI), Cambridge, UK. Before joining MatIC, Deepak did his first postdoc at Groupe de Physique des Matériaux, Université et INSA de Rouen, UMR CNRS 6634, Rouen, France. Deepak received his PhD degree from Coventry University (UK) and Deakin University (Australia) – under the Cotutelle program. Deepak’s interests lie in the field of materials and processes for resisting environmental degradation. He has experience with machine learning, Thermo-Calc, radiation damage, metal additive manufacturing, thermal spraying, atom probe tomography, and small-angle neutron scattering. At present, he is working on an EU-funded project (SEHRENE) to develop phase change materials and understand their corrosion behaviour.

Dr. ir. Alfonso Navarro López - Industrial Engineer and Materials Scientist

Dr. ir. Alfonso Navarro López

Industrial Engineer and Materials Scientist

Dr. ir. Alfonso Navarro López is an industrial engineer and materials scientist with 10-year international experience in R&D, especially in the processing of steel alloys and their physical and mechanical characterization. He is currently working as materials researcher at the Metallurgy Department at OCAS N.V. (OnderzoeksCentrum voor de Aanwending van Staal) in Ghent, Belgium. Before joining OCAS, Alfonso did his PhD degree and two one-year postdocs at the Materials Science and Engineering Department at Delft University of Technology (TUDelft). Alfonso has broad experience using several advanced materials characterization techniques and collaborating closely with universities (UGhent, Belgium; TU Eindhoven, Netherlands; Groningen University, Netherlands), research centers (IMR at Tohoku University, Japan; ESRF, France) and industries (ArcelorMittal, Tata Steel, Philips, VDL, Tenaris) all over the world. He is currently engaged in multidisciplinary projects related to the development of new steel grades as well as novel coatings based on compositionally complex alloys.

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