X-ray diffraction pattern analysis of CrFeCoNi high-entropy alloy deposited via cold spray

CrFeCoNi high-entropy alloy (HEA) powder with an equimolar composition was produced via gas atomization and applied as a coating using the cold-spray technique. X-ray diffraction patterns were analyzed to characterize the microstructure of the raw HEA powder and cold-sprayed coatings using Rietveld refinement methods. The HEA powders exhibited a single-phase face-centered cubic crystal structure with a lattice parameter of 0.357349(1) nm, a low microstrain of 4.3(0.17) × 10 −4 , and a crystallite size of 225(8) nm, attributed to the rapid cooling during atomization. In contrast, the cold-sprayed coatings exhibited broadened diffraction peaks, with a reduced crystallite size of 67.9(1.2) nm and an increased microstrain of 2.2(0.23) × 10 −3 , showing crystallite size refinement and an increase in the density of crystalline defects due to severe plastic deformation during deposition. Additional microstructural analysis revealed texture in the {200} plane and intrinsic stacking fault probabilities increasing to 4.4(0.21) × 10 −3 . These findings highlight microstructural changes produced by the cold-spray process. This study provides valuable insights into optimizing cold-spray parameters and tailoring HEA properties for industrial applications.