Weld overlaying of FeNiCrMnSi high entropy alloy over nuclear grade stainless steel SS316LN for improving high-temperature wear and corrosion characteristics

The need for high-performance materials in nuclear environments necessitates enhanced wear and corrosion resistance. This study investigates the weld overlaying of nuclear-grade stainless steel SS316LN with a FeNiCrMnSi high-entropy alloy to improve its high-temperature performance. The alloy was deposited using the gas tungsten arc welding process, achieving a defect-free, well-bonded overlay. The microstructural analysis confirmed a homogeneous grain structure with uniform elemental distribution and minimal dilution at the interface. The overlay exhibited a high hardness of 1080 ± 7 HV, contributing to superior wear resistance. Electrochemical testing demonstrated improved passivation behavior, though molten salt tests at 500°C and 700°C indicated selective leaching and oxidation. High-temperature wear tests revealed a non-linear wear rate governed by mechanical stresses and oxidation. The findings suggest that weld overlaying with this alloy enhances the durability of stainless steel components in extreme conditions, making it a promising approach for nuclear applications.