近年來，高熵合金面臨了一個大問題，當擴散速度過慢時會導致鑄造過程中產生缺陷，所以當擴散速度緩慢時，冷卻速度應該也必須比平時慢，否則將會產生裂縫及偏析。為了克服這個問題，本研究採用了高熵合金粉末，藉由降低合金的尺寸解決冷卻速度的問題。此外，粉末可以通過不同的製程應用於表面改質，而高熵合金因為其可以透過調整成份來獲得不同的特性，故其適用於不同需求的表面改質。
在此篇研究中，利用氣體霧化法取代傳統的球磨法製備AlCoCrFeNi及Al0.5CoCrFeNi2高熵合金粉末，並對其施以退火處理，探討退火溫度及時間對於微觀結構、晶體結構、相變化以及機械性質的影響。
藉由氣體霧化法製備之AlCoCrFeNi保留了其初始相BCC，然而，在經過900℃的退火處理超過3小時之後，FCC相及σ相開始出現，透過XRD及EBSD的分析後，結果顯示此合金的主要基底BCC相為FeCo的化合物，此外，FCC及σ相分別為AlNi3及Fe0.5Cr0.5化合物，析出的FCC及σ相能夠顯著的提高此合金之機械性質。為了解決此合金會在高溫環境下產生相變化的問題，此篇研究進一步改變了鋁及鎳的含量而得到了另一個合金系統Al0.5CoCrFeNi2，預期其由單一的FCC固溶體所組成，在經過1000℃且長時間的熱處理後，由NiAl及Fe所組成的BCC結構開始產生，但其依舊能在最初時保留其初始相。
此外，在本研究中，使用電漿噴塗法及濺鍍法將Al0.5CoCrFeNi2高熵合金粉末製備成兩種不同型態的鍍層，結果顯示在電漿噴塗實驗中，較強的功率能夠促使粉末完全熔化，從而使得塗層具有較少的缺陷，包括：空隙及未熔化完全的粉末。當電流從500A提升到750A時，塗層的元素分佈依舊保持均勻，相組成依舊維持在最初的FCC結構，而硬度隨著電流的提升由HV206上升到HV271，這是因為上述缺陷的減少使得塗層變得較為緻密。而在濺鍍塗層的結果仍然顯示出其與初始粉末一樣由純FCC相所組成。在實驗過程中，沉積速度及鍍層的密度會受到工作壓力及基板偏壓影響。在高壓力的環境下，能量會損失使得緻密度降低。此外，基板偏壓則會影響到金屬離子的擴散效率，因此可以藉由提高偏壓獲得品質較佳的鍍層。本研究所採用的兩種塗層製備方法都能夠獲得相同結構之鍍層，這也表明Al0.5CoCrFeNi2高熵合金能夠在高能量的環境表現出良好的穩定性，有利於之後在工業上的發展。

Recently, HEAs bulk face a big issue about sluggish diffusion which would cause the defect forming during casting. While the diffusion rate is slow, the cooling rate should be slower than usual. If not, the crack and segregation may occur. To overcome this problem, the HEAs powders were utilized in this study. By reducing the dimension of HEAs alloy, the sluggish cooling rate could be solved. Moreover, the powders could be applied on surface modification with various needs by using different processes; and HEAs alloy is a suitable material for surface modification duo to its variability which could be adjusted via tuning the element composition. In this study, AlCoCrFeNi and Al0.5CoCrFeNi2 high-entropy alloy (HEA) powders were fabricated by gas atomization process instead of ball milling method and the effect of annealing temperature and durations on the microstructure, crystal structure, phase evolution and mechanical properties were investigated.
The as-atomized AlCoCrFeNi powder could retain the initial phase which is composed of pure BCC phase. However, the FCC and minor sigma phases could obtain by conducting the annealing process. After the heat treatment at 900℃ for over 3 hours, the phase constitution was investigated by XRD and EBSD. The results exhibited that BCC is a FeCo compound which is the base of this HEA system, furthermore, FCC and sigma phases are measured as AlNi3 and Fe0.5Cr0.5 compounds, respectively, and the precipitated FCC and sigma phase could hence significantly increase the mechanical performance. In order to solve the problem of the phase stability which means the phase transition would occur at the high temperature, the contents of aluminum and nickel were further modified to achieve Al0.5CoCrFeNi2 alloy, it was expected to have a single FCC solid solution alloy. After the heat treatment at 1000℃ for long time, the BCC crystal structure of NiAl and Fe was formed, but it still could keep the initial phase in the beginning.
Furthermore, Al0.5CoCrFeNi2 powders were utilized to deposit two different coatings by plasma spray and sputtering processes in this study. In plasma spray process, the results indicated that higher working power could induce the powders fully smelted, resulting in a coating layer with fewer defects, including voids and un-melted powders. With the increase current from 500 to 750A, the element distribution retained uniform throughout the coating layer and the phase constitution stayed at the initial FCC phase. The hardness of dense spraying coatings possessed an increasing trend from HV206 to HV271 with working currents. Then, the analysis of sputtering coatings still displayed that the phase constitution of pure FCC was corresponding to the raw powders. The deposition rate and density were influenced by the sputtering pressure and substrate bias. High pressure could cause energy loss, resulting in the lower density. Moreover, the substrate bias would raise the diffusion rate of metal ions to obtain the thin films with high hardness. The coating prepared by these two methods possessed the same phase constitution, which indicated that Al0.5CoCrFeNi2 high entropy alloy could exhibit excellent stability in high-energy occasions. This also facilitates the subsequent development of the industry.

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