<p>Metallic combustion in oxygen-enriched environments remains one of the most unpredictable failure modes in aerospace propulsion and life-support systems, but design rules linking alloy chemistry to burning resistance are still missing. Exploiting the structurally simple, single-phase solid solution of CoCrFeNi high-entropy alloys (HEAs), we systematically investigated effects of Cr on flame retardancy with multiscale characterization and thermodynamic modeling. A sharp optimum at 30 at.% Cr raises the sustained-burning threshold by 89% (1.8 → 3.4 MPa), exceeding all conventional superalloys. Based on electron probe microanalysis (EPMA) element distribution and finite element thermal simulations, it is concluded that a liquid Cr<sub>2</sub>O<sub>3</sub> film forms on the melt pool during combustion. This film exhibits self-healing behavior and effectively suppresses oxygen ingress, representing a barrier mechanism distinct from traditional solid oxide scales. A valence-electron-concentration (VEC) criterion of ⩽8.0 quantitatively predicts the FCC→BCC transition that triggers sudden loss of flame resistance, converting electronic structure into an immediately applicable safety boundary. CoCrFeNi series HEAs exhibit a peak yield stress over 720 MPa without external coatings when deformed at 760 °C, providing a ready-to-use intrinsically flame-proof structural material. This work redefines Cr as a combustion-rate tuner rather than a simple oxide former and offers a universal design framework for next-generation combustion-proof high-performance alloys.</p>

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Enhanced flame resistance in CoCrFeNi high-entropy alloys via chromium tuning

  • Jiabin Yu,
  • Xiangyang Peng,
  • Hui Wang,
  • Xianzhen Wang,
  • Jinfeng Huang,
  • Wei Liu,
  • Yuchen Zhao,
  • Jinwei Zhu,
  • Zhongjiang Chen,
  • Dong He,
  • Yongliang Pan,
  • Guoliang Xie,
  • Yuan Wu,
  • Xiaobin Zhang,
  • Zhaoping Lu

摘要

Metallic combustion in oxygen-enriched environments remains one of the most unpredictable failure modes in aerospace propulsion and life-support systems, but design rules linking alloy chemistry to burning resistance are still missing. Exploiting the structurally simple, single-phase solid solution of CoCrFeNi high-entropy alloys (HEAs), we systematically investigated effects of Cr on flame retardancy with multiscale characterization and thermodynamic modeling. A sharp optimum at 30 at.% Cr raises the sustained-burning threshold by 89% (1.8 → 3.4 MPa), exceeding all conventional superalloys. Based on electron probe microanalysis (EPMA) element distribution and finite element thermal simulations, it is concluded that a liquid Cr2O3 film forms on the melt pool during combustion. This film exhibits self-healing behavior and effectively suppresses oxygen ingress, representing a barrier mechanism distinct from traditional solid oxide scales. A valence-electron-concentration (VEC) criterion of ⩽8.0 quantitatively predicts the FCC→BCC transition that triggers sudden loss of flame resistance, converting electronic structure into an immediately applicable safety boundary. CoCrFeNi series HEAs exhibit a peak yield stress over 720 MPa without external coatings when deformed at 760 °C, providing a ready-to-use intrinsically flame-proof structural material. This work redefines Cr as a combustion-rate tuner rather than a simple oxide former and offers a universal design framework for next-generation combustion-proof high-performance alloys.