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<p>Lead-cooled fast reactors (LFRs) pose significant technical challenges due to the corrosion of structural materials caused by liquid lead–bismuth eutectic (LBE). A plasma-sprayed FeCrAlNiNb high-entropy alloy coating was developed to enhance the wear resistance and LBE corrosion resistance of 316L stainless steel substrates. The process of plasma spraying power (28–38&#xa0;kW) was systematically optimized. The low porosity (0.8%) and high bond strength (57&#xa0;MPa) with the substrate of the coating were achieved with the power of 34&#xa0;kW, which led to a wear rate reduced by 50% compared to other power levels. After exposure to LBE corrosion for 2000&#xa0;h, an oxide film of 50&#xa0;nm (outer loose Cr oxide layer and inner dense Al<sub>2</sub>O<sub>3</sub> layer) was formed, which limited LBE penetration depth to less than 2&#xa0;μm. Combining the high wear resistance and LBE corrosion resistance, this coating provided an effective protective solution for LFR structural materials.</p>

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Superior wear and liquid lead–bismuth corrosion resistance of a FeCrAlNiNb high-entropy alloy coating via plasma spraying

  • 期刊论文

  • 发表日期：

    2026年4月24日

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  • Xiang-Yang Peng,
  • Yuan Liu,
  • Zhen Tian,
  • De-Zheng Wang,
  • Pei-Pei Cao,
  • Shuo Hou,
  • Li-Hong Zhai,
  • Guang-Yao Lu,
  • Shu-Jian Tang,
  • Xue-Cheng Lu,
  • Hui Wang,
  • Xiong-Jun Liu,
  • Xiao-Bin Zhang,
  • Yong Yu,
  • Yao-Zu Shen,
  • Xian-Zhen Wang,
  • Yuan Wu

摘要

Lead-cooled fast reactors (LFRs) pose significant technical challenges due to the corrosion of structural materials caused by liquid lead–bismuth eutectic (LBE). A plasma-sprayed FeCrAlNiNb high-entropy alloy coating was developed to enhance the wear resistance and LBE corrosion resistance of 316L stainless steel substrates. The process of plasma spraying power (28–38 kW) was systematically optimized. The low porosity (0.8%) and high bond strength (57 MPa) with the substrate of the coating were achieved with the power of 34 kW, which led to a wear rate reduced by 50% compared to other power levels. After exposure to LBE corrosion for 2000 h, an oxide film of 50 nm (outer loose Cr oxide layer and inner dense Al2O3 layer) was formed, which limited LBE penetration depth to less than 2 μm. Combining the high wear resistance and LBE corrosion resistance, this coating provided an effective protective solution for LFR structural materials.