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Nanoscale voids accelerate corrosion and post-corrosion wear in magnetron sputtered CoCrFeMnNi high entropy alloy films
KTH, School of Engineering Sciences in Chemistry, Biotechnology and Health (CBH), Chemistry, Surface and Corrosion Science. Department of Chemistry, McGill University, 845 Sherbrooke St. W, Montreal, Québec, H3A 0G4, Canada.
Department of Mining and Materials Engineering, McGill University, M.H. Wong Building, University Street, Montreal, QC, H3A 0C5, Canada.
Facility for Electron Microscopy Research, McGill University, 3640 University Street, Montreal, QC, H3A 0C7, Canada.
Department of Mining and Materials Engineering, McGill University, M.H. Wong Building, University Street, Montreal, QC, H3A 0C5, Canada.
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2026 (English)In: Surface & Coatings Technology, ISSN 0257-8972, E-ISSN 1879-3347, Vol. 526, article id 133353Article in journal (Refereed) Published
Abstract [en]

New materials for wear and corrosion protection are being explored in the family of high entropy alloys. However, there is limited work on wear-corrosion synergies of these alloys, particularly for magnetron sputtered thin films, where nanoscale morphology and defects strongly affect the performance and often yield different behaviors than for bulk counterparts. In this work, CoCrFeMnNi is tested as a protective thin film under non-ideal conditions. Wear-corrosion synergies are explored for films with and without low nanometer-scale voids. The influence of corrosion on wear is tested by microtribology on pre-corroded samples, while the influence of voids and wear on corrosion is tested by electrochemical tests of pre-worn and non-worn samples during optical microscopy in 3.5% NaCl solution. 1–10 nm wide intercolumnar voids cause the formation of a millimeter-scale zone of accelerated dissolution inside the film, which propagates between columns. Anodic polarization causes an electrochemically driven delamination of the coatings. Pre-scratching of the films does not alter this corrosion mechanism significantly, except for preferential initiation of delamination at the wear track. After corrosion, the wear rate is increased by up to 320% for voided films and decreased by up to 50% for the dense films. This work provides a more realistic view of the strength and limitation of magnetron sputtered high entropy alloys as protective coatings.

Place, publisher, year, edition, pages
Elsevier BV , 2026. Vol. 526, article id 133353
Keywords [en]
Corrosion, High Entropy Alloy, Magnetron Sputtering, Microtribology, Thin Film, Tribocorrosion, Wear
National Category
Materials Chemistry Surface- and Corrosion Engineering Other Materials Engineering Other Mechanical Engineering
Identifiers
URN: urn:nbn:se:kth:diva-378780DOI: 10.1016/j.surfcoat.2026.133353ISI: 001717927700001Scopus ID: 2-s2.0-105032531792OAI: oai:DiVA.org:kth-378780DiVA, id: diva2:2049502
Note

QC 20260330

Available from: 2026-03-30 Created: 2026-03-30 Last updated: 2026-03-30Bibliographically approved

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Medina, Leon Zendejas

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