The development of thick cold sprayed deposits of hard amorphous/nanocrystalline Aluminum High Entropy Alloys (Al HEA) is limited by their poor plastic deformability. To address this, Al HEA powder (Al90.05Ni4.3Y4.4Co0.9Sc0.35 (at. %)) is blended with soft Al 6061 in a 1:1 wt% ratio and cold sprayed. The microstructure of the composite deposits reveals that while Al HEA splats undergo limited deformation, Al 6061 splats deform extensively. Extreme deformation of Al 6061 captures the hard Al HEA particles, resulting in a composite deposit of 5 mm thickness, compared to 0.2 mm for pure Al HEA. Within the composite, Al HEA particles deform through shear band propagation and viscous flow, whereas Al 6061 splats deform via dislocation slip motion. These deformation mechanisms induce interface nanocrystallization, leading to a 123 % increase in lattice strain, a 67 % reduction in crystallite size, and an 800 % increase in dislocation density compared to the initial feedstock. This microstructural evolution, combined with the presence of hard Al HEA regions, results in a mean hardness of 2.56 GPa and an elastic modulus of 76 GPa. These values represent a 47 % and 6 % improvement over conventional polycrystalline cold-sprayed aluminum deposits. Thus, this study provides insights into the microstructural and interface evolution and its effect on indentation characteristics for making high-strength Al HEA deposits.
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