A new generation of wear-resistant coatings consisting of high-entropy alloy matrix and complex carbides for the energy industry

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This project is proposed to the NSERC - Mitacs Accelerate program for developing a new class of superior wear-resistant materials for protective surface layers, e.g., hardfacing overlays and coatings, in the form of composite which consists of a high-entropy alloy (HEA) matrix and complex carbides. The new overlays and coatings will be used to resist severe wear encountered in different sectors of Canada's energy industry, including oil sands, hydrogen fuel, hydroelectricity, wind energy, and coal mining. Wear can cause malfunction or failure of operation facilities, leading to high operation costs, short service life of facilities, and safety issues. The currently used overlays and coatings, e.g., WC/Ni alloy and WC/Co, have played an important role in protecting industrial facilities from wear attacks. However, these overlays and coatings have shortcomings, e.g., low wear resistance of the matrix materials, which are also prone to corrosion and thus less durable against wear in corrosive environments. This project is oriented to the development of a new generation of protective overlays/coatings, which consist of a high-entropy alloy (HEA) - matrix and complex carbides to resist severe wear in harsh operation conditions and aggressive environments, encountered in various sectors of energy production. The main outcomes will include prototype materials for commercial applications, guidelines for overlay/coating design, databases and standard for applications and further development. Minimizing wear of operation facilities, e.g., oil sands mining, will not only increase the competitiveness of Canadian oil industry in the global fuel market, but also promote clean energy production such as increased hydrogen production with lowered cost [extract hydrogen from oil sands (bitumen)], increased electricity production through the combustion of cheaper fossil fuels to power steam turbines, and improved efficiency of wind power production as well. This helps increase the clean energy utilization with reduced direct use of fossil fuels, helping minimize greenhouse gas emissions. The success of this project would have impact on the Canada energy industry and bring in significant benefits to Canadians in various aspects.