Determination of microstructural parameters in AlCrFeCoNi high-entropy alloy coatings by Williamson-Hall analysis

• Mechanically alloyed powders exhibit FCC + BCC (A2/B2) dual-phase structure • APS processing stabilizes a predominantly FCC (A1) phase in AlCrFeCoNi HEA coatings • Williamson–Hall analysis was applied to the dominant FCC phase to extract crystallite size, micro-strain, and dislocation density AlCrFeCoNi high-entropy alloy (HEA) coatings were deposited on 316L stainless steel by atmospheric plasma spraying (APS) technique. The high energy ball-milling method with different milling duration was used to prepare the AlCrFeCoNi powder feedstock. FESEM and XRD analyses revealed a dual-phase structure in the mechanically alloyed powders, consisting of FCC and BCC (A2/B2) phases. After atmospheric plasma spraying,…