New High-Entropy Alloy Coating Revolutionizes Aero-Engine Fuel Pump Wear and Erosion Resistance

Researchers have developed a breakthrough Al10Cr28Co28Ni34/Ag composite coating that significantly enhances the durability of aero-engine fuel pump components. By leveraging the FCC/FCC structural compatibility between the high-entropy alloy matrix and silver lubricant, this innovative material addresses the critical challenges of low-viscosity aviation kerosene environments. The coating effectively mitigates the combined risks of lubrication failure, mechanical wear, and cavitation erosion that typically plague high-speed fuel delivery systems.

The study, published in Tribology Advances, demonstrates that the shared face-centered cubic structure allows the material to respond uniformly to external forces. This synergy promotes energy absorption during plastic deformation and facilitates the in-situ formation of spherical particles that provide a rolling-sliding mechanism at the friction interface. Consequently, the coating achieves a friction coefficient below 0.1 and near-zero wear rates, marking a major leap in surface engineering for aerospace applications.

This advancement offers a robust solution for protecting thrust bearings, which are essential for maintaining engine reliability and flight safety. By overcoming the limitations of traditional resin-based coatings, such as poor heat resistance and structural mismatch, this high-entropy alloy composite provides a long-term, high-performance solution for demanding engine environments. These findings pave the way for more resilient propulsion technologies, effectively extending component lifespans under extreme operating conditions.