Effect of Mn content on corrosion and mechanical behaviors of Fe-based medium entropy alloy

Balancing mechanical and corrosion performance is a decisive factor in the use of high entropy and medium entropy alloys (H & MEAs) as advanced engineering structural materials. This study investigates the microstructure of Fe77.3-xMnxSi9.1Cr9.8C3.8 (x = 14, 23.2) HEAs by combining experiments and first-principles calculations to elucidate the effects of adjusting Mn content on the mechanical and corrosion properties of FCC and FCC + HCP phases. The results demonstrate that HEAs with low Mn content exhibit a single FCC phase, whereas increasing Mn content not only precipitates the HCP phase but also refines the grain size. The yield strength, compressive fracture strength, work hardening index, and plasticity of Fe77.3-xMnxSi9.1Cr9.8C3.8 (x = 14, 23.2 at.%) HEAs are 1300 and 1526 MPa, 2380 and 2332 MPa, 0.42 and 0.36, 16.7% and 16%, respectively. Both HEAs exhibit superior electrochemical and salt spray corrosion performance compared to 304 stainless steels, with the Fe63.3Mn14Si9.1Cr9.8C3.8 alloy performing the best, exhibiting a self-corrosion potential of −0.523V and a self-corrosion current density of 2.605 × 10−6 A cm−2. The excellent corrosion resistance of Fe63.3Mn14Si9.1Cr9.8C3.8 can be attributed to the moderate grain size, resulting in excellent passivation film characteristics, and the lower Mn content, leading to a higher Cr2O3 content in the passivation film. First-principles calculations reveal that Fe63.3Mn14Si9.1Cr9.8C3.8 has a lower density of states number at the Fermi level (i.e., Fe63.3Mn14Si9.1Cr9.8C3.8 is 214.145eV, Fe54.1Mn23.2Si9.1Cr9.8C3.8 is 337.077eV), a wider pseudogap width, higher work function (5.700ev, 5.189ev), and better stability. Additionally, there exists a strong trade-off between corrosion and mechanical properties due to the influence of the HCP phase and grain size.