Study on Microstructures and Properties of FeCoNiCuAlSix High-Entropy Alloy Composite Coatings by Laser Cladding

FeCoNiCuAl high-entropy alloys exhibit remarkable mechanical properties; nevertheless, these materials struggle to withstand harsh environments because of their insufficient resistance to wear and corrosion. The addition of Si can significantly enhance the alloy’s high-temperature performance, hardness, and wear resistance, thereby making it more suitable for applications in high-temperature or corrosive environments. To overcome these drawbacks, this research investigates how varying Si content affects the microstructure and properties of FeCoNiCuAl coatings. Composite coatings of FeCoNiCuAlSix (x = 0, 0.5, 1.0, 1.5, 2.0) were fabricated on 65 Mn substrates using laser cladding. Various testing methods, including metallographic microscopy, Vickers hardness testing, friction and wear testing, and electrochemical analysis, were employed to examine the phase structure, microstructure, and hardness of the coating. It is observed that the FeCoNiCuAl coating begins with a uniform FCC phase structure. However, as the Si content increases, a phase transformation to the BCC structure occurs. The microstructure is primarily composed of isometric crystals and dendrites that become finer and more compact with higher Si content. For the FeCoNiCuAlSi2.0 coating, the microhardness reaches 581.05 HV0.2. Additionally, wear resistance shows a positive correlation with Si content. Electrochemical testing in NS4 solution shows that the corrosion potential of the coating increases from −0.471 V for FeCoNiCuAl to −0.344 V for FeCoNiCuAlSi2.0, while the corrosion current density decreases from 1.566 × 10−6 A/cm2 to 4.073 × 10−6 A/cm2. These results indicate that Si addition plays a crucial role in enhancing the mechanical properties and corrosion resistance of FeCoNiCuAl coatings, making them more suitable for high-performance applications in extreme environments.