Microstructure, Hardness, Wear Resistance, and Corrosion Resistance of As-Cast and Laser-Deposited FeCoNiCrAl0.8Cu0.5Si0.5 High Entropy Alloy

FeCoNiCrAl0.8Cu0.5Si0.5 high-entropy alloys were fabricated using vacuum induction melting and laser deposition processes, followed by a comparison of the structural and mechanical properties of two distinct sample types. The as-cast FeCoNiCrAl0.8Cu0.5Si0.5 alloy is comprised of BCC1, BCC2, and Cr3Si phases, while the laser-deposited alloy primarily features BCC1 and BCC2 phases. Microstructural analysis revealed that the as-cast alloy exhibits a dendritic morphology with secondary dendritic arms and densely packed grains, and the laser-deposited alloy displays a dendritic structure without the formation of granular interdendritic regions. For mechanical properties, the as-cast FeCoNiCrAl0.8Cu0.5Si0.5 alloy demonstrated higher hardness than the as-deposited alloy, with values of 586 HV0.2 and 557 HV0.2, respectively. The wear rate for the as-cast alloy was observed at 3.5 × 10−7 mm3/Nm, with abrasive wear being the primary wear mechanism. Conversely, the as-deposited alloy had a wear rate of 9.0 × 10−7 mm3/Nm, characterized by adhesive wear. The cast alloy exhibited an icorr of 4.062 μA·cm−2, with pitting as the form of corrosion. The laser-deposited alloy showed an icorr of 3.621 μA·cm−2, with both pitting and intergranular corrosion observed. The laser-deposited alloy demonstrated improved corrosion resistance. The investigation of their microstructure and mechanical properties demonstrates the application potential of FeCoNiCrAl0.8Cu0.5Si0.5 alloys in scenarios requiring high hardness and enhanced wear resistance.