Microstructural Refinement, Tribological and Hardness Enhancement of AISI 304L Stainless Steel Substrate via TIG Arc‐Assisted In Situ Development of AlCrCoFeNi High‐Entropy Alloy Coating

This study investigates the development of an AlCrCoFeNi high‐entropy alloy (HEA) coating on an AISI 304L stainless steel substrate using the most economical process tungsten inert gas (TIG) arcing. X‐ray diffraction analysis reveals the formation of single‐phase solid solutions with both face‐centered‐cubic and body‐centered‐cubic structures in the HEA coating. Scanning electron microscopy with energy‐dispersive spectroscopy confirms uniform elemental distribution throughout the coating. MATLAB coding and finite element analysis are also done to validate the experimental data. The HEA‐coated samples exhibit a hardness of 750 HV 0.2 and a reduced coefficient of friction ranging from 0.6 to 0.8 indicating superior tribological performance. In comparison with uncoated and TIG‐treated samples without AlCrCoFeNi HEA layer, the coated specimen demonstrates significantly enhanced hardness and improved wear resistance with refined microstructure. These results highlight the potential of HEA coatings for industrial applications demanding high wear resistance and long‐term durability.