Microstructure and properties of CoCrFeNiAlxMo2-x high-entropy alloy coating by laser cladding

CoCrFeNiAlxMo2-x (x = 0, 0.5, 1, 1.5, and 2) high-entropy alloy coatings were applied to Q235 steel, and this study investigated the effect of x variations on microstructure evolution and properties. It was fount that as x increased, the crystal structure of the coatings transitioned from a face-centred cubic (FCC) + body-centred cubic (BCC) + σ + B2 phase to a BCC + σ + B2 phase, and eventually it become a BCC phase. Concurrently, the microhardness, wear resistance, corrosion resistance, and high-temperature oxidation resistance of the coatings initially increased and then decreased with the rise in x. The optimal values were achieved at x = 1. The enhancement in microhardness and wear resistance of high-entropy alloy (HEA) coatings was attributed to the change of phase type, dispersion strengthening and solid solution strengthening. Adding of the Al element generated a passivation film on the coatings' surface, which mitigated galvanic corrosion. Furthermore, an appropriate amount of Mo increased the thickness and density of the passivation film, thereby improving its corrosion resistance. During early-stage high-temperature oxidation, the Al underwent element undergoes rapid oxidation, while Mo promoted the formation of Al2O3, leading to an excellent high-temperature oxidation resistance. Additionally, mathematical model equations were used to fit the results, adding insights into the effects of Al and Mo content changes (x value) on the wear resistance, corrosion resistance, and high-temperature oxidation resistance of the coatings.