Solidification and tribological behaviors of CoCrFeNiSi0.5-(Al,Ti) non-equiatomic high entropy alloy coatings fabricated by direct laser deposition

In order to evaluate the difference in the effects of Al and Ti elements on the microstructure and tribological behaviors of CoCrFeNi-based high entropy alloy (HEA) coatings, CoCrFeNiSi0.5-(Al,Ti) non-equiatomic HEAs coatings were prepared using direct laser deposition (DLD). The phase constitution, solidification microstructure and tribological behaviors of the HEA coatings were investigated. The results indicated that CoCrFeNiSi0.5 HEA coating was composed of face centered cubic (FCC) phase with microstructure of columnar and cellular grains. The addition of Al and Ti led to a columnar-to-equiaxed transition (CET) in the HEA coatings. When only Al was added (CoCrFeNiSi0.5Al0.5), the primary phase transformed into a body centered cubic (BCC) phase (94 vol%). Additionally, Cr3Si formed in the interdendrite (ID) region, and a spinodal decomposition structure emerged in the dendrite (DR) region. Conversely, with the inclusion of Ti alone (CoCrFeNiSi0.5Ti0.5), the matrix maintained its FCC phase, but Ni16Ti6Si7 (G phase, 20.9 vol%) and Cr15Co9Si6 (15.1 vol%) were generated in the ID and DR regions, respectively. Incorporating both Al and Ti (CoCrFeNiSi0.5Al0.5Ti0.5) significantly reduced the G phase content in the ID region to 7.9 vol% and led to the formation of dispersed Fe3Al nanoparticles with an average size of 99 nm in the DR region. The CoCrFeNiSi0.5 HEA coating exhibited the lowest hardness (249 HV0.1), the highest friction coefficient (0.778), and the poorest wear resistance. For the HEA coatings containing Al and Ti, the microhardness significantly increased to over 700 HV0.1, and the friction coefficient decreased to around 0.6. However, the wear resistance of the CoCrFeNiSi0.5Al0.5 HEA coating was almost equivalent to that of the CoCrFeNiSi0.5 with a wear loss of 5.1 mg. By contrast, the HEA coatings containing Ti demonstrated notably improved wear resistance, with wear losses of only 2.2 mg and 2.4 mg for the CoCrFeNiSi0.5Ti0.5 and CoCrFeNiSi0.5Al0.5Ti0.5 HEA coatings, respectively.