Microstructure and Properties of CoCrFeNi(WC) High-Entropy Alloy Coatings Prepared Using Mechanical Alloying and Hot Pressing Sintering

The CoCrFeNi high-entropy alloy coatings (HEACs) with different weight ratios (10 and 30 wt.%) of WC additions have been prepared using mechanical alloying and a vacuum hot pressing sintering technique on a Q235 steel substrate. The microstructures, microhardness, wear resistance, and corrosion resistance of HEACs were studied. The CoCrFeNi(WC) powders were obtained by mixing the CoCrFeNi HEA powders and WC particles. The sintered products of both HEACs with high relative density contained one solid solution phase with face-centered cubic structure, WC, and unknown precipitate phases. The transition boundary had a good metallurgical bonding with the coating and substrate. The average microhardness values of CoCrFeNi HEACs with 10 and 30 wt.% WC additions reached 475 and 531 HV respectively, which were far higher than that of the substrate (160 HV). Moreover, both coatings exhibited better wear resistance than the substrate under the same wear conditions. The 30 wt.% WC HEAC displayed the lower friction coefficient, and the shallower wear groove depth. The grain refinement strengthening and second-phase particle strengthening could be beneficial to the enhanced hardness and wear resistance of coatings with WC additions. The corrosion behavior of the tested samples in the 3.5 wt.% NaCl solution were investigated using electrochemical polarization measurements. The CoCrFeNi(WC) coatings all revealed the improved corrosion resistance. Especially, a 10 wt.% WC addition remarkably enhanced the comprehensive corrosion resistance and easy passivation of CoCrFeNi HEAC.