Effect of high Fe content on the microstructure, mechanical and corrosion properties of AlCoCrFeNi high-entropy alloy coatings prepared by gas tungsten arc cladding

Arc cladding high-entropy alloy (HEA) coatings have the advantages of low cost and flexibility. It exhibits economic value to increase the proportion of Fe element in HEA systems. As a result, low-cost AlCoCrFeNi (Fe content of 42.5 at.%, 44.9 at.%, 47.5 at.%, 50.4 at.%) HEA coatings are prepared by gas tungsten arc (GTA) cladding and their microstructure, mechanical properties, and corrosion properties are investigated by XRD, SEM, EBSD, microhardness, nanoindentation, OCP, potentiodynamic polarization, and EIS. The valence electron concentration (VEC) plays an important role in the formation of phase structure. With the increase of Fe content, the phase structure of coating alloys changes from BCC to BCC + FCC, and the morphology changes from equiaxed grains to a dendritic structure. Coating alloy with higher Fe content displays lower microhardness and more active creep deformation due to the higher FCC fraction. The dual-phase (BCC + FCC) structure induces galvanic corrosion and deteriorates the corrosion properties. This work contributes to the fabrication of large-thickness and large-area HEA coatings at a low cost and provides an experimental basis for Fe-rich HEA design. [Display omitted] •AlCoCrFeNi HEA coatings of high Fe content (42.5 at.% ~ 50.4 at.%) are prepared by gas tungsten arc cladding.•As Fe content increases, phases change from BCC to BCC + FCC, morphology changes from granular to dendritic.•As Fe content increase, hardness decrease and corrosion resistance deteriorate.