Micro-structures and dry sliding wear properties of novel AlCrFeNiMo0.5-x(WC) high entropy alloy-ceramic composite coatings

Based on the problems of micro defects (cracks, pores, etc.), uneven distribution of strengthening particles, and poor bonding between strengthening particles and metal matrix in practical engineering applications, the new AlCrFeNiMo_0.5-x(WC) (x = 0, 5, 15, 30 wt%) composite coatings have been designed, and further prepared using laser cladding. Their micro-structures, micro-hardness and dry sliding wear properties were deeply explored. They exhibited the dendritic morphologies and consisted of BCC1, BCC2, and carbide phases. The AlCrFeNiMo_0.5-30 wt%(WC) coating had the highest hardness (772 HV), which was approximately 5 times that of Q235 steel substrate. With the increase of WC content, dry sliding wear properties showed an increasing trend, that is, AlCrFeNiMo_0.5-30 wt%(WC) coating had the lowest friction coefficient (0.50) and wear rate (9.23 × 10⁻⁶ mm³/(N · m)), exhibiting excellent tribological properties, which was attributed to the coupling effect of hard carbide and ductile BCC phases. It would be a promising wear-resistant coating material under dry sliding environment. This study not only has significant theoretical significance for understanding the failure patterns and performance evolution of new high entropy alloy/WC composite coating materials in dry sliding environments, but also demonstrates important value for expanding the application of new high entropy alloy/WC composite coating materials in practical engineering.