Effect of Laser Energy Density on the Properties of CoCrFeMnNi High-Entropy Alloy Coatings on Steel by Laser Cladding

High-entropy alloys (HEAs) have emerged as a novel class of materials with exceptional mechanical and corrosion properties, offering promising applications in various engineering fields. However, optimizing their performance through advanced manufacturing techniques, like laser cladding, remains an area of active research. This study investigated the effects of laser energy density on the mechanical and electrochemical properties of CoCrFeMnNi HEA coatings applied to Q235 substrates. Utilizing X-ray diffraction (XRD), this study confirmed the formation of a single-phase face-centered cubic (FCC) structure in all coatings. The hardness of the coatings peaked at 210 HV with a laser energy density of 50 J/mm2. Friction and wear tests highlighted that a coating applied at 60 J/mm2 exhibited the lowest wear rate, primarily due to adhesive and oxidative wear mechanisms, while the 55 J/mm2 coating showed increased hardness but higher abrasive wear. Electrochemical testing revealed superior corrosion resistance for the 60 J/mm2 coating, with a slow corrosion rate and minimal passivation tendency in contrast to the 55 J/mm2 coating. The comprehensive evaluation indicates that the HEA coating with an energy density of 60 J/mm2 exhibits exceptional wear and corrosion resistance.