Sliding Wear Behavior and Surface Integrity of Optimized Tungsten Inert Gas Welded AlCrCuNiFe High Entropy Alloy Claddings for Engineering Application Under Abrasive Conditions

Abstract In this study, equiatomic Al20Cr20Cu20Ni20Fe20 high entropy alloy (HEA) cladding was deposited on AISI 1045 steel using optimized tungsten inert gas (TIG) weld cladding parameters. The cladding was characterized through scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD), and Vickers microhardness tests to analyze its microstructure, elemental distribution, phase formation, and hardness. Tribological performance was evaluated via pin-on-disc abrasive wear tests using Taguchi's L9 design, with #220 grit SiC as the counterface at room temperature. The HEA cladding exhibited a dense structure with equiaxed and columnar dendritic grains, resulting from the adequate heat input. The microhardness values along the depth and width were 703.3 ± 2.45 HV₀.₃ and 728.1 ± 2.69 HV₀.₃, respectively, compared to 443 ± 4.2 HV₀.₃ for the substrate. Wear regime maps and input friction energy were analyzed to understand wear behavior. Under optimal wear conditions, the cladding showed 76.61% less wear volume and 13.24% lower coefficient of friction (CoF) than the maximum wear case. Worn surface analysis using SEM and 3D profilometry revealed nominal adhesive and abrasive wear under optimal conditions, whereas maximum wear samples showed severe abrasive and delamination wear. The results confirm the superior wear resistance and structural integrity of the TIG-cladded HEA layer.