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Chinese Journal of Lasers, Volume. 52, Issue 4, 0402203(2025)

Microstructure Evolution and Corrosion Resistance of FeCoCrNiMo High‐Entropy Alloy Coatings Fabricated via Extremely High‐Speed Laser Cladding

Hao Xiao1,3, Jian Huang1,4, Peng Wang2、*, Peixin Xu2, Yifei Xu2, Dongyue Zhang2, and Borui Du2
Author Affiliations
  • 1CCCC Second Harbor Engineering Company Co., Ltd., Wuhan 430040, Hubei , China
  • 2China Machinery Institute of Advanced Materials (Zhengzhou) Co., Ltd., Zhengzhou 450001, Henan , China
  • 3CCCC Highway Bridge National Engineering Research Centre Co., Ltd., Beijing 100032, China
  • 4Key Laboratory of Large-Span Bridge Construction Technology, Wuhan 430040, Hubei , China
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    Figures & Tables(17)
    Extremely high-speed laser cladding equipment and powder raw material. (a) Extremely high-speed laser cladding equipment; (b) FeCoCrNiMo high-entropy alloy powder morphology and particle diameter distribution; (c) surface defect result of polished 316L primer; (d) surface defect result of polished 304 coating

    Fig. 1. Extremely high-speed laser cladding equipment and powder raw material. (a) Extremely high-speed laser cladding equipment; (b) FeCoCrNiMo high-entropy alloy powder morphology and particle diameter distribution; (c) surface defect result of polished 316L primer; (d) surface defect result of polished 304 coating

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    XRD spectra of FeCoCrNiMo powder and coating

    Fig. 2. XRD spectra of FeCoCrNiMo powder and coating

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    Microstructes of FeCoCrNiMo high-entropy alloy coating captured by scanning transmission electron microscopy. (a) STEM images of the bright field of the coatings and the corresponding STEM-EDS maps; (b) selected-area diffraction pattern of superlattice points of the BCC precipitated phase; (c) selected-area diffraction pattern of superlattice points of the FCC matrix phase

    Fig. 3. Microstructes of FeCoCrNiMo high-entropy alloy coating captured by scanning transmission electron microscopy. (a) STEM images of the bright field of the coatings and the corresponding STEM-EDS maps; (b) selected-area diffraction pattern of superlattice points of the BCC precipitated phase; (c) selected-area diffraction pattern of superlattice points of the FCC matrix phase

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    SEM microstructure distribution of FeCoCrNiMo high-entropy alloy coatings. (a) Whole coating; (b) the top region of the coating; (c) the middle region of the coating; (d) the overlap position

    Fig. 4. SEM microstructure distribution of FeCoCrNiMo high-entropy alloy coatings. (a) Whole coating; (b) the top region of the coating; (c) the middle region of the coating; (d) the overlap position

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    Detection results and optical microscopy morphology of FeCoCrNiMo high-entropy alloy coating. (a)(b) Detection results of the cracked coatings without using 316L stainless steel as a primer, where the figure (a) corresponds to the cladding parameters of P=1.5 kW and u=15 m/min and the figure (b) corresponds to the cladding parameters of P=1.5 kW and u=5 m/min; (c) detection result of the uncracked coating using 316L stainless steel as a primer, corresponding to the cladding parameters of P=1.5 kW and u=5 m/min; (d)(e) optical microscopy morphology of the cracked coatings without using 316L stainless steel as a primer, where the figure (d) corresponds to the cladding parameters of P=1.5 kW and u=15 m/min and the figure (b) corresponds to the cladding parameters of P=1.5 kW and u=5 m/min; (f) optical microscopy morphology of the uncracked coating using 316L stainless steel as a primer, corresponding to the cladding parameters of P=1.5 kW and u=5 m/min

    Fig. 5. Detection results and optical microscopy morphology of FeCoCrNiMo high-entropy alloy coating. (a)(b) Detection results of the cracked coatings without using 316L stainless steel as a primer, where the figure (a) corresponds to the cladding parameters of P=1.5 kW and u=15 m/min and the figure (b) corresponds to the cladding parameters of P=1.5 kW and u=5 m/min; (c) detection result of the uncracked coating using 316L stainless steel as a primer, corresponding to the cladding parameters of P=1.5 kW and u=5 m/min; (d)(e) optical microscopy morphology of the cracked coatings without using 316L stainless steel as a primer, where the figure (d) corresponds to the cladding parameters of P=1.5 kW and u=15 m/min and the figure (b) corresponds to the cladding parameters of P=1.5 kW and u=5 m/min; (f) optical microscopy morphology of the uncracked coating using 316L stainless steel as a primer, corresponding to the cladding parameters of P=1.5 kW and u=5 m/min

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    Cross-sectional microstructure distributions of FeCoCrNiMo high-entropy alloy cracked coatings produced under different laser cladding linear velocities (No 316L stainless steel was used as a primer). (a) (c) Cross-sectional and local morphology of reticulated cracks in high-entropy alloy coating produced at a linear velocity of 15 m/min; (b) (d) cross-sectional and local morphology of stripe cracks in high-entropy alloy coating produced at a linear velocity of 5 m/min

    Fig. 6. Cross-sectional microstructure distributions of FeCoCrNiMo high-entropy alloy cracked coatings produced under different laser cladding linear velocities (No 316L stainless steel was used as a primer). (a) (c) Cross-sectional and local morphology of reticulated cracks in high-entropy alloy coating produced at a linear velocity of 15 m/min; (b) (d) cross-sectional and local morphology of stripe cracks in high-entropy alloy coating produced at a linear velocity of 5 m/min

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    Microstructure distributions of FeCoCrNiMo high-entropy alloy coating fabricated by EHLC on 316L primer layer (P=1.5 kW, u=5 m/min). (a) Whole coating; (b) the top region of the coating; (c) the middle region of the coating

    Fig. 7. Microstructure distributions of FeCoCrNiMo high-entropy alloy coating fabricated by EHLC on 316L primer layer (P=1.5 kW, u=5 m/min). (a) Whole coating; (b) the top region of the coating; (c) the middle region of the coating

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    Vickers hardness distribution of FeCoCrNiMo high-entropy alloy coatings produced by different linear velocities

    Fig. 8. Vickers hardness distribution of FeCoCrNiMo high-entropy alloy coatings produced by different linear velocities

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    FCC phase percentage and microstructure distribution in local regions of FeCoCrNiMo high-entropy alloy coatings fabricated at different linear velocities. (a) FCC phase percentage; (b)(d) local microstructure distribution and local surface scanning results of the coating fabricated at linear velocityof 15 m/min; (c)(e) local microstructure distribution and local surface scanning results of the coating fabricated at linear velocity of 5 m/min

    Fig. 9. FCC phase percentage and microstructure distribution in local regions of FeCoCrNiMo high-entropy alloy coatings fabricated at different linear velocities. (a) FCC phase percentage; (b)(d) local microstructure distribution and local surface scanning results of the coating fabricated at linear velocityof 15 m/min; (c)(e) local microstructure distribution and local surface scanning results of the coating fabricated at linear velocity of 5 m/min

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    Potentiodynamic polarisation curves and AC impedance diagram of FeCoCrNiMo high-entropy alloy and 304 stainless steel coatings. (a) Potentiodynamic polarisation curves; (b) AC impedance diagram

    Fig. 10. Potentiodynamic polarisation curves and AC impedance diagram of FeCoCrNiMo high-entropy alloy and 304 stainless steel coatings. (a) Potentiodynamic polarisation curves; (b) AC impedance diagram

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    Local corrosion morphology of FeCoCrNiMo high-entropy alloy coatings following neutral salt spray experiments of different durations

    Fig. 11. Local corrosion morphology of FeCoCrNiMo high-entropy alloy coatings following neutral salt spray experiments of different durations

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    • Table 1. Chemical composition of FeCoCrNiMo high-entropy alloy powder

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      Table 1. Chemical composition of FeCoCrNiMo high-entropy alloy powder

      ElementMass fraction /%
      Fe17.38
      Co18.34
      Cr16.16
      Ni18.26
      Mo29.85

    • Table 2. Cladding process parameters of 316L stainless steel primer and 304 stainless steel coating

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      Table 2. Cladding process parameters of 316L stainless steel primer and 304 stainless steel coating

      Coating type

      Laser power /

      kW

      		Gas flow for transporting powder /（L/min）

      Powder flow /

      （kg/min）

      Linear velocity /

      （m/min-1）

      Feed rate /

      （mm/r）

      316L primer1.8660100.3
      304 coating2.1660100.3

    • Table 3. Extremely high-speed laser cladding (EHLC) process parameters for FeCoCrNiMo cracked coatings without using 316L stainless steel as a primer

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      Table 3. Extremely high-speed laser cladding (EHLC) process parameters for FeCoCrNiMo cracked coatings without using 316L stainless steel as a primer

      No.Gas flow for transporting powder /（L/min）Powder flow /（kg/min）Linear velocity /（m/min）Feed rate /（mm/r）
      1660150.3
      2660150.3
      3660150.3
      4660100.3
      5660200.3
      666050.3

    • Table 4. EHLC process parameters for FeCoCrNiMo uncracked coating using 316L stainless steel as a primer

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      Table 4. EHLC process parameters for FeCoCrNiMo uncracked coating using 316L stainless steel as a primer

      ParameterValue
      Laser power /kW1.5
      Gas flow for transporting powder /（L/min）6
      Powder flow /（kg/min）60
      Linear velocity /（m/min）5
      Feed rate /（mm/r）0.3

    • Table 5. Fitting parameters for polarisation curves

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      Table 5. Fitting parameters for polarisation curves

      CoatingEcorr /VIcorr /（A/cm2）
      FeCrCoNiMo-0.3183.72×10-8
      304 stainless steel-0.4486.966×10-6

    • Table 6. Electrochemical impedance spectrum fitting results

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      Table 6. Electrochemical impedance spectrum fitting results

      CoatingR1 /（Ω·cm2）R2 /（Ω·cm2）
      FeCrCoNiMo8.38763740
      304 stainless steel5.2713252
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    Hao Xiao, Jian Huang, Peng Wang, Peixin Xu, Yifei Xu, Dongyue Zhang, Borui Du. Microstructure Evolution and Corrosion Resistance of FeCoCrNiMo High‐Entropy Alloy Coatings Fabricated via Extremely High‐Speed Laser Cladding[J]. Chinese Journal of Lasers, 2025, 52(4): 0402203

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    Paper Information

    Category: Laser Surface Machining

    Received: May. 16, 2024

    Accepted: Aug. 22, 2024

    Published Online: Jan. 17, 2025

    The Author Email: Wang Peng (wp919882185@163.com)

    DOI:10.3788/CJL240886

    CSTR:32183.14.CJL240886

    Topics

    laser devices and laser physics
    Lasers and Laser Optics
    Laser physics
    laser manufacturing
    Instrumentation, Measurement and Metrology