Effects of Mo content on the microstructure and mechanical properties of laser cladded FeCoCrNiMox (x = 0.2, 0.5) high-entropy alloy coatings

The laser cladding additive manufacturing technology and high-entropy alloys can serve as ideal techniques and materials for the surface repair of high-speed train axles. Coatings of FeCoCrNiMox (x = 0.2, 0.5) were prepared on EA4T axle steel using laser cladding technology, and their phase, structure, and mechanical properties were analyzed using X-ray diffraction (XRD), electron backscatter diffraction (EBSD) and electron channeling contrast imaging (ECCI) characterization techniques. Additionally, the mechanical properties of the coatings were tested, and first-principles calculations were used to verify and calculate the material's mechanical performance. The research findings indicate that an increase in Mo content leads to a greater degree of lattice distortion, causing a leftward shift in diffraction peak positions. Significant differences in the microstructure from the substrate to the coating surface were observed, with columnar grain structure at the bottom of the cladding layer and equiaxed dendrites dominating the coating surface. The increase in Mo content promotes the formation of σ phase while also refining the grain size. ECCI results show that both types of coatings consist of a high-density dislocation cell structure and Mo-rich particles. With an increase in Mo content, the peak hardness of the coating increased from 456.5 HV to 469.4 HV, while the impact energy decreased from 56 J to 16 J, attributed to the increase in dislocation density and the greater quantity of σ phase. First principles calculations verified that the comprehensive mechanical properties of FeCoCrNiMo0.2 are superior, providing theoretical guidance for the optimization and design of the coatings.