Study on the Microstructure and Properties of CoCrFeNiMo High-Entropy Alloy Coatings Prepared by Atmospheric Plasma Spraying

This study employed atmospheric plasma spraying (APS) technology to successfully fabricate CoCrFeNiMo high-entropy alloy (HEA) coatings under varying spraying currents and systematically investigated the effects of the spraying current on the microstructure, mechanical properties, and tribological behavior of the coatings. Results showed that the material composition remained consistent across different current levels, primarily consisting of face-centered cubic (FCC) solid solution phases, FeCr₂O₄ spinel phases, and Cr-rich FCC1 phases. The FCC matrix was dispersed with spherical Cr oxide particles smaller than 30 nm in diameter, which significantly enhanced the strength of the coatings. As spraying current increased, both porosity and microhardness exhibited a non-monotonic trend—initial optimization followed by deterioration. At 500 A spraying current, the coating achieved optimal performance, with the lowest porosity (0.42%) and highest microhardness (569.8 HV). Correspondingly, this condition also yielded the best wear resistance, with stable friction coefficients and wear rates reaching 0.49 and 6.91 × 10⁻⁵ mm³/N m, respectively. Abrasion surface analysis revealed that excessively low or high currents triggered distinct wear mechanisms leading to reduced wear resistance.