Tribological Properties of Plasma Sprayed FeCoNiCrAl High Entropy Alloy Coating

FeCoNiCrAl high entropy alloy coating was fabricated on the surface of ZL109 aluminum alloy substrate by plasma spraying under different spraying powers (40, 50, 60 kW). The microstructure, phase composition, hardness and tribological properties of the coating were studied. The results show that with the increase of spraying power, the spread-like morphology on the surface of the FeCoNiCrAl high entropy alloy coating increased, the number of holes decreased, the surface became smoother and the porosity decreased. The coatings prepared under different spraying power were mainly composed of BCC phase. With the increase of spraying power, the microhardness of the coating increased. When the spraying power was 60 kW, the friction coefficient of the coating was the smallest, and the wear resistance was the best. At the load of 20 N, the main wear mechanism of the coating was abrasive wear along with a small amount of fatigue wear. At the load of 40 N, the main wear mechanism was fatigue wear.