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Ultra-high-speed laser cladding (UHSLC) not only offers an efficient solution to the limitations of conventional laser cladding but also aligns with the contemporary objectives of material conservation and efficiency enhancement in metal protective coatings. This study investigates the fabrication of CrFeCoNiMo 0.2 high-entropy alloy (HEA) coatings using UHSLC and traditional laser cladding (TLC) methods. Key aspects such as macroscopic forming quality, element distribution, dilution rate, grain morphology, hardness, and electrochemical corrosion properties of both UHSLC and TLC coatings are thoroughly examined. Notably, UHSLC-produced coatings, with their significantly reduced thickness ranging from 100 to 300 μm, demonstrate an impressively low substrate dilution rate compared to the 2–3 mm thickness of TLC coatings. The rapid solidification inherent in UHSLC leads to smaller grain sizes in the coating, resulting in enhanced hardness. Moreover, the UHSLC coating exhibits superior corrosion resistance, characterized by a lower maintaining-passivity current density in 1 mol/L H 2 SO 4 and a higher self-corrosion potential relative to TLC coatings. This work presents a novel approach, employing high-efficiency and low-cost laser-cladding technology, to minimize dilution in the matrix and improve the coating properties of HEAs. • There are no macroscopic and microscopic defects in HEAs prepared by UHSLC. • Uniform distribution of elements in ultra-thin coating of CrFeCoNiMo 0.2 HEA. • The CrFeCoNiMo 0.2 HEA nanocrystalline coating was synthesized by UHSLC. • Nanocrystalline CrFeCoNiMo 0.2 HEA coating exhibit excellent corrosion resistance. [ABSTRACT FROM AUTHOR]

The AlCoCrFeNi 2.1 eutectic high-entropy alloy (EHEA) has become one of the hottest research topics owing to its comprehensive mechanical properties. In this study, the AlCoCrFeNi 2.1 EHEA was fabricated via the laser powder bed fusion (L-PBF) technique, and the grain morphology, eutectic structure, mechanical properties, and deformation mechanism were investigated. The results indicate that the samples have superfine grains and nano-lamellar eutectic structures, attributable to the high cooling rate of the L-PBF process. Furthermore, the phenomenon of solute trapping was observed in the boundary of the FCC and B2 semi-cohesive phase in the nano-lamellar eutectic structure. Based on the special eutectic structure of the AlCoCrFeNi 2.1 EHEA prepared using the L-PBF technique, the samples exhibited an exceptional tensile strength of up to 1.6 GPa, accompanied by tensile ductility of over 9.5 %. The improvement of mechanical properties may be attributable to the Hall–Petch strengthening and back stress effect caused by refining the eutectic structure, whereas the growth of the nano-lamellar structure may be closely related to the solute-trapping effect. • Nano-lamellar EHEA with K–S type OR was prepared by additive manufacturing. • The L-PBF EHEA exhibited an exceptional tensile strength of up to 1.6 GPa. • The solute trapping phenomenon was observed at the boundary of nano-lamellar. [ABSTRACT FROM AUTHOR]

To further strengthen the AlCoCrFeNi high-entropy alloy (HEA) coating prepared by high-speed laser cladding (HLC), laser remelting (LR) was chosen to reprocess it. The effects of LR on the topography, microstructure, growth orientation, phase distribution, and properties were investigated. It was revealed that there were a large number of liquid phase separation (LPS) zones in the HLC coating because of an ultrafast cooling rate. After LR, the LPS zones were eliminated. Compared to HLC coating, the microhardness increased from 622 HV to 762 HV, and the friction coefficient and the wear weight loss were reduced by 0.1 and 0.5 mg, respectively. In electrochemical testing, the self-corrosion potential increased by 45.9 mV and the self-corrosion current density decreased by one order of magnitude. Meanwhile, EBSD analysis indicated that the LPS zones were prone to recrystallization. The LPS zones were nickel-poor, low hardness, also BCC phase, and had a clearer (101) orientation. With the elimination of the LPS zones, the kernel average misorientation values were reduced, Taylor factor values and high angle grain boundaries were increased, and the average grain size was reduced from 2.43 μm to 2.12 μm. Eventually, for LR coatings, the combination of fine grain strengthening, solid solution strengthening, spalling reduction, and Cr element segregation resulted in better wear and corrosion resistances. The overall results show that a reasonable LR application can induce the microstructure of the HLC coating and improve its service properties. ● The AlCoCrFeNi high-entropy alloy coatings were prepared by high-speed laser cladding (HLC) and reprocessed by laser remelting (LR).● There were a large number of liquid phase separation (LPS) zones in the HLC coating. After LR, the LPS zones were replaced by fine equiaxed crystals.● The LPS zones were nickel-poor and low hardness, had a clearer (101) orientation, and tended to spall off in the wear test, causing a decrease in the overall wear resistance of the coating.● As a result of the elimination of the LPS zones, the microhardness and wear resistance of the LR coating were improved by solid solution strengthening and fine grain strengthening.● Appropriate undercooling and more high angle grain boundaries caused by LR provided a larger driving force for grain boundary segregation. The elemental content of Cr at the grain boundaries became higher, and the corrosion resistance of the LR coatings increased significantly. [Display omitted] • HLC led to a large number of the LPS zones in the AlCoCrFeNi HEA coating. • LR could successfully eliminate the LPS zones. • Recrystallization made the grains of the LPS zones coarse and soft. • The microhardness and wear resistance of the coating were improved by LR. • Higher Cr content at grain boundaries boosted corrosion resistance of LR coating. [ABSTRACT FROM AUTHOR]