Wear resistance enhancement by Cu nano-platelet in CrCoNiCu medium-entropy alloy films

In response to the persistent challenge of optimizing the tribological performance of engineered coatings without compromising material hardness, this study investigates the potential of medium-entropy CrCoNiCu alloy films. Fabricated via sputtering and subsequently aged at 200 °C for 24 h, these films are examined for their mechanical and tribological behaviors through nanoindentation and reciprocal sliding wear tests. The primary result reveals that the sputtering fabrication yields a single face-centered cubic phase enriched with stacking faults and twins due to a vapor quenching and an increase in defective nuclei formation. The aging treatment uniquely facilitates the formation of Cu-rich phases, featuring repetitive plate-like structures along twin boundaries, by altering diffusion pathways to enhance diffusivity at the applied low temperature. Remarkably, this process not only increases the hardness of the films by 1.5 GPa but also leads to significant improvements in their tribological performance, with reductions in friction coefficients and wear volumes by 12.1% and 90.1%, respectively. The tribological properties originate with the synergistic effects of precipitation hardening and the lubricating layer inducing the reduction of abrasive wear and inhibition of direct contact between sliding surfaces. These findings illuminate that the CrCoNiCu alloy exhibits an exceptional capacity for superior wear resistance at soft metals, offering a compelling strategy to navigate the traditional trade-off between wear rate and hardness in the design of advanced engineering materials.