CoCrFeMnNi0.8V/Cr3C2-Ni20Cr High-Entropy Alloy Composite Thermal Spray Coating: Comparison with Monolithic CoCrFeMnNi0.8V and Cr3C2-Ni20Cr Coatings

High-entropy alloys (HEAs) are revolutionizing the field of surface engineering, challenging traditional alloy frameworks with their superior mechanical attributes and resistance to corrosion. This investigation delves into the properties of the CoCrFeMnNi0.8V HEAs, both as a standalone material and when blended with Cr3C2-Ni20Cr, to evaluate their efficacy as cutting-edge surface treatments. The addition of vanadium to the CoCrFeMnNi0.8V alloy results in a distinctive microstructure that improves hardness and resistance to abrasion. The incorporation of Cr3C2-Ni20Cr particles enhances the alloy’s toughness and longevity. Employing high-velocity oxy-fuel (HVOF) thermal spray methods, these coatings are deposited onto steel substrates and undergo detailed evaluations of their microstructural characteristics, abrasion, and corrosion resistance. Findings reveal the CoCrFeMnNi0.8V coating’s exceptional ability to withstand corrosion, especially in environments rich in chlorides. The hybrid coating benefits from the combination of the HEA’s inherent corrosion resistance and the enhanced wear and corrosion resistance provided by Cr3C2-Ni20Cr, delivering comprehensive performance for high-stress applications. Through the fine-tuning of the application process, the Cr3C2-Ni20Cr reinforced high-entropy alloy coating emerges as a significant advancement in protective surface technology, particularly for use in marine and corrosive settings. This study not only highlights the adaptability of HEAs in surface engineering but also prompts further investigation into innovative material pairings.