Investigations on the metallurgical profile of hard-faced mild steel with high entropy alloy AlCrMnFeNi through weld overlaying process

High-entropy alloys (HEAs) exhibit superior high-temperature mechanical, corrosion, and tribological characteristics compared to conventional alloy systems. However, their limited formability and brittleness restrict the applicability of HEAs in many engineering applications. The weld overlaying process was used to investigate the microstructural evolution and mechanical properties of mild steel (MS) hard-faced using the AlCrMnFeNi HEA. The properties of the deposited HEA and conjoined interface were characterized using instrumental analysis. The results indicated good metallurgical bonding (absence of microsegregation, pores, and cracks) between the MS substrate and the HEA. The hardness of the HEA coating was in line with existing research. Hence, this developed composite structure is a candidate material for applications demanding erosion and wear resistance, such as earthmoving components.