As-cast Microstructure Research Articles

Inhomogeneous Skin Formation and Its Effect on the Tensile Behavior of a High Pressure Die Cast Recycled Secondary AlSi10MnMg(Fe) Alloy

AbstractThe current study investigated the microstructure evolution, mechanical properties, and fracture behavior of a high pressure die cast (HPDC) novel secondary alloy. The as-cast microstructure comprised (i) Primary α-Al, (ii) α-Al15(FeMn)3Si2 intermetallics, and (iii) Al–Si eutectics. The microstructure starting from the surface through the depth of the HPDC casting consisted of (i) fine-grained skin at surface, (ii) increased Al–Si eutectics at intermediate location, and (iii) coarse α-Al dendrites at center. Accordingly, the hardness increased from skin to the intermediate section and then decreased toward the center of the casting. The formation of skin layer was highly discontinuous, which was attributed to the complicated fluid flow pattern inside the die cavity. The skin layer indicated to slightly improve the strength of the HPDC alloy; however, it restricted the ductility of the material with a large variation. Such ductility behavior resulted from a fracture mechanism triggered by the inhomogeneous skin because of its poor bonding with the adjacent matrix. Even though the secondary alloy contained casting defects and α-Al15(FeMn)3Si2 intermetallics that are known to be driving factors for the fracture in such materials, the effects from the inhomogeneous skin turned out to be predominant in the current study.

Microstructure evolution from homogeneous as-cast state to annealed heterogeneous structure and mechanical properties of Al-Zn-Mg-Cu alloys with trace TiB2 particles

Materials with a final heterogeneous structure (HS) possess an excellent combination of strength and ductility. However, fine and homogeneous grains are desired in as-cast ingots to avoid defects. The evolution from an as-cast homogeneous microstructure to a pronounced HS owing to the trace addition of TiB2 particles was studied in Al-Zn-Mg-Cu alloys with traditional thermomechanical treatment. It is revealed that the triple junctions and over 2 μm precipitates co-located with TiB2 enhance the particle-stimulated nucleation of recrystallization. The dislocation density difference between the recrystallized and recovered grains is further enhanced by cold rolling. A pronounced HS with alternating soft and hard domains accompanied by multimodal precipitates is modulated, realizing a synergy of yield strength as 632.4 MPa and elongation as 8.8%. It is confirmed that the HS, rather than precipitates, is the primary source of geometrically necessary dislocations (GNDs), leading to the synergy of strength and ductility. Atomistic simulations on the deformation behavior of HS were used to elucidate the strain partition and role of GNDs on mechanical properties. Our results provide a convenient route to fabricate heterogeneous Al-Zn-Mg-Cu alloy by trace addition of ceramic particles in ingots casting instead of elaborated controlling of deformation processing.

THE EFFECT OF ANNEALING REGIME ON THE PRECIPITATION OF FeCoNiAl0.75Nb0.25 HIGH ENTROPY ALLOY

This paper investigates the effect of the annealing regime on the precipitation of FeCoNiAl0.75Nb0.25 high entropy alloy. The as-cast microstructure consists of coarse dendritic phases that are replaced by equiaxed morphology, and the distribution of the interdendritic phase becomes regularly better with increasing time and annealing temperature up to 825ºC. The precipitated process begins at 700ºC for 8 hours, shortening to 4 hours when the annealing temperature increases. The size of this phase is only a few μm. The fraction of the precipitated phase increases and the size of the dendritic phase is reduced as the annealing temperature is up to 825ºC, while this size rises in the 925ºC/16 hours regime. The microstructure is coarse, and the precipitated phase gradually disappears when the annealing is at 1000ºC. The HV3 hardness of the alloy increases with annealing time when the temperature is lower than 825ºC and reaches the highest value of ~ 614 kg/mm2 at 600ºC/ 24 hours; this value begins to decrease for the 925ºC/16 hours regime. Meanwhile, the hardness gradually decreases with increasing annealing time at 1000ºC. It can be expected due to the rapid coarsening of the dendritic phase, the decrease in the proportion of the precipitated phase in the alloy, and the appearance of plastic flow phenomena at grain boundaries.

Interaction of microstructure evolution mechanism in Ti-0.3Mo-0.8Ni alloy with initial lamellar microstructure during isothermal compression below the β-transus

The flow behavior and interaction of microstructure evolution mechanisms for a near α Ti-0.3Mo-0.8Ni alloy with as-cast lamellar microstructure are investigated at temperatures of 800∼880 °C in the α+β region with wide strain rate range from 0.01s−1 to 30s−1 during isothermal compression. It is demonstrated that the main reasons of flow softening in the true stress-true strain curves are the kinking of lamellar α, dynamic α→β transformation (DT), dynamic spheroidization (DS), and dynamic recovery (DRV) of β grain. The instability phenomena such as adiabatic shear band (ASB) and flow localization (FL) are the main causes of the stress collapse in the curves at higher strain rate. The dislocation density at the kinking position of initial lamellar α is higher. With the increase of strain rate, the mechanism of the DS changes from flat separation to slat shear. The diffusion of the β-stabilizer results in starting the DT, promoted by the thermodynamic coupling. The interactions between different microstructure evolution mechanisms are extremely complex. In the early stage of hot deformation, the DT promotes the kinking of lamellar α. With the increase of deformation amount, the DT inhibits the DS at higher strain rates, and conversely, the DS promotes the DT. At lower strain rates, the DT and DS accelerate each other in the middle and late stages of hot deformation. The DT and DS are restricted by the process of lamellar α kinking in the middle and late stages of hot deformation.

Enhanced oxidation resistance in nano-lamellar CoCrFeNiNbx (0.45 ≤ x ≤ 0.55) eutectic high entropy alloy during cyclic oxidation at 700–1100 °C

We report the superior oxidation resistance of nano-lamellar CoCrFeNiNbx (x = 0.45, 0.50, 0.55 atom ratio) eutectic high entropy alloy (EHEA) at 700–1100 °C. The as-cast microstructure comprises of nano-lamellar eutectic FCC+Laves phases. The oxidation kinetics followed the parabolic rate in between 700–800 °C, whereas, near-parabolic kinetics is followed at 900 °C. The addition of Nb improves the oxidation and spallation resistance of the EHEAs. A protective outer-oxide layer containing Cr2O3, FeCr2O4-type spinels, whereas, an inner-oxide layer containing Nb2O5, CrNbO4 were formed during oxidation. The mechanism of protection and the superiority of EHEAs as high temperature alloy are explored.

Mechanical property improvements of LPBF-AlSi10Mg via forging to modify microstructure and defect characteristics

Additive Manufacturing (AM) processes have versatile capabilities but are susceptible to the formation of as-cast non-equilibrium microstructures, process-induced defects, and porosity, which have deleterious effects on the mechanical performance. As part of our NSF-ERC-HAMMER program, isothermal forging was investigated as a novel post-processing technique for refining microstructure, reducing process defect severity, and thereby improving mechanical properties. Specimens of Laser Powderbed Fusion (LPBF) AlSi10Mg were fabricated over a range of process parameters and tensile tested as a baseline. Initial work focused on duplicate AM material that was then hot forged with 20 % strain to investigate the effects of isothermal forging at one temperature and strain rate on the microstructure, tensile, and fatigue properties of the as-deposited materials. The microstructures, process-induced defect populations, and tensile/fatigue properties of both as-deposited and forged materials were quantified and analysed by OM, EBSD, XCT, and SEM by various NSF-ERC-HAMMER team members. Isothermal hot forging was found to induce recrystallisation and modify process-induced defect geometry along with increasing tensile ductility. The effects of AM deposition parameters and forge post-processing conditions on LPBF AlSi10Mg will be discussed in terms of microstructure, mechanical properties, and fractography.

Multi-scale influences of as-cast microstructure heritability on intermediate/high temperature stress rupture behaviors of [111]-oriented Ni-based single crystal superalloy

Multi-scale influences of as-cast microstructure heritability on intermediate/high temperature stress rupture behaviors of [111]-oriented Ni-based single crystal superalloy

Effect of eutectic microstructure on load transfer and creep resistance in Al-Ce alloys

This study investigates the compressive creep response of hypo- and near-eutectic Al-Ce alloys via finite-element modeling (FEM), by considering the composite response of a weak, fast-creeping Al matrix containing slow-creeping Al11Ce3 eutectic reinforcement. In the as-cast microstructure of an eutectic Al-12.5 wt%Ce alloy, the Al11Ce3 eutectic phase is lamellar, regardless of the various cross-sectional geometries (Chinese-script, fish-bone, and comb-like). FEM models based on these various lamellar microstructures investigate the effect of Al11Ce3 reinforcement volume fraction, orientation, and geometry on load transfer performance between matrix and reinforcement during creep deformation. FEM predicts that, when the lamellar Al11Ce3 phase is continuous along the loading direction (where load transfer is most effective), the creep resistance of the alloy is barely affected by cross-sectional geometry of the Al11Ce3 reinforcement or by the solid-solution strengthening of the Al matrix, at constant Al11Ce3 volume fraction. However, alloy creep resistance and load transfer between phases are significantly reduced when applying load parallel to aligned, discontinuous lamellae, and they can be improved by matrix solid-solution strengthening. Furthermore, Al11Ce3 short plates (as created in Al-12.5Ce by coarsening of lamellae upon over-aging at 590 °C/24 h) provide the least creep resistance and load transfer. Lastly, multi-colony FEM models are created by combining colonies with various lamellar orientations to approximate the creep performance of polycrystalline hypo- and near-eutectic alloys which, when compared to experimental data for hypoeutectic Al-7Ce and for near-eutectic Al-(10–13)Ce, provide better predictions than single-colony FEM models or analytical solutions.

Effect of wall thickness on the microstructure and properties of a fourth-generation single crystal superalloy

This study investigated the effect of various thicknesses (0.3–1.5 mm) on the as-cast and heat-treated microstructures of the fourth-generation single crystal superalloy. The microstructures and fracture characteristics of samples with various thicknesses were analyzed after high-temperature stress rupture tests at 1100 ℃/137 MPa. The results showed that as the alloy thickness increased from 0.3 mm to 1.5 mm, the degree of segregation between dendritic core and inter-dendritic significantly increased. The increased segregation was attributed to the slower solidification rate of the 1.5 mm-thick sample compared to the 0.3 mm-thick sample. Lower solidification rates and higher degrees of dendritic segregation enhanced the area fraction of eutectics, the primary dendrite arm spacing (PDAS), the and area fraction of pores. After stress rupture tests, the rupture life of the alloy increased from 81 h to 333 h. It was observed that in the 0.3 mm-thick sample, microcracks initiated at the surface and extended into the matrix. On the contrary, as for the 1.5 mm-thick sample, microcracks initiated at the matrix and propagated towards the surface. To evaluate the influence of oxidation, interrupted stress rupture tests were conducted in air atmosphere to investigate the thickness debit effect. Surface oxidation led to the initiation of microcracks on the surface and change the morphology and area fraction of the internal γ′ phase, as well as the effective load-bearing area of the samples. TEM and EBSD were employed to characterize the deformation characteristics of samples with various thicknesses, and the influence of thickness on deformation mechanisms was discussed as well.

Microstructure and Properties of Complex Concentrated C14–MCr2 Laves, A15–M3X and D8m M5Si3 Intermetallics in a Refractory Complex Concentrated Alloy

Abstract: The refractory complex concentrated alloy (RCCA) 5Al–5Cr–5Ge–1Hf–6Mo–33Nb–19Si–20Ti–5Sn–1W (at.%) was studied in the as-cast and heat-treated conditions. The partitioning of solutes in the as-cast and heat-treated microstructures and relationships between solutes, between solutes and the parameters VEC and Δχ, and between these parameters, most of which are reported for the first time for metallic UHTMs, were shown to be important for the properties of the stable phases A15–Nb3X and the D8m βNb5Si3. The nano-hardness and Young’s modulus of the A15–Nb3X and the D8m βNb5Si3 of the heat-treated alloy were measured using nanoindentation and changes in these properties per solute addition were discussed. The aforementioned relationships, the VEC versus Δχ maps and the VEC, Δχ, time, or VEC, Δχ, Young’s modulus or VEC, Δχ, nano-hardness diagrams of the phases in the as-cast and heat-treated alloy, and the properties of the two phases demonstrated the importance of synergy and entanglement of solutes, parameters and phases in the microstructure and properties of the RCCA. The significance of the new data and the synergy and entanglement of solutes and phases for the design of metallic ultra-high temperature materials were discussed.

High-temperature tensile rupture property of (Nb,W) co-alloying TiAl-based alloys

In order to explore whether (Nb,W) co-alloying TiAl-based alloys with relatively higher W addition have better high-temperature tensile rupture property, Ti-44Al-4Nb-1 W-0.1B alloy is designed and prepared. Ti-44Al-8Nb-0.1B alloy and Ti-44Al-7.2Nb-0.2 W-0.1B alloy are also prepared for comparative study. The rupture property testing is carried out at 800 °C and different tensile stresses. The property data, macro/microstructure evolution, fracture surface, W content, crack failure behaviors are studied. The results show that the (Nb,W) co-alloying alloys have better rupture property than the pure Nb alloying alloy. For the (Nb,W) co-alloying alloys, the higher W contained Ti-44Al-4Nb-1 W-0.1B alloy has the better property under lower tensile stress, and the lower W contained Ti-44Al-7.2Nb-0.2 W-0.1B alloy has the better property under higher tensile stress. The relationships of rupture life t and stress σ for the three alloys are given. All the three alloys have a coupling fracture mode of ductile fracture and brittle fracture. The ductile fracture exhibits the typical dimple characteristics. The brittle fracture exhibits the typical trans-granular cleavage, river-like pattern and trans-lamella fracture characteristics. The higher the stress, the more brittle fracture characteristics there are. After rupture property testing, the (α2 + γ) lamella colony sizes of the three alloys all decrease, indicating that DRX and grain boundary slip occur not only along (α2 + γ) lamella colony boundary, but also inside it. The colony boundary regions have the stress concentration, where the B2 phase produces the better buffering and coordination, and as well as the dislocation tangles, DRX and grain boundary slip can be found by EBSD and TEM. EPMA results show that the more W added in the alloy, the more W content is in the (α2 + γ) lamella matrix, which is beneficial for the rupture property. However, more W addition will also lead to the formation of more B2 phase in the initial as-cast microstructure. So that, under higher tensile stress, when the stress intensity factor K is higher, the crack failure is more likely to occur.

Effect of Ce Addition on Microstructure, Thermal Conductivity, and Mechanical Properties of As-Cast and As-Extruded Mg-3Sn Alloys.

In the present research, the impacts of Ce additions at various concentrations (0, 1.0, 3.4, and 4.0 wt.%) on the evolution of the microstructure, mechanical properties, and thermal conductivity of as-cast and as-extruded Mg-3Sn alloys were investigated. The findings demonstrate that adding Ce caused the creation of a new ternary MgSnCe phase in the magnesium matrix. Some new Mg17Ce2 phases are generated in the microstructure when Ce levels reach 4%. The thermal conductivity of the Mg-3Sn alloy is significantly improved due to Ce addition, and the Mg-3Sn-3.4Ce alloy exhibits the highest thermal conductivity, up to 133.8 W/(m·K) at 298 K. After extrusion, both the thermal conductivity and mechanical properties are further improved. The thermal conductivity perpendicular to the extrusion direction of Mg-3Sn-3.4Ce alloy could achieve 136.28 W/(m·K), and the tensile and yield strengths reach 264.3 MPa and 227.2 MPa, with an elongation of 7.9%. Adding Ce decreases the dissolved Sn atoms and breaks the eutectic α-Mg and Mg2Sn network organization, leading to a considerable increase in the thermal conductivity of as-cast Mg-3Sn alloys. Weakening the deformed grain texture contributed to the further enhancement of the thermal conductivity after extrusion.

Microstructure and mechanical properties of Ti3Zr1.5Nb(1-x)V(1+x)Al0.25 (x =0, 0.2, 0.4, 0.6, 0.8, and 1.0) refractory complex concentrated alloys

Refractory complex concentrated alloys (RCCAs) have garnered significant attention due to their exceptionally high yield strengths, yet their practical applications are severely limited by high density and inherent brittleness. This study seeks to develop novel RCCA systems with enhanced strength and ductility by strategically modulating Group VB elements. The synergistic effects of Nb and V on the as-cast microstructure and mechanical properties at both room and elevated temperatures of the Ti3Zr1.5Nb(1-x)V(1+x)Al0.25 (x = 0, 0.2, 0.4, 0.6, 0.8, and 1.0) RCCAs were investigated in detail. Alloys with x ≤ 0.4 exhibit a single body-centered cubic (BCC) phase structure, while further V additions leads to the precipitation of a hexagonal ZrV2-type C14 Laves phase and even a V-enriched BCC phase in the interdendritic regions. With the increase in V concentration, the alloys display progressively enhanced strength. Notably, the Ti3Zr1.5Nb0.6V1.4Al0.25 alloy demonstrates optimal mechanical properties, achieving a tensile yield strength of ∼ 1024 MPa, a plastic strain of ∼ 12 % at room temperature, and a compression yield strength of ∼ 689 MPa at 600 ℃. However, the precipitation of brittle phases along grain boundaries results in reduced plasticity in alloys with high V concentrations. The high yield strength of these alloys is primarily attributed to the intrinsic yield strength of the constituent elements, grain boundary strengthening, and solution strengthening induced by severe lattice distortion. This study offers a paradigm for understanding the impact of alloy composition on the structure and properties of RCCAs.

Determining critical Zn/Ca atomic ratio and its role in mechanical and corrosion properties of biodegradable Mg-Ca-Zn-Mn alloys

Mg-Ca-Zn-Mn alloys are promising for applications in biodegradable bone fixation devices. The Zn/Ca atomic ratio in the compositions of these alloys is important to their corrosion and mechanical properties. This paper investigated the Zn/Ca ratio using a phase-focused approach based on CALPHAD (CALculation of PHAse Diagrams) modeling and experimental validation. Six Mg-0.5Ca-xZn-0.5Mn (all wt.%) alloys were cast with x = 0.96, 1.15, 1.47, 1.69, 1.94, and 3.81 so that the Zn/Ca atomic ratio spanned from 1.18 to 4.66. The microstructure is studied in the as-cast, solution-treated, and as-rolled conditions. A critical ratio was determined to be 2.77, above which Mg2Ca phase can be suppressed in as-cast microstructure. In the solution-treated condition, a Zn/Ca ratio of less than 2.0 was required to dissolve the Ca2Mg6Zn3 phase. Alloys below 2.0 Zn/Ca were found to have yield strength of 300 MPa and a corrosion rate of 0.25 to 0.3 mg/cm2/day as measured by both weight loss and hydrogen evolution. In alloys above 2.0 Zn/Ca, the yield strength decreased to 280 MPa and the corrosion rate measured by weight-loss increased to 0.5 mg/cm2/day. Above the critical ratio, the yield strength was the highest at 347 MPa but a corrosion rate of 0.4 mg/cm2/day. The Zn/Ca region with the best combination of corrosion resistance and mechanical properties is between 1.18 and 1.8 (in rolled sheet condition), which provides important guidance for biomedical Mg-Ca-Zn alloy design and optimization.

Effect of different Zn/Mg ratios on the uniformity of 7185+TiB2/TiC aluminum alloy thick plates

Three types of 7185+TiB2/TiC aluminum matrix composites with different Zn/Mg ratios were prepared in this work through a water-cooled copper casting process. The effects of Zn/Mg ratio on the microstructure and mechanical properties of 20-mm-thick composites were studied by optical microscopy, electron back scattering diffraction, transmission electron microscopy, and tensile mechanical testing. The results showed that the addition of appropriate TiB2/TiC particles refined the as-cast microstructure of the alloy, and with a decrease in Zn/Mg ratio, the grain size distribution became more uniform, the crystalline phase content gradually increased, and the uniformity of the alloy increased. After aging, as the Zn/Mg ratio decreased, the size of the precipitated phase decreased, and the strengthening effect of the alloy improved. The tensile strengths of the surface layer, 1/4 layer, and center position of the A3 alloy were 558, 568, and 572 MPa, respectively. The strength difference among the different thickness layers was the smallest, and the elongation rate was greater than 12%, resulting in the best uniformity.

Machine learning and experimental study on a novel Cr–Mo–V–Ti high manganese steel: Microstructure, mechanical properties and abrasive wear behavior

Machine learning combined with traditional experimental methods can promote the efficient research and development of materials. In this work, five kinds of algorithm models combined with a genetic algorithm (GA) were used to optimize the compositions of the alloyed high manganese steel. And then the effect of solid solution temperatures on the microstructure, mechanical properties, and impact wear properties of the steel were systematically investigated. The results showed that Categorical Boosting (CB) model exhibited the high validation accuracy (R2 > 0.95, RMSE<4.11, MAE<2.44). Based on the trained CB model and GA, the optimal steel compositions were obtained. The as-cast microstructure of the steel contained coarse austenite, little pearlite and networks and irregular carbides. After water toughening treatment, the pearlite completely dissolved into the matrix and the number of carbides gradually decreased. Compared to as-cast alloy, the austenite grain size significantly decreased, and it decreased first and then increased with the increase of solid solution temperatures. The average impact energy, ultimate tensile strength (UTS) and elongation (EL) of the steel increased and then decreased with the increase of solid solution temperatures. However, the wear loss showed an opposite trend. The steel of water quenching at 1100 °C with an average impact energy of 185.1 J, hardness of 242.4 HBW, UTS of 742 MPa, yield strength (YS) of 458 MPa, and EL of 37.4%, exerted best impact toughness, mechanical properties and wear resistance. It was attributed to the interactions among dispersed small sized second phases, high density dislocations, fine austenite grains and twins.

Microstructure and Mechanical Properties of As-Cast and Hot Extruded–Sheared ZG61 Alloy

Microstructure and Mechanical Properties of As-Cast and Hot Extruded–Sheared ZG61 Alloy

Dendritic Si growth morphologies in highly undercooled Al–Si alloys

The morphology of primarily crystallizing Si in hypereutectic Al-(20, 40, 55) wt%Si alloys during conventional casting (nucleation undercooling ΔT<1 K) and solidification at high undercoolings (ΔT up to 335 K) has been investigated. As expected, at higher undercoolings a higher nucleation frequency and fast growth of primary Si is observed, leading to the formation of multiple microstructural zones. Instead of the well-known plate-like Si in the as-cast microstructure, various morphologies of primary Si such as faceted and non-faceted blocky morphologies as well as dendrites with aligned side branches showing constant spacing features are observed after solidification at high undercoolings. The special Si dendrites only grow in a limited range of melt concentrations and undercoolings. The transition from faceted to non-faceted growth appears to occur in several steps, as Si dendrites with similar features of the secondary arms as in non-faceted metal alloys are also observed.

Microstructure evolution and nano-precipitate of multi-stage heat-treated Ti–45Al–2Nb–2Cr-0.3C alloy

This work thoroughly examined the microstructure evolutions of the cast Ti–45Al–2Nb–2Cr-0.3C alloy after multi-stage heat treatments, involving solid solution, cyclic quenching and isothermal annealing. The experimental findings revealed that solid solution and isothermal annealing processes decreased the lattice constants of component parameters, while the cyclic quenching resulted in the lattice expansion. The blocky (B2+γ) phases, which had been distributed along the colony boundary of the as-cast microstructure, disappeared after multi-stage heat treatment, and the lamellae showed a trend of thinning first and then thickening. In addition, the cyclic quenching process resulted in a large number of dislocations and stacking faults within γ lamellae. These crystal defects could act as heterogeneous nucleation sites, lowering the energy barrier of Ti2AlC precipitated from the lamellar matrix during the isothermal annealing stage. The dispersed Ti2AlC particles, with an average size of 45 ± 15 nm, showed the following coherent relationship with the lamellar matrix, [1‾216‾]Ti2AlC//[001]γ and (101‾0)Ti2AlC//(2‾20)γ.

Microstructure, Hardness, Wear Resistance, and Corrosion Resistance of As-Cast and Laser-Deposited FeCoNiCrAl0.8Cu0.5Si0.5 High Entropy Alloy

FeCoNiCrAl0.8Cu0.5Si0.5 high-entropy alloys were fabricated using vacuum induction melting and laser deposition processes, followed by a comparison of the structural and mechanical properties of two distinct sample types. The as-cast FeCoNiCrAl0.8Cu0.5Si0.5 alloy is comprised of BCC1, BCC2, and Cr3Si phases, while the laser-deposited alloy primarily features BCC1 and BCC2 phases. Microstructural analysis revealed that the as-cast alloy exhibits a dendritic morphology with secondary dendritic arms and densely packed grains, and the laser-deposited alloy displays a dendritic structure without the formation of granular interdendritic regions. For mechanical properties, the as-cast FeCoNiCrAl0.8Cu0.5Si0.5 alloy demonstrated higher hardness than the as-deposited alloy, with values of 586 HV0.2 and 557 HV0.2, respectively. The wear rate for the as-cast alloy was observed at 3.5 × 10−7 mm3/Nm, with abrasive wear being the primary wear mechanism. Conversely, the as-deposited alloy had a wear rate of 9.0 × 10−7 mm3/Nm, characterized by adhesive wear. The cast alloy exhibited an icorr of 4.062 μA·cm−2, with pitting as the form of corrosion. The laser-deposited alloy showed an icorr of 3.621 μA·cm−2, with both pitting and intergranular corrosion observed. The laser-deposited alloy demonstrated improved corrosion resistance. The investigation of their microstructure and mechanical properties demonstrates the application potential of FeCoNiCrAl0.8Cu0.5Si0.5 alloys in scenarios requiring high hardness and enhanced wear resistance.