Lightweight refractory high-entropy alloy coatings (RHEAcs) of AlXNbMo0.5Ti1.5Ta0.5Cr0.5 (where x = 0, 0.1, 0.2, and 0.3) were fabricated on 316L stainless steel surface by pre-placed powder laser cladding (LC) technology. The incorporation of Al element significantly enhanced the forming quality of coatings, resulting in nearly defect-free coatings with a thickness of 1.2-1.4mm. Microstructural analysis revealed that the coatings were primarily composed of body-centered cubic (BCC) solid solution and C15-Laves phase. Due to the influence of a single brittle BCC phase, the Al-free coating exhibited high strength and brittleness, leading to numerous defects caused by thermal stress. The introduction of Al element refined the microstructure and facilitated the formation of Laves phases at grain boundaries, thereby alleviating stress to a certain extent. Consequently, the microhardness of the RHEAcs was significantly higher than that of the substrate, with the Al-free coating achieving the highest microhardness of 1250 HV, which was 5.89 times that of the substrate. Wear resistance results indicated that, prior to annealing, RHEAcs with varying Al content outperformed 316L stainless steel. Post-annealing, the coatings exhibited significantly lower friction coefficients compared with the annealed 316L substrate. The Al-free coating showed significant accumulation of abrasive particles, leading to severe abrasive and oxidative wear. Conversely, post-annealing oxidation induced the formation of dense and directional oxide accumulation, resulting in a notable improvement in wear resistance. Finally, the underlying strengthening mechanisms have been proposed and analyzed.
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