High entropy alloys (HEAs) constitute a new class of advanced metallic alloys that exhibit exceptional properties due to their unique microstructural characteristics. HEAs contain multiple (five or more) elements in equimolar or nearly equimolar fractions compared to traditional alloy counterparts. Due to their potential benefits, HEAs can be fabricated with thermal spray manufacturing technologies to provide protective coatings for extreme environments. In this study, the AlCoCrFeMoW and AlCoCrFeMoV coatings were successfully developed using flame spraying. The effect of W and V on the HEA coatings were investigated using X-ray diffraction, scanning electron microscopy, energy dispersive spectroscopy, and micro-hardness testing. Furthermore, performance of the coating under abrasive loading was investigated as per ASTM Standard G65. Microstructural studies showed different oxides with solid-solution phases for all the HEA coatings. Hardness results were higher for the AlCoCrFeMoV coatings followed by AlCoCrFeMoW and AlCoCrFeMo coatings. Lower wear rates were achieved for the AlCoCrFeMoV coatings compared to AlCoCrFeMoW and AlCoCrFeMo coatings. The evolution of multiple oxide phases and underlying microstructural features improved the resistance to abrasive damage for the AlCoCrFeMoV coatings compared to other HEA coatings. These results suggest that the flame-sprayed HEA coatings can be potential candidates for different tribological interfaces while concurrently opening new avenues for HEA coating utilization.

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