This paper focuses on the microstructure, phase composition, mechanical, tribological and corrosion properties of high-entropy alloys (HEAs) in the CoCrCuFeNi system depending on copper content, which was varied from 0 to 20 at. % with an increment of 5%. CoCrCuFeNi alloys were manufactured by powder metallurgy methods: mechanical alloying and hot pressing of element mixtures. The solubility limit of copper in CoCrFeNi solid solution was found to be 9 at. %. Segregation of irregularly shaped copper grains sized 1–30 μm is observed at concentrations above this solubility limit. As copper concentration increases, the phase composition of CoCrCuFeNi alloys changes from the single phase based on FCC1 solid solution (Cu = 0–5 at. %) to the dual-phase FCC1 + FCC2 alloy (Cu = 10–20 at. %), where FCC1 is the main phase and FCC2 is the secondary copper-rich phase. Tribological tests have shown that doping the CoCrFeNi alloy with copper increased wear resistance by 23% due to solid solution hardening. As copper content rises above 20%, the content of the secondary FCC2 phase increases, while wear resistance and alloy hardness decline. An analysis of wear tracks and wear products has shown that abrasion of CoCrCuFeNi alloys occurs via the abrasive-oxidative wear mechanism. The corrosion tests of CoCrCuFeNi HEAs in 3.5% NaCl solution had demonstrated that doping the alloy with copper at low concentrations (5–10%) leads to decreasing of corrosion resistance, possibly due to the formation of undesirable oxide Cu₂O along with protective Cr₂O₃. At high copper concentrations (15–20%) galvanic corrosion is suppressed due to coarsening of FCC2 grains and thus decreasing the specific contact surface area between the cathode (FCC2) and the anode (FCC1).

The synergistic effect of simultaneous mechanical wear, chemical/electrochemical corrosion (tribocorrosion) and microbial attack poses a serious threat to marine and coastal infrastructure. To address this important problem, we have developed composite coatings consisting of TaC (25–35 at.%) and a corrosion-resistant α-Fe(Cr,Ni,Mo)-based metal matrix, as well as bactericidal elements (Cu, Ag). Coatings 50–75 μm thick were obtained by electrospark deposition in vacuum. The coatings possess high hardness (up to 10 GPa) and resistance to cyclic dynamic loads compared with the stainless steel (SS) substrate. Tribocorrosion experiments showed that the decrease in the corrosion potential associated with the removal of a passivating film from the surface during friction was 2–2.5 times smaller for the Ag-containing coating than for the other tested materials. The material passivation rates were also different: almost instantaneous passivation of the Ag- and Cu-doped coatings, and slow passivation for several minutes of the Ag/Cu-free coating and SS. The Ag-containing coating shows the lowest friction coefficient (0.2–0.25) and a minimal wear rate (1.6 × 10⁻⁶ mm³/Nm) in artificial seawater. The Ag-doped coating also exhibits the most positive value of corrosion potential and the lowest current density. After exposure in seawater for 20 days, only the Ag-doped coating showed no signs of pitting corrosion. All the studied materials have a pronounced bactericidal effect against Bacillus cereus Arc30 bacteria. The resulting coatings can be used to protect steel products from tribocorrosion and fouling in seawater.

Marine and coastal infrastructures usually suffer from synergetic effect of corrosion and wear known as tribocorrosion, which imposes strict requirements on the structural materials used. To overcome this problem, novel composite wear- and corrosion-resistant xTiC-Fe-CrTiNiAl coatings with different TiC content were successfully developed. The coatings were obtained by the original technology of electrospark deposition in a vacuum using xTiC-Cr₂Ti-NiAl (x = 0, 25, 50, 75%) electrodes. The structure and morphology of the coatings were studied in detail by XRD, SEM, and TEM. The effect of TiC content on the tribocorrosion behavior of the coatings was estimated using tribological and electrochemical (under stationary and wear conditions) experiments, as well as impact testing, in artificial seawater. The TiC-free Fe-Cr₂Ti-NiAl coating revealed a defective inhomogeneous structure with transverse and longitudinal cracks. Introduction of TiC allowed us to obtain coatings with a dense structure without visible defects and with uniformly distributed carbide grains. The TiC-containing coatings were characterized by a hardness and elastic modulus of up to 10.3 and 158 GPa, respectively. Formation of a composite structure with a heavily alloyed corrosion-resistant matrix based on α-(Fe,Cr) solid solution and uniformly distributed TiC grains led to a significant increase in resistance to stationary corrosion and tribocorrosion in artificial seawater. The best 75TiC-Fe-CrTiNiAl coating demonstrated the lowest corrosion current density values both under stationary (0.03 μA/cm²) and friction conditions (0.8 μA/cm²), and was characterized by both a 2-2.5 times lower wear rate (4 × 10⁻⁶ mm³/Nm) compared to AISI 420S steel and 25TiC-Fe-CrTiNiAl and a high fracture toughness.

High-entropy coatings are highly promising for protecting steel parts in coastal and marine infrastructure from corrosion and tribocorrosion. This study examines the properties of medium- and high-entropy Fe–Co–Cr–Ni–(Cu) coatings produced by vacuum electrospark deposition. The coatings, with thicknesses of up to 30 μm and varying copper content, exhibit a single-phase solid solution structure with an FCC lattice and a dense, homogeneous morphology. The addition of 14 at.% Cu was found to enhance corrosion resistance, shifting the corrosion potential to 100 mV. In friction conditions within artificial seawater, the inclusion of copper also improved tribocorrosion properties, raising the corrosion potential during friction to –165 mV. This improvement is attributed to the galvanic deposition of dissolved copper on the worn areas of the coating, which also reduces the friction coefficient from 0.37 to 0.26. The Fe–Co–Cr–Ni–(Cu) coatings demonstrate high wear resistance, ranging from 5.6 to 9.6·10^–6 mm³/(N·m). The findings confirm the potential of these coatings for applications in environments subject to both friction and corrosion.

Ta–Zr–Si–B–C coatings were deposited by magnetron sputtering (MS) of a TaSi₂–Ta₃B₄–(Ta, Zr)B₂ multi-component target in an Ar + C₂H₄ gas mixture. TaC–Cr–Mo–Ni based coatings were obtained by electro-spark deposition (ESD) using TaC–Cr–Mo–Ni electrode. The composition and structure of the coatings were studied using scanning electron microscopy, energy-dispersive spectroscopy, glow discharge optical emission spectroscopy and X-ray diffraction. Mechanical and tribological properties of coatings were determined using nanoindentation and pin-on-disk tests. The study showed that the coatings have a homogeneous and defect-free structure, with the main structural component being the fcc-TaC phase. The MS coating exhibited a 30 % higher concentration of the TaC phase compared to the ESD coating. The TaC crystallite sizes for the MS and ESD coatings were 3 and 30 nm, respectively. The presence of a high fraction of the carbide phase and small crystallite size for the MS coating resulted in superior hardness (H = 28 GPa) compared to the ESD sample (H = 10 GPa). Both coatings exhibited similar values of the friction coefficient (about 0.15) and demonstrated reduced wear rates (<10^–7 mm³/(N·m)). The deposition of coatings on a steel substrate led to a decrease in the friction coefficient by five times and the wear rate by four orders of magnitude. Pilot tests were conducted on coatings applied to wedge gate valve of shut-off devices used in the oil and gas industry for pumping liquids. The results indicated that the service life of the steel wedge gate valve increased by 25 and 70 % with deposited MS and ESD coatings, respectively.