Using induction remelting assisted with cold spraying, AlCoCrCuFeNi_x (x = 0, 0.5, 1, 1.5, 2) HEA coatings with different Ni contents were prepared on the surface of 45# steel. Results show that the AlCoCrCuFeNi_x HEA coatings structure is mainly composed of dendrites and interdendrites. As the Ni content increase, the BCC phase structure content in the coating first increases and the decreases, and the FCC phase structure content first decreases and then increases; when 0 ≤ x ≤ 0.5, the dendritic structure in the coating is BCC phase and the interdendritic structure is FCC phase; when 0.5 ≤ x ≤ 2, the dendritic structure in the coating is FCC phase and the interdendritic structure is BCC phase. When x=0.5, the performance of the coating is the best, the hardness is 534.7HV, the coefficient of friction is 0.38, and the wear rate is 4.37 × 10⁻⁵mm³N⁻¹mm⁻¹ .

Abstrasct: High-aluminum bronze alloy powder was mixed with 16 wt% Al₂O₃ powder to prepare low-pressure gas dynamic spray coatings with different sized powder particles. The mechanical properties of coatings were tested and the surface, cross section and stretch section of coatings were observed by scanning electron microscopy. Uniform experiment was performed to analyze the effects of particle size of the high-aluminum bronze and Al₂O₃ powder on coating performance. Experimental results shows that the degree of deformation of the high-aluminum bronze particle in the coating increased with decreasing particle size in the high-aluminum bronze and Al₂O₃ in the mixed powder. The degree of deformation of the high-aluminum bronze particle in the coating affected the mechanical properties of the coating showing a linear relationship between powder size and coating performance. When the particle size of Al₂O₃ and high-aluminum bronze particle ranged between 23–25 μm, the coating has the outstanding mechanical properties.