To enhance the wear resistance of Ti6Al4V substrates, FeCoNiCrMo coatings were fabricated by laser cladding under varying laser energy densities (Led). The phase composition, microstructure, mechanical properties, and corrosion resistance of coatings were systematically investigated. The results revealed that increasing Led facilitated the formation of σ-CrMo phase, which contributed to improved mechanical properties of the coatings. At a Led of 110 J/mm 2, a seaweed nanostructured eutectic (300–400 nm) composed of Al Ni and σ phase was observed. This optimized microstructure exhibited an average microhardness of 871 HV 0.3, with a wear track width and depth of 853 μm and 20 μm, respectively. Additionally, the corrosion current density merely 2.641 × 10 −6 A/cm 2, indicating a substantial improvement in both mechanical and corrosion performance compared to Ti6Al4V substrate. Conversely, excessive Led promoted solidification crack formation within the coatings, which subsequently deteriorated their corrosion resistance.
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