Effect of Si Content on the Mechanical Behavior, Corrosion Resistance, and Passive Film Characteristics of Fe–Co–Ni–Cr–Si Medium-Entropy Alloys

The nominal compositions of Fe₆₅Co_10−xNi_10−xCr₁₅Si_2x (x = 1, 2, and 3 at.%) medium-entropy alloys (MEAs) were designed and fabricated by vacuum arc melting. Their microstructure, hardness, and mechanical properties were systematically characterized. Corrosion behavior was evaluated in 3.5 wt.% NaCl solution by potentiodynamic polarization and electrochemical impedance spectroscopy. The investigated MEAs exhibit a dual-phase microstructure composed of face-centered cubic (FCC) and body-centered-cubic (BCC) phases. With increasing Si content, yield strength and ultimate tensile strength increase, while uniform elongation decreases. Hardness also increases with increasing Si content. For the x = 3 MEA, the yield strength, ultimate tensile strength, and hardness of are ~518 MPa, ~1053 MPa, and 262 ± 4.8 HV, respectively. The observed strengthening can be primarily attributed to solid solution strengthening effect by Si. Polarization curves indicate that the x = 3 MEA exhibits the best corrosion resistance with the lowest corrosion current density ((0.401 ± 0.19) × 10⁻⁶ A × cm⁻²) and corrosion rate ((4.65 ± 0.19) × 10^–2 μm × year⁻¹)). Equivalent electric circuit analysis suggests the formation of a stable passive oxide film on the MEAs. This conclusion is supported by the capacitive behavior, high impedance values (> 10⁴ Ω cm²) at low frequencies, and phase angles within a narrow window of 80.05°~80.64° in the medium-frequency region. The passive-film thickness was calculated and the corrosion morphology was analyzed by SEM. These results provide a reference for developing high-strength, corrosion-resistant, medium-entropy alloys.