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<p>Ni60 alloy is extensively utilized to enhance substrate surface properties owing to its high hardness and superior wear and corrosion resistance. However, its high crack sensitivity, especially during the fabrication of thick cladding layers, severely restricts practical applications. To solve this problem, this study adopted laser cladding to fabricate crack-free high-thickness Ni60 cladding layers on 1Cr18Ni9 steel. Cracking was effectively suppressed by optimizing laser power and substrate preheating temperature. The microstructure evolution, cracking suppression mechanism, mechanical properties, and tribological properties of the cladding layers were systematically investigated. Through synergistic parameter control, a 4.2&#xa0;mm crack-free cladding layer was successfully achieved. The preheated multilayer cladding samples consist of a γ-Ni matrix, Ni<sub>3</sub>B, Cr<sub>7</sub>C<sub>3</sub>, CrB, and minor Cr<sub>23</sub>C<sub>6</sub>, which contribute to their enhanced performance. Fine equiaxed grains dominated the cladding zone, whereas columnar grains prevailed in the overlap region. Lower laser power promotes finer grains and more abundant CrB precipitation. The 1400 W double-layer cladding layer exhibited the highest microhardness (750 HV<sub>0.5</sub>, ~ 4 times that of the substrate) via CrB reinforcement and grain refinement. This condition also achieved the lowest wear weight loss ratio (9.6 × 10<sup>–5</sup>), the narrowest and shallowest wear scars, and superior wear resistance governed by abrasive, fatigue, and mild oxidative wear. All cladding layers exhibited interfacial bonding strengths exceeding the cohesive strength of the cladding, with the 1400 W cladding layer reaching over 383&#xa0;MPa. Overall, this study addresses the major challenge of cracking in thick Ni60 cladding layers and establishes distinct microstructure-property-wear relationships, providing a promising strategy for enhancing wear resistance and facilitating the reliable repair of stainless steel components.</p>

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Microstructure evolution, mechanical performance, and wear mechanisms of crack-free multilayer Ni60 coatings fabricated by laser cladding

  • 期刊论文

  • 发表日期：

    2026年3月2日

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  • Miao Sun,
  • Lei Wang,
  • Yi Chen,
  • Jianxun Zhang,
  • Bingheng Lu

摘要

Ni60 alloy is extensively utilized to enhance substrate surface properties owing to its high hardness and superior wear and corrosion resistance. However, its high crack sensitivity, especially during the fabrication of thick cladding layers, severely restricts practical applications. To solve this problem, this study adopted laser cladding to fabricate crack-free high-thickness Ni60 cladding layers on 1Cr18Ni9 steel. Cracking was effectively suppressed by optimizing laser power and substrate preheating temperature. The microstructure evolution, cracking suppression mechanism, mechanical properties, and tribological properties of the cladding layers were systematically investigated. Through synergistic parameter control, a 4.2 mm crack-free cladding layer was successfully achieved. The preheated multilayer cladding samples consist of a γ-Ni matrix, Ni3B, Cr7C3, CrB, and minor Cr23C6, which contribute to their enhanced performance. Fine equiaxed grains dominated the cladding zone, whereas columnar grains prevailed in the overlap region. Lower laser power promotes finer grains and more abundant CrB precipitation. The 1400 W double-layer cladding layer exhibited the highest microhardness (750 HV0.5, ~ 4 times that of the substrate) via CrB reinforcement and grain refinement. This condition also achieved the lowest wear weight loss ratio (9.6 × 10–5), the narrowest and shallowest wear scars, and superior wear resistance governed by abrasive, fatigue, and mild oxidative wear. All cladding layers exhibited interfacial bonding strengths exceeding the cohesive strength of the cladding, with the 1400 W cladding layer reaching over 383 MPa. Overall, this study addresses the major challenge of cracking in thick Ni60 cladding layers and establishes distinct microstructure-property-wear relationships, providing a promising strategy for enhancing wear resistance and facilitating the reliable repair of stainless steel components.