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<p>This work develops a Colmonoy 88 alloy reinforced with 50 wt.% tungsten carbide (WC) coating on ASTM A213 Grade T22 steel using laser cladding to address severe air-jet erosion encountered in boiler and high velocity particle environments. The coating formed a dense, metallurgically bonded layer with an average thickness of 562&#xa0;µm and a hardness of 1054 ± 18 HV. Air-jet erosion behavior was evaluated using a central composite design with varying velocities, particle sizes, and impingement angles. Analysis of variance confirmed that all three parameters significantly influenced erosion mass loss (<i>p</i> &lt; 0.0001). The clad surface exhibited around 70% lower erosion compared with the uncoated T22 substrate. Desirability-based optimization identified 37.39&#xa0;m/s, 235&#xa0;µm, and 48.77° as the minimum erosion condition. SEM fractography showed ductile ploughing in the T22 and brittle micro-chipping in the coating, indicating a shift in erosion mechanism due to the reinforced microstructure. The study integrates Colmonoy 88 + WC cladding with RSM-based optimization and mechanistic erosion analysis to enhance particle erosion resistance in power-plant components. Its novelty lies in combining laser-clad Colmonoy 88 + 50 wt.% WC on T22 steel with an RSM-driven erosion evaluation and optimization framework.</p>

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Erosion Performance Optimization and Mechanistic Insights of 88 + 50% WC Laser-Clad Coatings on T22 Steel Using Response Surface Methodology

  • 期刊论文

  • 发表日期：

    2026年3月3日

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  • Maninder Kaur,
  • Khushdeep Goyal,
  • Deepak Kumar Goyal

摘要

This work develops a Colmonoy 88 alloy reinforced with 50 wt.% tungsten carbide (WC) coating on ASTM A213 Grade T22 steel using laser cladding to address severe air-jet erosion encountered in boiler and high velocity particle environments. The coating formed a dense, metallurgically bonded layer with an average thickness of 562 µm and a hardness of 1054 ± 18 HV. Air-jet erosion behavior was evaluated using a central composite design with varying velocities, particle sizes, and impingement angles. Analysis of variance confirmed that all three parameters significantly influenced erosion mass loss (p < 0.0001). The clad surface exhibited around 70% lower erosion compared with the uncoated T22 substrate. Desirability-based optimization identified 37.39 m/s, 235 µm, and 48.77° as the minimum erosion condition. SEM fractography showed ductile ploughing in the T22 and brittle micro-chipping in the coating, indicating a shift in erosion mechanism due to the reinforced microstructure. The study integrates Colmonoy 88 + WC cladding with RSM-based optimization and mechanistic erosion analysis to enhance particle erosion resistance in power-plant components. Its novelty lies in combining laser-clad Colmonoy 88 + 50 wt.% WC on T22 steel with an RSM-driven erosion evaluation and optimization framework.