Oscillating laser post-processing of NiCrCoFeCBSi/WC thermally sprayed coatings

Abstract

In the present experimental study, the transverse oscillating laser beam technique was applied for the post-melting of metal matrix composite coatings, thermally sprayed with nickel-based self-fluxing NiCrCoFeCBSi alloy and 40 wt.% WC, to improve their hardness and wear resistance. The study was conducted using the single module optical fiber laser at 300 W power, >9554 W/cm2 power density, 250–1000 mm/min laser speed, 1 mm and 2 mm transverse oscillation amplitude. Scanning electron microscopy, energy dispersive spectroscopy, Knop hardness measurements, and “Ball-on-disc” dry sliding tests were conducted to study the effect of the processing parameters on the molten pool geometry and microstructure, hardness, and tribology of the processed layers. Oscillating laser processing with an amplitude of 1 mm, 250–750 mm/min laser operating speed, and sample preheating to 400 °C gave a satisfactory result: wide and shallow molten pools of ~200–350 μm in depth, hardness between ~1100 and 1200 HV0.2 and minimum cracks obtained. The coatings obtained with laser beam oscillation and preheating, and ~1150 HV0.2 hardness showed an improvement in the wear resistance and friction coefficient (~0.33) of ~2.9 times and ~20%, respectively, compared with the respective values of the coatings remelted in furnace.