Microstructure and properties of laser cladding WC/Ni composite coatings with different compositionsAbstract
This study addresses the issue of cracking in WC/Ni60 cladded layers with high WC content. The effects of different WC contents on the formation quality, microstructure, and microhardness of WC/Ni15 cladded layers, as well as the influence of various nickel alloys (Ni15, Ni35, and Ni60) on Ni+20% WC cladded layers, were investigated. The results show that as the WC content increases, the microstructure of WC/Ni15 cladded layers becomes denser and finer, with the formation of W-rich compounds and carbides such as Ni2W4C and W2C, resulting in an increase in hardness. When the WC mass fraction reaches 50%, cracks and larger pores appear in the WC/Ni15 cladded layer, and the higher viscosity of the melt pool causes W-rich compounds to be uniformly distributed throughout the layer. At a WC mass fraction of 20%, the pores in the cross-sections of WC/Ni15, WC/Ni35, and WC/Ni60 cladded layers decrease sequentially. The microstructure transitions from cellular to dendritic, the dendrite spacing decreases, and hardness increases, with W-rich compounds mainly concentrated at the top of the cladded layer. In the Ni60+20% WC cladded layer, the increase in borides leads to the formation of cracks. The Ni15+40% WC cladded layer, however, does not exhibit cracks and has a hardness comparable to that of the Ni60+20% WC cladded layer. Under the same conditions, adding a high content of WC particles to Ni15 powder results in a crack-free cladded layer with higher hardness, making it more favorable for industrial applications of WC/Ni cladded layers.
Keywords:
Laser cladding; WC/Ni coating; Cracking; Microstructure; Mechanical properties
1. INTRODUCTION
As an advanced surface modification technology, laser cladding enables the fabrication of coatings with high hardness, superior wear resistance, and strong corrosion resistance, significantly improving the mechanical properties of material surfaces. The technology has been widely applied in fields such as coal mining, metallurgy, and aerospace [1,2,3,4]. In WC/Ni composite coatings, WC particles exhibit excellent wettability with Ni-based powders, which helps suppress crack formation and improves surface morphology and quality [5,6,7,8,9]. Consequently, extensive research has been conducted both domestically and internationally on the laser cladding of WC/Ni composite coatings.
LIU et al. [10] and HU [11] investigated the effect of WC content on the WC/Ni35 and WC/Ni50 cladded layers, respectively. The results showed that as the WC content increased, the hardness and wear resistance of the cladded layers improved. However, the formation quality of the cladded layers deteriorated, and the number of cracks in the WC/Ni50 cladded layer increased when the WC mass fraction exceeded 10%. LI et al. [12] studied the effect of WC content on the microstructure of the WC/Ni60 cladded layer, and the results indicated that the carbide morphology in the cladded layer changed with WC mass fractions of 20%, 33%, and 50%, being characterized by interdendritic distribution, eutectic structure, and large independent blocky carbides, respectively. The studies by YANG et al. [13] and ZHAO et al. [14] both demonstrated that as WC content increased, the hardness and wear resistance of the WC/Ni coatings improved, but the porosity of the cladded layer also increased. Additionally, TIAN et al. [15], ORTIZ et al. [16], and GARCÍA et al. [17] investigated the effects of WC content on the formation quality, microstructure, hardness, and wear resistance of WC/Ni coatings. LEI et al. [18] optimized the process parameters for the Ni60+25% WC cladded layer, and their results showed that scanning speed had the greatest influence on the coating width, while powder feed rate had the most significant effect on the coating height and dilution ratio.
The aforementioned studies primarily focus on the influence of WC content on the microstructure and properties of various cladding layers, such as WC/Ni35, WC/Ni50, and WC/Ni60. A key observation is that the main difference in these studies lies in the selection of nickel-based self-fluxing powders, including Ni35, Ni50, and Ni60. However, research on the effect of WC content on the microstructure and properties of WC/Ni15 cladding layers remains limited. Compared to Ni15, Ni35, Ni50, and Ni60 powders, the contents of hard particles such as B, Si, Cr, and C increase sequentially, which enhances the hardness and wear resistance. However, this also expands the γ-phase region of austenite, resulting in a decrease in Ni content and an increased susceptibility to cracking in the cladded layer [19]. Therefore, for WC/Ni15, WC/Ni35, and WC/Ni60 cladded layers with the same WC content, the microstructure, mechanical properties, and crack sensitivity of the cladded layers differ. Currently, no studies have investigated the differences in microstructure and properties among WC/Ni15, WC/Ni35, and WC/Ni60 cladding layers with identical WC content. Additionally, WC content significantly influences the crack sensitivity of the cladding layer; in some instances, cracks have been observed in the WC/Ni50 cladding layer even when the WC mass fraction is as low as 10% [11]. The presence of cracks has consistently posed a critical challenge to the industrial application of laser cladding. Cracks can lead to substantial brittle detachment of coatings during wear, severely compromising their service life.
Based on the aforementioned research, this study prepares WC/Ni cladded layers on a 45 steel substrate and investigates the effect of WC content on the microstructure and properties of WC/Ni15 cladded layers. Under conditions of constant WC content, the influences of Ni15, Ni35, and Ni60 powders on the microstructure and properties of WC/Ni cladding layers are examined. The goal is to develop a high WC content WC/Ni15 crack-free cladding layer and identify alternative solutions for the easily crackable WC/Ni60 cladding layers, thereby providing theoretical guidance for their large-scale industrial applications.
2. MATERIALS AND METHODS
2.1. Test materials
Pure WC powder, spherical in shape with a purity of 99.9% and a particle size range of 45 to 109 um, was used. Ni-based self-fluxing powders with grades Ni15, Ni35, and Ni60, all with a particle size range of 45 to 109 um, were also selected. The chemical compositions of these Ni-based powders are listed in Table 1. WC/Ni cladded layers with different compositions were prepared for the experiment. For the Ni15 powder, WC mass fractions of 20%, 40%, and 50% were used. Additionally, for a WC mass fraction of 20%, Ni35 and Ni60 powders were selected to prepare WC/Ni35 and WC/Ni60 cladded layers. In total, five different compositions of cladded layers were prepared. Before the experiment, the powders were thoroughly mixed using a mixer and dried to remove moisture.
2.2. Test equipment and process parameters
The substrate in this study is 45 steel, which is extensively used in engineering structural components, shafts, and gears. A YSL6000 laser was employed to apply a laser cladding coating on its surface. Coaxial powder feeding was utilized during the cladding process, with the laser’s integrated powder feeder and water cooling system facilitating powder delivery and cooling. Argon was used as the shielding gas. The optimized process parameters were as follows: laser power set at 3 kW, focal length of 30 mm, scanning speed of 10 mm/s, feeding rate of 1 r/min, and the area of the cladding layer was uniformly 50 mm × 50 mm.
2.3. Testing methods
Dye penetrant was employed to detect surface cracks in the cladding layer through color rendering. The cladding layer was cut into specimens measuring 10 mm × 5 mm × 15 mm through using wire cutting. The cross-section was sanded and polished, and then corroded using an aqua regia solution prepared by mixing hydrochloric acid and nitric acid in a 3:1 volume ratio. The microstructure was observed using a Sigma300 scanning electron microscope (SEM), which was equipped with energy dispersive spectroscopy (eds) for localized area analysis.
The hardness of the cladding layer’s cross-section was measured with an HVS-1000Z microhardness tester, applying a load of 200 g and a holding time of 10 seconds. Additionally, the phase composition of the cladding layer was analyzed using a Smart Lab SE diffractometer, with a scanning angle range from 10° to 80°, a step size of 0.05°, and a scanning speed of 14°/min.
3. RESULTS AND DISCUSSION
3.1. Macroscopic morphology of WC/Ni cladded layers with different compositions
The five types of cladding layers were prepared using the optimized process parameters. Surface cracks in the cladding layers were detected using dye penetrant, while cross-sectional porosity was examined through scanning electron microscopy. The results are presented in Figures 1 and 2, respectively.
Surface morphology of different laser cladding layers: (a) Ni15+40 mass% WC; (b) Ni15+20 mass% WC; (c) Ni15+50 mass% WC; (d) Ni60+20 mass% WC; (e) Ni35+20 mass% WC.
Cross section morphology of different laser cladding layers: (a) WC/Ni15; (b) WC/Ni35; (c) WC/Ni60; (d) Ni15+50%.
Comparing the macroscopic morphology of the five-component cladding layers, the surface quality of the Ni15+40% WC and Ni15+20% WC cladding layers (represented by mass fraction) is satisfactory, with no observable cracks. The morphologies are illustrated in Figures 1a and 1b. Cracks were observed in the Ni15+50 mass% WC, Ni35+20 mass% WC, and Ni60+20 mass% WC cladded layers, as shown in Figures 1c, 1d, and 1e. The Ni15+50 mass% WC cladding layer exhibited numerous horizontal and vertical cracks, whereas only a few cracks perpendicular to the cladding direction were present in the Ni60+20 mass% WC cladding layer. For the Ni15+50% WC cladding layer, the higher thermal conductivity of WC compared to Ni results in accelerated cooling of the molten pool, thereby increasing the stress within the molten pool and generating additional cracks.
Through observing the cross-section of the cladding layer in Figure 2, it is revealed that WC does not fully decompose during the cladding process, and it retains a spherical morphology. When the mass fraction of WC is 20%, the cross-sectional morphologies of the WC/Ni15 and WC/Ni35 cladding layers are depicted in Figures 2a and 2b, respectively, both showing the presence of porosity. In contrast, the WC/Ni60 cladding layer exhibits no pores, as illustrated in Figure 2c. This difference can be attributed to the increased content of Si and B elements in the Ni60 powder under the same WC content. Si and B possess strong deoxygenation and slagging abilities, which facilitate their reaction with oxygen and oxides in the molten pool. Consequently, the high levels of Si and B significantly reduce the oxygen content and inclusions within the molten pool, thereby decreasing the formation of pores in the cladding layer [20]. Although no pores are present in the WC/Ni60 cladding layer, cracks still occur under the same conditions due to the increased concentrations of hard particles such as Cr and C. Figure 2d shows the cross-section of the Ni15+50% WC cladding layer, where numerous pores are evident, including some reaching sizes of hundreds of micrometers. The presence of a large quantity of WC results in the decomposition of C, which reacts with O to form CO and CO2. Additionally, the high volume of WC raises the viscosity of liquid Ni, reducing the duration of the molten pool and hindering the escape of generated gases before solidification. Consequently, these gases tend to accumulate in the upper area of the cladding layer, forming larger pores [14].
3.2. Phase analysis of WC/Ni cladded layers with different compositions
Three types of cladded layers, Ni15+20% WC, Ni60+20% WC, and Ni15+50% WC, were selected for XRD analysis, and the results are shown in Figure 3. The main phases in the Ni15+20% WC cladded layer include γ(Fe, Ni), CrSi2, M23C6, M7C3, FeW2B, WC, etc.; the main phases in the Ni60+20% WC cladded layer include γ(Fe, Ni), Ni4B3, Ni17W3, M7C3, Fe3Ni3B, WC, Cr-Ni-Fe-C, etc.; and the main phases in the Ni15+50% WC cladded layer include γ(Fe, Ni), M7C3, Ni4B3, Ni2W4C, W2C, CrSi2, WC, C, etc. These findings indicate that, at a WC mass fraction of 20%, the Ni60-based cladding layer forms more boride phases compared to the WC/Ni15 cladding layer. Additionally, as the WC content in the Ni15-based cladding layer increases from 20% to 50%, there is a notable increase in tungsten-containing compounds, along with the formation of free carbon. This increase in W-rich and C-rich phases in higher WC content cladding layers contributes to the microstructural evolution and mechanical properties observed, underscoring the critical impact of WC concentration on phase composition and overall cladding performance.
XRD patterns of different cladding layers: (a) Ni15+20%WC; (b) Ni60+20% WC; (c) Ni15+50% WC.
3.3. Microstructure of WC/Ni cladded layers with different compositions
When the WC mass fraction is 20%, the microstructure of the WC/Ni15, WC/Ni35, and WC/Ni60 cladding layers is presented in Figures 4 to 6. As observed in these figures, the microstructure becomes denser and finer in the sequence of WC/Ni15, WC/Ni35, and WC/Ni60. Specifically, the microstructures of the WC/Ni15 and WC/Ni35 cladding layers primarily consist of columnar and cellular crystals. In the WC/Ni60 cladding layer, equiaxed and dendritic crystals are observed at the bottom and top, with the growth direction of the columnar crystals at the bottom exhibiting a more pronounced vertical orientation, aligning perpendicularly to the interface along the temperature gradient. This behavior can be attributed to the higher concentrations of Cr, B, Si, and C in the Ni60 powder compared to the Ni15 and Ni35 powders, resulting in an increased number of non-uniform nucleation sites during the melting process. This, in turn, facilitates the formation of more compounds, effectively refining the grain size [21].
Energy spectrum analysis was conducted on regions A to G of the WC/Ni15, WC/Ni35, and WC/Ni60 cladding layers, with results summarized in Table 2. Comparing the energy spectrum results of regions A, B, D, and F reveals that at a WC mass fraction of 20%, the bottom portions of the WC/Ni15, WC/Ni35, and WC/Ni60 cladding layers, regardless of being white or black, predominantly consist of Ni and Fe. Therefore, their microstructure is identified as a γ (Fe, Ni) solid solution, where Cr, B, Si, W, and other elements contribute to solid solution strengthening. Conversely, energy spectrum analysis of regions C, E, and G at the top white regions of the cladding layers indicates a significant increase in W content, accompanied by a decrease in Ni and Fe concentrations. Thus, W-rich compounds primarily reside in the upper sections of the cladding layer. Based on the analysis results from literature [13] and XRD, the main phases in the microstructure are Ni2W4C, M23C6, and others. This phenomenon occurs because, during the molten pool formation, WC decomposes into W and C. During the cooling process, areas with high W content at the top of the cladding layer nucleate and grow, leading to the formation and precipitation of new compounds. As solidification progresses, the partially decomposed WC settles at the bottom due to gravitational effects. Hence, in cladding layers with a WC mass fraction of 20%, W-rich compounds predominantly exist at the top.
EDS analysis results at different positions in 5 types of cladding layers (mass fraction,%).
The microstructure of the WC/Ni15 cladding layer is illustrated in Figures 4, 7, and 8 at WC mass fractions of 20%, 40%, and 50%, respectively. A comparison of these microstructures indicates that as the WC mass fraction increases from 20% to 40% and then to 50%, the cladding layer’s microstructure becomes denser and finer, with dendrites serving as the primary structural component. Based on the macroscopic morphology analysis of the cross-sectional fused cladding layer in Figures 2, it can be observed that as the WC mass fraction increases, the number of unmelted WC particles in the cladding layer also increases. The WC boundaries act as sites for non-uniform nucleation, leading to the formation of rod-like or fine granular structures with a radial distribution. Due to the lower temperature of the residual WC particles in the liquid metal, when the melt near the unmelted WC solidifies, heat is directed towards the residual WC, resulting in localized directional cooling. As a result, most of the microstructure is rod-shaped and grows perpendicular to the WC particle boundaries.
Energy spectrum analyses of regions H and L in the Ni15+40% WC and Ni15+50% WC cladding layers are provided in Table 2. Energy dispersive spectroscopy (eds) analysis of the white phases in the H, I, K, and L regions reveals a high W content. Combined with the XRD analysis results, it is inferred that these phases are likely W-rich compounds formed by the melting and re-precipitation of WC particles [13, 22], such as FeW2B, W2C, and others. Therefore, for high-content WC/Ni15 cladding layers with WC mass fractions of 40% and 50%, the white structures at the upper and lower regions predominantly consist of W-rich compounds, contrasting with the Ni15+20% WC cladding layer. As WC content increases, the viscosity in the molten pool escalates, reducing the sedimentation rate of WC particles. Consequently, in the Ni15+50% WC cladding layer, the WC distribution becomes more uniform, as shown in Figure 2d. This uniform distribution of W-rich compounds, which represent a hard, brittle phase, is susceptible to stress concentration, leading to the formation of pores and cracks [23]. This observation aligns with the findings from the surface morphology analysis. Additionally, the energy spectrum analysis of regions A, D, F, and J in the cladding layers indicates that the black areas are primarily composed of a γ (Fe, Ni) solid solution formed from the Ni-based powder during melting.
3.4. Hardness of WC/Ni cladding layers with different compositions
Figure 9 presents the microhardness measurements of the five types of cladding layers. The data indicate that for the WC/Ni15 cladding layer, microhardness increases with higher WC content, achieving an average value of 1039.5 HV at a WC mass fraction of 50%. This increase can be attributed to the presence of numerous W-rich compounds and a greater variety of carbides, which contribute to the enhanced hardness of the cladding layer.
At a WC mass fraction of 20%, the microhardness values of the cladding layers exhibit a sequential increase from WC/Ni15 to WC/Ni35 and finally to WC/Ni60. This trend is due to the increased content of alloying elements such as Cr, B, and Si in these cladding layers, which facilitates the formation of more amorphous phases. The resulting microhardness is further augmented by the strengthening effects of these alloying elements [24, 25].
Moreover, Figure 9 shows that the microhardness values for the Ni60+20% WC and Ni15+40% WC cladding layers are comparable, with average values of 852.1 HV and 816 HV, respectively. This suggests that while the compositions differ, the mechanical properties achieved are similar under the specific conditions tested, highlighting the complexity of interactions between composition and microstructure in determining the hardness of cladding materials.
4. CONCLUSION
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As the WC content increases in the WC/Ni15 cladding layer, the number of pores and compounds rich in W also increases, leading to enhanced hardness. Notably, when the WC mass fractions are 20% and 40%, the WC/Ni15 cladding layer remains crack-free. However, at a WC mass fraction of 50%, the appearance of cracks and larger pores is observed, accompanied by a dense distribution of W-rich compounds throughout the cladding layer.
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When the WC mass fraction is fixed at 20%, the three types of fused cladding layers—WC/Ni15, WC/Ni35, and WC/Ni60—demonstrate reduced porosity and increased hardness. Additionally, the variety of boride phases increases, with W-rich compounds predominantly located at the top of the fused cladding layer. The Ni15+40% WC cladding layer exhibits no cracking, whereas the WC/Ni60 fused cladding layer develops cracks.
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The primary phases identified in the prepared cladding layers include γ (Fe, Ni), M7C3, WC, and M23C6. In the WC/Ni15 cladding layer, an increase in WC content correlates with a broader range of compounds. Specifically, at a WC mass fraction of 20%, the diversity of boride species present in the WC/Ni15, WC/Ni35, and WC/Ni60 cladding layers increases sequentially..
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The microhardness of the Ni60+20% WC cladding layer is comparable to that of the Ni15+40% WC cladding layer. However, while the Ni15+40% WC layer remains crack-free, the Ni60+20% WC layer exhibits cracking.
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For WC/Ni15 and WC/Ni60 cladding layers with the same WC content, the cracking sensitivity of the WC/Ni15 cladding layer is lower. Therefore, for applications where strict requirements are placed on crack formation in the cladding layer, it is recommended to incorporate a higher content of WC particles into the Ni15 powder. This approach can yield crack-free cladding layers with improved mechanical properties, making them more suitable for industrial applications.
5. ACKNOWLEDGMENTS
This work is supported by the Key Research Project of Natural Science in Universities in Anhui under Grant No. 2022AH051911.
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Publication Dates
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Publication in this collection
21 Mar 2025 -
Date of issue
2025
History
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Received
13 Nov 2024 -
Accepted
13 Feb 2025
