Effect of in Situ NbC Synthesis Via Laser Cladding on Microstructure and Slurry Erosion of Carbide-Reinforced Iron-Based Coatings

T. Wang, M. S. Wang, Z. Y. Wang,T. Z. Xu,C. L. Wu,C. H. Zhang, S. Zhang,H. T. Chen

MATERIALS TODAY COMMUNICATIONS（2025）

Shenyang Univ Technol | Chinese Acad Sci | Wuzhou Univ | Shenyang Dalu Laser Technol CO LTD

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Abstract

Slurry erosion is a significant cause of overflow components failure. To enhance the slurry erosion resistance of 0Cr13Ni4Mo martensitic stainless steel used in overcurrent components, this paper employs laser fusion cladding technology to apply carbide-reinforced iron-based composite coatings on its surface. The study examines the microstructure, microhardness, and slurry erosion behavior of these coatings. The findings reveal a robust metallurgical bond between the fusion cladding layer and the substrate. The inclusion of Nb effectively prevents porosity and defects. Thermodynamic theory confirms the formation of NbC in the coating, which acts as a heterogeneous nucleation point during solidification, promoting grain refinement. Additionally, the Nb element facilitates the solid solution of Cr in the fusion cladding layer, enhancing solid solution strengthening. The microhardness of the 9Nb coating increased to 650 +/- 7.2 HV, largely due to the strengthening effect of the in situ synthesized NbC. NbC also fosters the development of small-angle grain boundaries and geometrically necessary dislocations, with the proportion of small-angle grain boundaries in the 9 Nb coating reaching 83.72 % and the rho GND reaching 3.054 x 1016 m-2 The combined effects of fine-grain strengthening, solid-solution strengthening, second-phase strengthening, and dislocation strengthening mechanisms result in improved microhardness and slurry erosion resistance. In a 200-hour slurry erosion test, the weight loss of the 9 Nb coating was minimized to 0.22 +/- 0.02 mg, representing a reduction of 148 % compared to the substrate and 41 % compared to the 0 Nb coating, demonstrating exceptional slurry erosion resistance. The addition of Nb increases the volume fraction of carbides in the coating, which enhances the "protrusion effect" of these carbides and thereby significantly reduces weight loss due to slurry erosion. Furthermore, while the substrate primarily exhibits ductile fracture under erosion, the two coatings display a damage mode that combines both brittleness and ductility.

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Key words

Laser cladding,Fe-based composite cladding,NbC,Slurry Erosion,In-situ reaction

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