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<p>Thermal-sprayed coatings frequently exhibit inherent defects, including porosity, microcracks, and weak mechanical bonding, which deteriorate their overall quality. Laser remelting offers an effective means to refine the microstructure of these coatings and results in limiting these defects. In this regard, the current study investigates the effect of laser remelting (LR) at 300&#xa0;W and 500&#xa0;W on the microstructure, mechanical properties, and tribological performance of HVOF-sprayed WC-NiCr coatings. Laser remelting significantly refined the coating microstructure, reducing porosity and enhancing phase stability. The microhardness increased by 8% (LM1, 300&#xa0;W) and 19% (LM2, 500&#xa0;W) due to improved WC precipitation and the formation of secondary oxides. Tribological tests demonstrated a 27% reduction in the coefficient of friction (COF) and a 19% decrease in wear rate for LM2, attributed to the formation of protective tribolayers, including WO<sub>3</sub> and NiWO<sub>4</sub>. Additionally, surface roughness (Sa) was reduced by 39%, contributing to smoother wear tracks and lower material loss. These findings highlight laser remelting as an effective post-processing technique to enhance the wear resistance, surface integrity, and mechanical robustness of HVOF-sprayed WC-NiCr coatings. The improved tribological performance suggests that laser-remelted coatings can serve as a sustainable and high-performance alternative to cobalt-based coatings, particularly for applications in aerospace, mining, and energy sectors, where extreme wear conditions prevail.</p> Graphical Abstract <p></p>

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Advancing Wear Resistance of HVOF-Sprayed WC-NiCr Coatings Through Laser Remelting

  • 期刊论文

  • 发表日期：

    2026年3月7日

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  • Navneet K. Singh,
  • S. V. V. N. Siva Rao,
  • Vijay Kumar,
  • Gidla Vinay,
  • Harpreet Singh,
  • Partha Pratim Bandyopadhyay

摘要

Thermal-sprayed coatings frequently exhibit inherent defects, including porosity, microcracks, and weak mechanical bonding, which deteriorate their overall quality. Laser remelting offers an effective means to refine the microstructure of these coatings and results in limiting these defects. In this regard, the current study investigates the effect of laser remelting (LR) at 300 W and 500 W on the microstructure, mechanical properties, and tribological performance of HVOF-sprayed WC-NiCr coatings. Laser remelting significantly refined the coating microstructure, reducing porosity and enhancing phase stability. The microhardness increased by 8% (LM1, 300 W) and 19% (LM2, 500 W) due to improved WC precipitation and the formation of secondary oxides. Tribological tests demonstrated a 27% reduction in the coefficient of friction (COF) and a 19% decrease in wear rate for LM2, attributed to the formation of protective tribolayers, including WO3 and NiWO4. Additionally, surface roughness (Sa) was reduced by 39%, contributing to smoother wear tracks and lower material loss. These findings highlight laser remelting as an effective post-processing technique to enhance the wear resistance, surface integrity, and mechanical robustness of HVOF-sprayed WC-NiCr coatings. The improved tribological performance suggests that laser-remelted coatings can serve as a sustainable and high-performance alternative to cobalt-based coatings, particularly for applications in aerospace, mining, and energy sectors, where extreme wear conditions prevail.

Graphical Abstract