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<p>Fe-based amorphous coatings are widely used in petrochemical, mining, and power generation industries due to their excellent wear and corrosion resistance derived from the unique amorphous structure. Therefore, wide-beam laser cladding was employed to investigate the role of powder feed rate on microstructure and wear performance. The coatings exhibited amorphous–crystalline composite structure, with the amorphous phase content increasing then decreasing as the feed rate increased, peaking at about 72% at 0.8&#xa0;rpm (3.2&#xa0;g/min). This condition produced a gradient microstructure with a uniform interfacial layer and finely dispersed hard particles, achieving a peak hardness of 928.7&#xa0;HV<sub>0.2</sub> and a specific wear rate of 6.26 × 10<sup>−7</sup>&#xa0;mm<sup>3</sup>/N·m by forming a protective oxide tribolayer. Lower or higher feed rates instead led to coarse crystalline growth or defects, triggering severe abrasive or brittle wear. The wear resistance arises from a synergistic strengthening–toughening mechanism: The hard amorphous matrix and dispersed crystalline phases support a stable protective tribolayer during sliding.</p>

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Microstructural Evolution and Tribological Performance of Fe-Based Amorphous Coatings via Wide-Beam Laser Cladding: Role of Powder Feed Rate

  • 期刊论文

  • 发表日期：

    2026年8月2日

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  • Yiqi Wang,
  • Zequn Zhang,
  • Zeyang Zhang,
  • Xingmei Zhang,
  • Qun Zhang

摘要

Fe-based amorphous coatings are widely used in petrochemical, mining, and power generation industries due to their excellent wear and corrosion resistance derived from the unique amorphous structure. Therefore, wide-beam laser cladding was employed to investigate the role of powder feed rate on microstructure and wear performance. The coatings exhibited amorphous–crystalline composite structure, with the amorphous phase content increasing then decreasing as the feed rate increased, peaking at about 72% at 0.8 rpm (3.2 g/min). This condition produced a gradient microstructure with a uniform interfacial layer and finely dispersed hard particles, achieving a peak hardness of 928.7 HV0.2 and a specific wear rate of 6.26 × 10−7 mm3/N·m by forming a protective oxide tribolayer. Lower or higher feed rates instead led to coarse crystalline growth or defects, triggering severe abrasive or brittle wear. The wear resistance arises from a synergistic strengthening–toughening mechanism: The hard amorphous matrix and dispersed crystalline phases support a stable protective tribolayer during sliding.