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<p>Laser cladding (LC) is an effective surface-engineering technique for depositing protective coatings to enhance component performance and service life. Owing to the LC process complexity and resultant variability, advanced optimization is required for consistent coating properties. This study applies a hybrid optimization framework Criteria Importance through Inter-Criteria Correlation (CRITIC) combined with Grey Relational Analysis to select optimal laser power, scanning speed, and powder feed rate (PFR) for depositing FeCoCrNiMo high-entropy alloy (HEA) on EN24 steel. Responses considered were clad width, clad height, dilution percentage, heat-affected zone (HAZ), and hardness. Optimal settings (1530&#xa0;W, 2.8&#xa0;mm/s, 13.19&#xa0;g/min) produced improved hardness, dilution ratio, increased clad height/width, and substantial HAZ reduction. Mechanical testing and EDS mapping confirmed a uniform columnar dendritic clad with effective metallurgical bonding. XRD revealed retention of a dominant FCC matrix alongside noticeable σ- and µ-phase formation under multi-track cladding, enhancing hardness and wear resistance while preserving toughness. Results demonstrate that FeCoCrNiMo HEA, when deposited under optimized LC parameters, offers a robust thermo-mechanical and wear-resistant coating solution suitable for high-temperature applications.</p>

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Experimental investigation and Multi-response optimization of single and Multi-track laser cladding attributes for FeCoCrNiMo high entropy alloy

  • 期刊论文

  • 发表日期：

    2026年2月27日

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  • Vikas Diwakar,
  • Mohd Zaheer Khan Yusufzai,
  • Meghanshu Vashista

摘要

Laser cladding (LC) is an effective surface-engineering technique for depositing protective coatings to enhance component performance and service life. Owing to the LC process complexity and resultant variability, advanced optimization is required for consistent coating properties. This study applies a hybrid optimization framework Criteria Importance through Inter-Criteria Correlation (CRITIC) combined with Grey Relational Analysis to select optimal laser power, scanning speed, and powder feed rate (PFR) for depositing FeCoCrNiMo high-entropy alloy (HEA) on EN24 steel. Responses considered were clad width, clad height, dilution percentage, heat-affected zone (HAZ), and hardness. Optimal settings (1530 W, 2.8 mm/s, 13.19 g/min) produced improved hardness, dilution ratio, increased clad height/width, and substantial HAZ reduction. Mechanical testing and EDS mapping confirmed a uniform columnar dendritic clad with effective metallurgical bonding. XRD revealed retention of a dominant FCC matrix alongside noticeable σ- and µ-phase formation under multi-track cladding, enhancing hardness and wear resistance while preserving toughness. Results demonstrate that FeCoCrNiMo HEA, when deposited under optimized LC parameters, offers a robust thermo-mechanical and wear-resistant coating solution suitable for high-temperature applications.