Investigation of laser cladding using Inconel 625-Enhanced Fe-Based Coatings: Microstructure, wear Behavior, and corrosion resistance properties

To improve the surface quality, corrosion resistance, and wear resistance of ductile iron (DI), laser cladding technology was utilized to deposit Fe-based alloy with varying amounts of Inconel 625 (0 wt% 15 wt% and 30 wt %) onto DI substrates. This study aimed to achieve an optimal balance between cost-efficiency and performance. The coatings were fabricated using a six-pass, three-layer laser cladding process and systematically evaluated through electrochemical corrosion tests, hardness measurements, and wear resistance assessments. Advanced microstructural analyses, including elemental distribution and phase characterization, were performed employing optical microscopy (OM), X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS). Results revealed that adding an appropriate amount of Inconel 625 effectively eliminated interfacial whitening. The Fe-based coating with 30%wt Inconel 625 exhibited superior corrosion resistance and a hardness of 304 HV, approximately 1.7 times higher than that of the substrate. Furthermore, the wear mechanism transitioned from abrasive wear to adhesive wear with the incorporation of Inconel 625. This study provides a scientific foundation for optimizing the surface quality of Fe-Inconel625 coatings via laser cladding, highlighting promising advancements in material properties for corrosion and wear resistant applications.