Characterization of High-Speed Laser-Clad coatings - IN625 on cast irons

Abstract

Extreme high-speed laser cladding (EHLA) is an innovative coating method for depositing metal powders onto metallic substrates to enhance corrosion resistance. This study investigates the corrosion resistance and cladability of three nickel-based Alloy 625 powders (0–5 wt.% Fe) deposited on cast iron using EHLA. Corrosion resistance was evaluated through three batches of salt spray tests, while clad quality was assessed using Alicona imaging to analyze dilution, heat-affected zone (HAZ), and penetration depth. Results revealed that enhancing the quality of the powder feedstock significantly reduces hot cracks and dilution. Furthermore, optimizing process parameters such as laser power, rotational speed, and powder feed rate is crucial for achieving high-performance claddings, as these factors directly influence thermal gradients, cooling rates, and material deposition, which in turn determine the homogeneity and overall quality of the cladding. These findings emphasize the importance of precision in feedstock selection and process control to meet industrial demands for durable, corrosion-resistant claddings.