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ABSTRACT
It has been established that laser cladding technique is useful for enhancing surface performances, hence extending the life of many components in severe corrosive-wear environments. However, a comparative study of the surface performances of laser coatings made via powder and wire feeding systems has not been performed. Inconel 625 powder and wire were deposited on the AISI 304 substrate using similar processing parameters. The microstructure, together with the depth of substrate penetration and the degree of dilution of the deposited tracks, was examined using an optical microscope and a scanning electron microscope (equipped with an energy-dispersive spectrometer). The micro-hardness was measured using a Vickers hardness tester. At optimized parameters, laser tracks of Inconel 625 wire and powder had a strong metallurgical bond at the track–substrate interface and no crack and pore were deposited. Due to the higher laser beam infiltration and a larger depth of substrate penetration, higher substrate dilution was observed in the powder-fed tracks. The tracks comprise continuous ϒ-matrix and secondary compounds (rich in Nb and Mb). However, finer dendritic microstructure and higher number density of inter-dendritic precipitates were observed in a typical powder laser track compared with the corresponding wire laser track. The typical powder laser track demonstrated higher hardness (245 HV0.3) compared with the corresponding wire laser track (224 HV0.3).