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The initial melting quality of a high-speed laser cladding layer has an important impact on its post-treatment and practical application. In this study, based on the repair of hydraulic support columns of coal mining machines, the influence of high-speed laser cladding process parameters on the quality of Fe-Cr-Ni alloy coatings was investigated to realize the accurate prediction of coating quality. The Taguchi orthogonal method was used to design the L25(56) test. The prediction models of the relationship between the cladding process and the coating quality were established using the Random Forest (RF) and AdaBoost (Adaptive Boosting, AB) algorithms, respectively. Then, the prediction accuracy of the two models was compared, and the process parameter features were screened for importance evaluation. The results show that the AB prediction model is more accurate than the RF prediction model and more sensitive to abnormal data. The importance evaluation based on the AdaBoost model shows that the scanning speed has a great influence on the height and surface roughness of the coating. On the other hand, the overlap rate is the most important factor in controlling the dilution ratio and near-surface grain size of high-speed laser melting coatings. In addition, the micro-hardness of the coating and the thermal effect of the substrate can be effectively enhanced by adjusting the laser power and scanning speed. Finally, it was verified that the AB prediction model could accurately estimate the quality indexes of the coating with a prediction error less than 6%. The results show that it is feasible to predict the quality of high-speed laser cladding with the AB algorithm. It provides a basis for the adjustment of process parameters in the subsequent quality control process of cladding. [ABSTRACT FROM AUTHOR]

Ultra-high-speed laser cladding (UHSLC) not only offers an efficient solution to the limitations of conventional laser cladding but also aligns with the contemporary objectives of material conservation and efficiency enhancement in metal protective coatings. This study investigates the fabrication of CrFeCoNiMo 0.2 high-entropy alloy (HEA) coatings using UHSLC and traditional laser cladding (TLC) methods. Key aspects such as macroscopic forming quality, element distribution, dilution rate, grain morphology, hardness, and electrochemical corrosion properties of both UHSLC and TLC coatings are thoroughly examined. Notably, UHSLC-produced coatings, with their significantly reduced thickness ranging from 100 to 300 μm, demonstrate an impressively low substrate dilution rate compared to the 2–3 mm thickness of TLC coatings. The rapid solidification inherent in UHSLC leads to smaller grain sizes in the coating, resulting in enhanced hardness. Moreover, the UHSLC coating exhibits superior corrosion resistance, characterized by a lower maintaining-passivity current density in 1 mol/L H 2 SO 4 and a higher self-corrosion potential relative to TLC coatings. This work presents a novel approach, employing high-efficiency and low-cost laser-cladding technology, to minimize dilution in the matrix and improve the coating properties of HEAs. • There are no macroscopic and microscopic defects in HEAs prepared by UHSLC. • Uniform distribution of elements in ultra-thin coating of CrFeCoNiMo 0.2 HEA. • The CrFeCoNiMo 0.2 HEA nanocrystalline coating was synthesized by UHSLC. • Nanocrystalline CrFeCoNiMo 0.2 HEA coating exhibit excellent corrosion resistance. [ABSTRACT FROM AUTHOR]

Solid-solution agglomerated ZrO 2 -based powders co-doped with Gd 2 O 3 , Yb 2 O 3 and Y 2 O 3 rare earth oxides were synthesized by solid-phase sintering and spray drying. The corresponding GYYZO coating was prepared by using atmospheric plasma spraying, while the 8YSZ coating was also prepared as a control group for the high temperature performance investigation. The high temperature structure and phase stability as well as the sintering resistance of both coatings were investigated by SEM, XRD, DSC, EPMA and TEM observations. The results showed that the 8YSZ coating began to undergo a phase transition of tetragonal (t) phase to monoclinic (m) after 50 h heat treatment at 1400 °C, while the GYYZO coating remained free of phase transition even heat-treated for up to 200 h, demonstrating a better phase stability. In addition, as an indicator of sintering resistance of the coating, the porosity of the 8YSZ coating decreased up to 90.1 % after 200 h heat treatment, while that of the GYYZO coating decreased only 20.6 %. The superior high temperature performance of GYYZO coating can be explained by the pinning effect of nano-pores on grain boundaries. The formation of nano-pores was associated with the evolution of defect clusters in the coating, which were facilitated by the substitution defects and oxygen vacancies created by the Gd Yb co-doping. During the heating process, these clusters migrated along with the grain boundaries and formed pearl-string-like nano-pores at the grain boundaries. The eventual formation of nanopores not only further inhibits grain boundary migration to reduce sintering, but also prevents the segregation of Y elements to hinder t-phase to m-phase transition. • GYYZO coating has excellent phase stability and sintering resistance at high temperature. • The nanopores of GYYZO coating have pinning effect on grain boundaries. • The pinning effect of nanopores can inhibit grain boundaries migration and Y elements segregation. [ABSTRACT FROM AUTHOR]

The AlCoCrFeNi high-entropy alloy coatings were prepared by laser cladding (LC) and reprocessed by laser remelting (LR). Laser remelting caused cracks on the coating surface, but the cracks of boronized laser remelting (LR-B) coating were significantly suppressed. Compared to the LR coating, the microhardness of the LR-B coating increased from 643 HV to 1008 HV, the friction coefficient decreased from 0.55 to 0.45, and the self-corrosion potential increased by 134 mV. The crack elimination contributed to the transition of 25% of the BCC phase to the FCC phase. The property enhancement was mainly due to the fine grain strengthening, dislocation strengthening, and Cr 2 B reinforced particles as reinforced phase. [Display omitted] • A trace amount of boron was doped in the protective gas during laser remelting. • The cracks of the boronized laser remelting (LR-B) coating were significantly suppressed. • With the addition of boron, the FCC phase and Cr 2 B were formed. • The Cr 2 B second-phase strengthening increased microhardness and wear resistance. • The Cr 2 B particles in the LR-B coating resulted in excellent corrosion resistance. To avoid cracking of the AlCoCrFeNi high-entropy alloy (HEA) coating during laser remelting (LR), a trace amount of boron (B) was doped in the protective gas. Compared to the LR coating, the cracks of the boronized laser remelting (LR-B) coating were significantly suppressed, the microhardness increased from 643 HV to 1008 HV, the friction coefficient decreased from 0.55 to 0.45, and the self-corrosion potential increased by 134 mV. The crack elimination mainly contributed to the transition of 25 % of the BCC phase to the FCC phase, and the property enhancement was due to the fine grain strengthening, dislocation strengthening, and Cr 2 B reinforced particles generation. This novel finding can be applied to other BCC structure HEA coatings for macroscopic crack control and optimization of wear and corrosion resistances. [ABSTRACT FROM AUTHOR]