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Aluminium Metal Matrix Composite (MMC) is gradually gaining popularity in various engineering applications. This is due to their light weight and favourable physical and chemical properties. Weldability study of them is, therefore, important to facilitate fabrication of components. In this work, autogeneous bead-on-plate TIG welding of Al-7.7%-SiC MMC was performed using Argon as the shielding gas. Heat input and gas flow rate were input variables. Central Composite Design (CCD) of Response Surface Methodology (RSM) was the design of experiment followed in this work. Bead geometry (depth of penetration, height of reinforcement and bead width) and hardness of weld-bead were measured. At a low value of heat input (0.438 kJ/mm) and low value of gas flow rate (10 l/min), lowest height of reinforcement with a value of 0.112 mm is obtained. Both heat input and gas flow rate have effect on bead width. Lowest value of bead width of 4.836 mm may be the recommended one. Considering the variation of bead geometry with the two factors chosen, a high value of gas flow rate (14 l/min) with high heat input (0.702 kJ/mm) may be recommended for adoption that gives high depth of penetration of 2.238 mm. [ABSTRACT FROM AUTHOR]

This study focuses on the investigation of AA2014-SiC MMNCs and their properties, manufactured through a novel stir-ultrasonic-squeeze casting technique. The combination of these three methods gives better dispersion of the SiC nanoparticles as well as lesser porosity of the casting. The weight percentage of SiC added was varied to study the effect of it on the properties. Microstructural analysis was carried out to understand the dispersion of SiC nanoparticles within the aluminium. The addition of SiC nanoparticles significantly improved the tensile strength, yield strength, and hardness up to 5%wt. At 7% wt. of SiC, these properties deteriorated. The tribological properties of the AA2014-SiC MMNCs were studied using a ball-on-plate linear reciprocation type multi-function tribometer. As the hardness of the composite increased with %wt of SiC, the wear rate and coefficient of friction of the composite decreased significantly up to 5 wt% SiC beyond which both the properties again have increased. [ABSTRACT FROM AUTHOR]

A thermal neutron-absorbing metal matrix composite (MMC) comprised of Al3Hf particles in an aluminum matrix was developed to filter out thermal neutrons and create a fast flux environment for material testing in a mixed-spectrum nuclear reactor. Intermetallic Al3Hf particles capture thermal neutrons and are embedded in a highly conductive aluminum matrix that provides conductive cooling of the heat generated due to thermal neutron capture by the hafnium. These Al3Hf-Al MMCs were fabricated using powder metallurgy via hot pressing. The specimens were neutron-irradiated to between 1.12 and 5.38 dpa and temperatures ranging from 286 °C to 400 °C. The post-irradiation examination included microstructure characterization using transmission electron microscopy (TEM) and energy-dispersive X-ray spectroscopy. This study reports the microstructural observations of four irradiated samples and one unirradiated control sample. All the samples showed the presence of oxide at the particle–matrix interface. The irradiated specimens revealed needle-like structures that extended from the surface of the Al3Hf particles into the Al matrix. An automated segmentation tool was implemented based on a YOLO11 computer vision-based approach to identify dislocation lines and loops in TEM images of the irradiated Al-Al3Hf MMCs. This work provides insight into the microstructural stability of Al3Hf-Al MMCs under irradiation, supporting their consideration as a novel neutron absorber that enables advanced spectral tailoring. [ABSTRACT FROM AUTHOR]

This study investigates metal matrix composites fabricated by cold spraying nickel (Ni) as the matrix with two different chromium carbide/nickel chrome (CrC/NiCr) cermet powder formulations as the reinforcement onto A514 steel. The research focuses on understanding the effects of the metallic binder (NiCr) ratio in the cermet particles and the matrix-to-cermet (i.e., Ni-to-CrC/NiCr) ratio in the feedstock blend on the microstructure and mechanical properties of the resulting composites. The microstructure of the as-received powders and the cold-sprayed deposits was analyzed using x-ray diffraction (XRD), scanning electron microscopy (SEM), and energy-dispersive x-ray spectroscopy (EDS) techniques, while the mechanical performance of the deposits was evaluated using microhardness, tensile, and triple-lug shear tests. Results indicate that increasing the binder percentage in the cermet particles enhances deposition efficiency, leading to a higher area fraction of the retained cermet in the final deposit, improved interparticle adhesion, reduced porosity, and superior ductility and shear strength. The study also identifies three distinct crack propagation patterns that explain the variations in fracture behavior among different MMCs and metallic deposits. These patterns are governed by the extent of cracking in the cermet particles and the interparticle bonding strength, which in turn affect the ultimate tensile strength (UTS) of the coatings. [ABSTRACT FROM AUTHOR]

Magnesium-based materials, which are known for their light weight and exceptional strength-to-weight ratio, hold immense promise in the biomedical, automotive, aerospace, and military sectors. However, their inherent limitations, including low wear resistance and poor mechanical properties, have driven the development of magnesium-based metal matrix composites (Mg-MMCs). The pivotal role of powder metallurgy (PM) in fabricating Mg-MMCs was explored, enhancing their mechanical and corrosion resistance characteristics. The mechanical characteristics depend upon the fabrication methodology, composition, processing technique, and reinforcement added to the magnesium. PM is identified as the most efficient due to its ability to produce near-net shape composites with high precision, cost-effectiveness, and minimal waste. Furthermore, PM enables precise control over critical processing parameters, such as compaction pressure, sintering temperature, and particle size, which directly influence the composite's microstructure and properties. This study highlights various reinforcements, mainly carbon nanotubes (CNTs), graphene nanoparticles (GNPs), silicon carbide (SiC), and hydroxyapatite (HAp), and their effects on improving wear, corrosion resistance, and mechanical strength. Among these, CNTs emerge as a standout reinforcement due to their ability to enhance multiple properties when used at optimal weight fractions. Further, this study delves into the interaction between reinforcement types and matrix materials, emphasizing the importance of uniform dispersion in preventing porosity and improving durability. Optimal PM conditions, such as a compaction pressure of 450 MPa, sintering temperatures between 550 and 600 °C, and sintering times of 2 h, are recommended for achieving superior mechanical performance. Emerging trends in reinforcement materials, including nanostructures and bioactive particles, are also discussed, underscoring their potential to widen the application spectrum of Mg-MMCs. [ABSTRACT FROM AUTHOR]

An approach for optimizing the poling conditions of metal matrix piezoelectric composite (MMPC) using a series capacitor model is proposed and its verification is performed. The oxide film formed around the electrodes in MMPC is necessary for insulation between the electrodes and the metal matrix, however, during the poling process, the oxide film deprives the polarizing electric field and prevents polarization of piezoelectric ceramics. Therefore, a method to optimize the polarizing voltage using the thickness and dielectric constant of the oxide film in a series capacitor model with a simplified structure of the MMPC is required. In addition, the validity of the proposed method is investigated by output voltage obtained from fabricated composites that performed the poling process. The results of the optimization show that optimal polarization is not possible with the Ni and Ti oxide films used in this study. However, the results of the polarization treatment of the actual composite material confirmed the validity of the proposed method, as the output voltage improvement is in line with the proposed method. [ABSTRACT FROM AUTHOR]

With the development of industry, gear materials are developing towards ultra-high strength, high wear resistance, high temperature resistance, corrosion resistance and lightweight. The application of composite materials in gears can reduce gear weight, prolong gear life and improve gear transmission efficiency. This study categorized composite gears into three groups based on the type of matrix: polymer matrix composite gears, metal matrix composite gears, and non-metallic matrix composite gears. Subsequently, the research progress of composites for gears was introduced, respectively, common processing methods of composite gears were reviewed, and the failure modes and influencing factors of different matrix materials were discussed. Following this, the influence of various reinforcements on the properties of composite gears was analyzed, and the application scenarios of different composite gears were listed. Furthermore, this review summarized the common processing methods and their strengthening mechanisms of composite gears. Finally, the developmental trend of composites in gears were also discussed. [ABSTRACT FROM AUTHOR]

Nowadays, the use of bimetallic laminates with special capabilities is increasing and has experienced high growth. These properties include high mechanical properties, corrosion resistance, lightweight, and thermal stability. Among the technologies of multilayer composite materials, Accumulative Press Bonding (APB) as a solid-phased method of welding is one of the most common techniques for the production of multilayer composites. One of the most important aims for this choice is the press pressure, which can create a strong and suitable mechanical connection between produced metal layer components. In this study, the APB method has been used to produce bimetal aluminum/copper bulk composites as its novelty for the first time. After that, the effect of pressing parameters such as strain and number of layers on the stress distribution has been investigated. The shear stress among the layers reached 4 MPa for the samples with eight layers which is a good condition to generate a successful bonding. With increasing the thickness reduction ratio, the stress applied to the layers has also increased. As the thickness decreases, the interlayer shear stresses also increase which leads to a better bonding between layers. With increasing the thickness reduction ratio, the amount of layers sinking in each other was greater than before, which led to the crushing of copper layers along the entire length of the sample. During the process, as the number of passes increased, the volume of virgin material in the direction of the press rose, which led to increased compaction and better adhesion of Al and Cu layers to each other. The bonding strength enhances from 47 to 95 N for samples manufactured with one and four cycles of APB due to the increment of virgin metal normal to the pressing direction showing a 102% enhancement. [ABSTRACT FROM AUTHOR]

This study aimed to optimize friction stir processing parameters to enhance the mechanical properties of AA 5083/coal composites, a novel material combination with potential applications in marine environments. By systematically varying process parameters such as tilt angle, traverse speed, and rotational speed using a Taguchi experimental design, the FSP process was optimized. Signal-to-noise ratio and analysis of variance techniques were used to determine the most influential parameters on microhardness and ultimate tensile strength. A regression model was developed to predict composite behavior under these optimal conditions. This study found that a combination of 900 rpm, 60 mm/min, and a 2° tilt angle significantly improved mechanical properties. This research contributes to the advancement of FSP for producing high-performance, lightweight, and corrosion-resistant aluminum composites, particularly for marine applications. [ABSTRACT FROM AUTHOR]

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The reinforcing effect of β-Mg14YNd2 precipitates and SiC whiskers has been evaluated in a WE54-15%(vol.%)SiCw composite using synchrotron radiation diffraction during compression tests from room temperature to 300 °C. The addition of SiC whiskers slightly increases the yield stress compared to an unreinforced WE54 alloy. However, whiskers are not effective in increasing the temperature at which the mechanical strength of the unreinforced WE54 alloy begins to decay. The plastic deformation process is controlled by the magnesium matrix over the entire compression temperature range. On one hand, β-Mg14YNd2 precipitates assume an additional transferred load from the magnesium matrix just after the yield point in both the WE54 alloy and WE54-15%SiCw composite. The magnitude of transferred load becomes smaller as the temperature increases due to the relaxation process around precipitates. On the other hand, the reinforcing effect of SiC whiskers is greater than that of β-Mg14YNd2 precipitates, although its effect also tends to disappear at temperatures equal to or higher than 200 °C. [ABSTRACT FROM AUTHOR]

The present paper focuses on the technological approach to manufacturing composite in the form of Inconel 625 reinforced with tungsten carbide particles. Twenty-four samples with reinforcement amounts ranging from 30 to 90% (wt.%) and different numbers of deposited layers were manufactured with the use of Laser Engineered Net Shaping (LENS®). The metallurgical quality, microstructure, chemical and phase composition as well as hardness of the produced composites were determined. Digital microscopy, X-ray powder diffraction and SEM-EDS were employed for this purpose. Despite numerous cracks, the fabricated samples exhibited a greater hardness than single-layer coatings of analogous composition also produced by additive techniques. This phenomenon is likely a result of repeated crystallization of the composites in remelted areas. A dual mechanism of material strengthening is observed in the additively manufactured composites, both by the presence of reinforcing particles and precipitates of secondary phases.

Abstract This study investigates the erosion behavior of Al–SiC and Al–WC metal-based composites in a solid particle impingement environment developed through powder metallurgy. Micro-sized powders of SiC and WC were utilized in different weight proportions (0–10 wt%) for fabricating the composite samples. The angle of impingements of 30–90° and impact velocity of 30–90 m/s were used for solid particle erosion testing. Microstructure was characterized by XRD, SEM, and EDS. The results of the ANOVA test indicate that impact velocity is the most significant factor, followed by reinforcement content. SiC composite with reinforcement content of 2.5 and 5 wt% showed ductile erosion behavior at lower angles of impingements and brittle behavior at higher angles of impingements. On the other hand, 10 wt% of SiC indicated a semi-ductile erosion behavior. The reinforcement content is 5 and 10 wt % of WC showed a semi-ductile erosion behavior, whereas 2.5 wt% of WC showed a mix of ductile and brittle behavior. At a 30° angle of impingement, SiC (10 wt%) provides the best erosion performance, whereas, at 90° (i.e., at normal), WC (10 wt%) performs better than all other composites. SiC (5 wt %) comes out to be the best performer at 45° of the angle of impingement.

Wire Electrical Discharge Machining (WEDM) to achieve high-quality finishes by minimizing the experimental errors in the application of Metal Matrix Composites, which are often necessary with various manufacturing industries. The Al 6061 composites have been made by the fabrication the alloy through stir casting process. In this work, metallurgical and the effect of machining characteristics of Al alloy, Al 6061, through reinforcing with B4C and Fe2O3 investigated. This work an effort has been made on applying Taguchi and ANOVA methods in order to optimize the outcomes L16 orthogonal array was utilized in this investigation. The third dimension perspective to this composite has been acquired for the input settings, comprising higher composites (wt.%) and current, lower pulse on time (Ton) and pulse off time (Toff), and the output variables, which include material removal rate (MRR), electrode wear rate (EWR), and depth, with the aid of the Signal to Noise (S/N) and the small is preferable. The analysis of these trial results via S/N ratios makes it clear that the minimized pulse on and off and more current found in machining, and lower pulse on and off, optimal results parameters were also reached. [ABSTRACT FROM AUTHOR]

Robust electrochemical sustainability of tailored high‐performance nanocomposites is integral to advanced electrochemical energy conversion and storage (EECS) systems. Functions, such as nanoscale ionic‐diffusion distance, electrocatalytic reactions, electrical conductivity, and fluid distribution, of transition metal dichalcogenide (TMD)‐based nanostructures have been extensively designed and studied. However, challenges in materials selection, operational scalability, and design flexibility of TMD‐incorporated metal‐matrix composites (MMCs) consisting of non‐noble metallic nanostructures and their originating TMD materials have scarcely been studied. Highlighting the effectiveness of emerging additive manufacturing techniques in sustainable energy supply and storage, laser powder bed fusion (L‐PBF) can offer a directly added dual‐functionality to fabricated complex multimaterial and TMD‐incorporated MMC electrocatalytic electrodes. In this review, the characteristics of composite powder feedstock and optimizing process parameters are critically emphasized from another perspective to maintain a balance between mechanical robustness and enhanced electrochemical response. It is demonstrated how factors such as surface roughness, particle shape, and rheological characteristics of TMDs can influence the flowability of composite powder feedstock and the electrochemical performance of L‐PBF‐processed electrodes. The review further aims to contribute compiled information for use in the rapidly growing global market for advanced energy storage systems, underscoring the transformative potential of L‐PBF and TMD‐incorporated MMCs in modernizing the EECS components. [ABSTRACT FROM AUTHOR]

Aluminium-carbon nanotube (Al-CNT) composites have proven to offer a lot of potential for applications involving friction and wear. This study investigated the wear behaviour of Al-CNT composites with uniformly dispersed CNTs without structural damage at concentrations of 0.5 wt%. The wear behaviour of these composites has been compared with that of pure aluminium, which was fabricated using the identical wet shake mixing, compaction, and extrusion procedure. The study aimed to determine how CNT concentration and applied stress influence the wear behaviour of composite materials. Scanning electron microscope (SEM) was used by the researchers to examine the surface features of the worn samples. The study showed a significant increase in hardness and wear resistance with adding CNT. Compared to pure aluminium, the composite containing 0.5 wt. % CNTs demonstrated a 25% reduction in wear rate, and the average value of the coefficient of friction (µ) also decreased. The wear rate and coefficient of friction increased when samples containing 0.5 wt. % CNTs were subjected to various loading scenarios. The major contribution of CNTs to improving wear characteristics was discovered through SEM investigation of these worn surfaces. Using the ANSYS Workbench, a built finite element model was used to perform contact analysis on the disc and pin. Analytical results and experimental data were contrasted, and the ANSYS data was utilised to assess the process parameters. The comparison confirmed the analysis accuracy and dependability, which showed a consistent agreement between the analytical findings and the experimental results. [ABSTRACT FROM AUTHOR]

Metal matrix composites (MMCs) are widely recognized as a dependable solution for fulfilling the requirements of engineering materials, including but not limited to mechanical properties, physical density, and outstanding resistance to wear. Al-alloy based metal matrix composites (AMMCs) have gained significant attention in both the aviation and automobile structural sectors due to their notable advantages in terms of performance, cost-effectiveness, and environmental sustainability. This research study focuses on the application of the Taguchi technique to forecast machining parameters for electrical discharge machining of an aluminum metal matrix composite added with 5 weight fraction of (B4C) and 6wt% of flyash. The L9 orthogonal array was developed in order to optimize the material removal rate (MRR) and surface roughness (RHA) by using the factors such as current, pulse on time, and pulse off time. The anticipated outcome was assessed through the utilization of analysis of variance (ANOVA). [ABSTRACT FROM AUTHOR]

Al–Si-based alloys are widely used in the automobile and aerospace industries, whereas high entropy alloys have emerged with many attractive properties. In this study, AlCoCrFeNi high entropy alloy (HEA) is employed to improve the properties of AlSi10Mg alloy through a metal matrix composite approach. Metal matrix composite powder mixture was sintered at 500°C using a hot press at a pressure of 50 MPa. HEA phase was found to be distributed uniformly. An increase of 20 and 40% in hardness and compressive strength were observed by reinforcing HEA in AlSi10Mg alloy. [ABSTRACT FROM AUTHOR]

The paper examines the microstructural evolution of alloy 1565ch of the Al-Mg-Mn-Zn-Zr system during thermomechanical treatment, including severe plastic deformation by high-pressure torsion or equal channel angular pressing according to the Conform scheme and subsequent isothermal rolling at 200°C. Formation of the nanostructured and ultrafine-grained states in alloy 1565ch with the controlled distribution of the Al3Mg2, Al6Mn and Al3Zr phases both inside grains and at their boundaries allows for the effect of superplasticity at the temperatures 250 and 300°C and strain rates 5 × 10–2, 10–2, and 5 × 10–3 s–1. Microstructural analysis by transmission electron microscopy shows that superplastic deformation at the temperatures 250 and 300°C allows a homogeneous ultrafine-grained state to be preserved. The studied ultrafine-grained aluminum alloy 1565ch has a high strength and the ability to relieve stresses, and therefore it can be favorably used as the matrix material in composites reinforced with continuous boron fibers. In the paper, we use this alloy to study special features of production of a multilayer (foil–fiber–foil) metal matrix composite by isothermal pressing under low-temperature superplastic conditions. This method has a positive effect on the mechanical properties of the composite, such as ultimate strength at 200°C, impact strength at room temperature, and fracture toughness at room temperature. [ABSTRACT FROM AUTHOR]

Laser melt injection (LMI) provides a new route for fabricating multi-material components with tailored physical performance and distributed functional properties. However, the widespread industrial adoption of metal matrix composite (MMC) fabricated by LMI is still hampered by repeatability and reliability compared to monolithic alloys. This study presents promising results that aim to bridge the knowledge gap by determining a novel method to correlate visual and infrared images with the quality of MMC. A CNN architecture-based hybrid fusion model integrating molten pool and spatter features is proposed based on process understanding for quality monitoring of MMCs fabricated by LMI. The laser energy density and powder feed rate are intentionally tuned to fabricate WC reinforced MMC with four different ceramic particle states. Five models are established based on the single-sensor data, data-level fusion, feature-level fusion, and multi-level hybrid fusion respectively and compared in quality identification performance by four quantitative metrics and two visualization models. The results show that the three multi-sensor fusion models can significantly improve the classification accuracy compared to the single sensor-based model. Compared with data-level fusion and feature-level fusion, the proposed multi-level hybrid fusion model can integrate the advantages of the two fusion models and exhibits the best classification performance by multiple feature extraction channels with complementary and redundant data. The InceptionV3-based hybrid fusion model achieves the highest overall accuracy of 97.44% among the four state-of-the-art CNN architectures. [ABSTRACT FROM AUTHOR]

Use of metal matrix composites (MMCs) in automobile and aerospace industries is increasing predominantly since the last few decades, because of their logical amalgamation of properties, principally high strength and low weight. Though selection of matrix and reinforcements are the primary decisive factors of composite properties, the effect of fabrication method on its properties cannot be ignored. Accordingly, this paper accentuates a comprehensive review on different fabrication methods of MMCs as adopted by researchers in open literature. Outcome of the study revealed existence of three broad categories of composite fabrication methods, i.e. liquid state processing, semi-solid processing and solid state processing. However, many researchers have modified these methods suitably to achieve uniformity in reinforcement dispersion and enhanced properties. A case study on squeeze casting route to fabricate and investigate the microstructure and properties of Al 7075 base alloy and nano-TiB2 reinforced Al 7075 MMC is also emphasised in this paper. Results of the case study implied that the fabricated MMC was with very low porosity content (0.106%), near uniform distribution of reinforcements along with some segregated TiB2 regions in its microstructure. The MMC possessed higher mechanical properties (microhardness, tensile strength and compressive strength) than those of the base matrix alloy. [ABSTRACT FROM AUTHOR]

Aluminum alloys have advanced to meet the growing demand for strong, lightweight materials. The 2219 aluminum alloy has gained popularity due to its superior mechanical properties and high copper content. However, despite these improvements, the wear characteristics of metal matrix composites with ceramic reinforcements have been suboptimal. This study aims to develop metal matrix composites that improve the mechanical and wear properties of AA2219 aluminum alloy. A homogeneous mixture was created using a 3D mechanical mixer/miller apparatus. ZrO2 and B4C reinforcements were added to the matrix in ratios of 5%, 10%, and 15%, including hybrid composites with both reinforcements. Mechanical and wear characteristics were analyzed, and a 3D profilometer was used to evaluate wear properties and determine tribological parameters. The results showed that the pulverized reinforcement particles were uniformly dispersed within the matrix. The sample with a hybrid reinforcement comprising 15% of the total composition exhibited the highest hardness, measuring 164.96 hV. This study demonstrates that incorporating ceramic reinforcements in specific ratios can significantly enhance the mechanical and wear properties of 2219 aluminum alloy composites. [ABSTRACT FROM AUTHOR]

The primary purpose of this study is to gain a deeper understanding of the structure and mechanics of an ex-situ A356/Cu-coated with different weight percentages (x: 1, 3) of SiC stir-cast metal matrix composite. This study aims to improve silicon carbide's wetting and adhesion characteristics by fabricating a Cu-coated composite utilizing an electrolytic deposition technique based on aluminum. This green manufacturing method significantly reduces environmental impact compared to traditional coating processes, a crucial aspect in today's world. Examination of the optical microstructure of the SiC composite revealed a clustering of reinforcements within the matrix, potentially resulting from additional barriers formed during the stirring process that impede the movement of SiC particles. Furthermore, incorporating copper-coated SiC reinforcement led to a more even distribution of reinforcements in the matrix. The ultimate tensile strength, yield strength, and hardness of the 3 wt% copper-coated metal matrix composite cast are 225.97 MPa, 130.27 MPa, and 76.5 BHN, respectively, demonstrating superior mechanical properties compared to the other cast composites. The study opens potential paths for further advancements in composite technology. [ABSTRACT FROM AUTHOR]

With regard to an inherent understanding of electrical conductivity exhibited by monolithic metals and alloys system and metal matrix composite system under alternating current field, a long-standing unresolved issue, an analytical model is developed following classical free electron theory along with a typical conceptualisation of 'effective relaxation time' that combines conventional relaxation time (in view of collision of free electrons with lattice defects) and the time between successive cyclic reversals of electric field (the inverse of frequency). Two prime phenomena (electron scattering and polarisation at particle–matrix interface) are further conceived for metal matrix composite system containing particles. The developed model is found to closely follow (% deviation << 10) the available experimental result in the literature on A.C. electrical conductivity of 6063Al alloy and 6063Al–TiO2 composite systems. The model further ascertains certain system-specific parameters; such as, relaxation time under A.C. field, effective scattering factor and effective relaxation time aid from interface polarisation to specify the system behaviour under alternating current field. Accordingly, the model adequately explains the declining trend of A.C. electrical conductivity with increasing frequency in monolithic alloy system and an enhancement of A.C. electrical conductivity in metal matrix composite system in the presence of particles together with a non-declining trend even on increasing frequency. [ABSTRACT FROM AUTHOR]

This study used statistical tools to optimise WC/Co/Ni welds and model construction to improve the mechanical properties of coatings by laser cladding. The effect of the parameters on the wear performance of the weld was determined by analysis of variance. In addition, a polynomial model was constructed using the response surface method based on the experimental data of the orthogonal array designed by Taguchi. The experimental results show that there are white initial precipitation carbides and grey areas of WC mixed with Co and Ni compounds, while less wear and less plastic deformation are observed with WC/Co/Ni alloys. By adding Co/Ni alloys, the composite coating extension is seen to have good anti-wear performance. Based on the regression model, a pairwise interaction model was successfully constructed and further modelling of the 3D contour of the wear behaviour was explored. Comparing all the experiments, the predictions of the interaction model were found to be reliable, with an average error of 8.75%. The findings show that there is a very close match between the predicted values of RSM for wear performance and the experimental data, which proves the effectiveness of the Taguchi design-based RSM in improving the mechanical properties of laser cladding. [ABSTRACT FROM AUTHOR]