Enhancing Tribological Performance of SS-316 Through Microwave Cladding of NiCr-Cr₃C₂ Composite: Fabrication, Characterization, and Optimization

This study has employed hybrid microwave heating (MH) to fabricate a wear-resistant 25 wt.% (NiCr) + 75 wt.% (Cr₃C₂) composite cladding on SS-316 steel. Operating at 900 W and 2.45 GHz, a microwave oven successfully deposited clads with ~ 0.7-mm thickness. X-ray diffraction (XRD) analysis confirmed the presence of hard carbide and intermetallic phases in the Fe-Ni-Cr matrix. Scanning electron microscopy (SEM) revealed a dense structure with uniformly distributed carbide particles, enhancing microhardness by 3.83 times compared to the substrate. Wear tests on a pin-on-disc tribometer demonstrated superior wear resistance over SS-316, attributed to embedded carbide particles. Integration of response surface methodology (RSM) optimized the process parameters, showing microwave cladding's potential in enhancing wear resistance and advancing surface modification techniques.