Mechanical, Metallurgical, and Cavitation–Corrosion Analysis of WC-NiCrBSi Cermet Coating Developed Via. Laser Cladding

The current research study underscores the potential of WC-Colmonoy-6 coatings for applications in marine, aerospace, and energy sectors, where enhanced resistance to synergistic cavitation and corrosion damage is critical. The study involves the investigation of mechanical, metallurgical, and cavitation-corrosion behavior of tungsten carbide (WC) and Colmonoy-6 based cladding developed via laser cladding on SS410 steel substrates. The developed clad exhibited a dense microstructure with minimal porosity and a uniform distribution of WC particles, as verified through FESEM, EDS, and XRD. Cavitation erosion testing revealed a significant reduction in mass loss for the cladded samples, with a 45% lower mass loss (9.29 mg) compared to the uncladded substrate (16.95 mg) under the most aggressive conditions. Salt spray testing confirmed enhanced corrosion-erosion resistance, with the laser cladded coatings showing a 28% reduction in cumulative mass loss after 168 hours exposure in 3.5% NaCl environment. Wettability analysis further demonstrated improved water contact angle by approximately 50%, reducing water retention and the risk of corrosion. Further, artificial neural network (ANN) modeling accurately predicted cavitation erosion performance, highlighting the cladded coatings' consistent behavior. Overall, the findings provide a comprehensive understanding of the optimized process parameters and microstructural attributes contributing to superior coating performance.