Effect of laser energy density on cracking susceptibility and wear resistance of laser-clad tribaloy T-800 coatings on DD5 single-crystal alloys

In order to enhance the wear resistance of DD5 single-crystal alloys, Tribaloy T-800 wear-resistant coatings were prepared on their surfaces using laser-cladding technology. This study examines the effect of laser energy density on the cracking susceptibility and wear resistance of laser-clad Tribaloy T-800 coatings on DD5 single-crystal alloys. Three distinct laser energy densities (η1=33 J/mm², η2=50 J/mm², η3=60 J/mm²) were applied to create the coatings. The results show that the microstructures of the T-800 laser-clad coatings mainly consist of primary, coarsened, and spheroidized Laves phases, as well as Co-based solid solution and eutectic structures. The phases include Co3Mo2Si phase (Laves phase) and face-centered cubic Co-based solid solution. However, increasing laser energy density enhanced elemental diffusion at the heterogeneous joining interface of the DD5 substrate/T-800 coating, leading to higher Ni content in the coating. This resulted in a reduction in the tendency and content of Mo-rich Laves phase formation respective contents of 53.2 %, 49.2 %, and 47.5 %. Moreover, the decrease in the difference between laser cladding temperature and initial temperature, ∆T, led to reduced thermal stress at the interface, σ, contributing to a decrease in cracking susceptibility (a), with corresponding values of 0.16184, 0.00034, and 0.00022. Thermal expansion coefficients of materials in the cracked region near the interface, measured according to the CALPHAD method, Jmatpro software, and average EDS elemental content data at the crack edge, surpassed those of the corresponding DD5 substrate. Consequently, cracks in the coatings originated from stretching at the interface, with paths tending to cross Laves phase particles in a cleavage mode. The average microhardness of the coatings decreased due to reduced Laves phase content, with values of 783.4 HV0.5, 741.7 HV0.5, and 708.2 HV0.5, respectively, while the fatigue wear of T-800 coatings increased due to exacerbated wear damage from cracking defects. Specifically, average COFs were 0.659, 0.583, and 0.506, with corresponding mass losses of 7.1 mg, 3.4 mg, and 2.9 mg, respectively. The wear mechanisms observed encompassed fatigue wear, abrasive wear, and oxidative wear.