Optimization of defects and high temperature corrosion resistance of laser cladding FeCrAl coatings: Influence of process parameters

To enhance the surface quality and high-temperature corrosion resistance of FeCrAl coatings further, a laser cladding technique was employed to deposit Fe-13Cr-7Al coatings on the surface of 12Cr1MoV heat-resistant steel. The study investigated the influence of laser power, scanning speed, and powder feed rate on the quality and high-temperature corrosion resistance of the Fe-13Cr-7Al coatings. Utilizing 25 orthogonal experiments, coatings were prepared and evaluated through high-temperature corrosion tests to explore the corrosion resistance and mechanisms microstructural analysis of the coatings, including their elemental distribution and corrosion mechanisms, was conducted using optical microscopy (OM), X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS). The optimal parameter combinations for laser cladding coatings were discussed. The results indicated that the coating quality was optimal within specific ranges of parameters (laser power 1875–2250 W, scanning speed 33–44 mm/s, powder feed rate 12–18 g/min); deviations outside these ranges led to issues such as incomplete coverage or coating detachment from the substrate. The structure of the laser cladded Fe-13Cr-7Al coatings consisted of columnar grains and α-Fe phase. In high-temperature corrosion testing, the coatings exhibited superior corrosion resistance compared to the substrate, with nearly twice the corrosion resistance variation observed under different process parameters. This study provides a scientific basis for optimizing laser cladding process parameters of Fe-13Cr-7Al coatings, demonstrating that precise control of process parameters significantly enhances the high-temperature corrosion resistance of coatings, thereby opening new possibilities for improving material performance in high-temperature applications.