Laser-directed energy deposition of WC/FeCrCo shell-mimetic laminated structure for enhanced wear resistance

: To address the insufficient hardness and wear resistance of FeCrCo alloys, inspired by biological shell architectures, a FeCrCo/WC composite with a shell-mimetic laminated structure was fabricated via laser-directed energy deposition (L-DED). By comparing the WC/FeCrCo shell-mimetic laminated structure and the pure FeCrCo deposit with respect to microstructure, hardness, phase composition, and wear resistance, the influence of WC particle distribution and interlayer interfacial coupling on the tribological performance is investigated. The results show that the WC/FeCrCo shell-mimetic structure exhibits excellent interlayer bonding and a refined microstructure. The average microhardness of the shell-mimetic structure increases by 27.60% compared to that of the pure FeCrCo deposit, which is attributed to grain refinement, the strengthening effect of WC particles, and the formation of carbide phases. Under loads of 90 N, 120 N, and 150 N, the wear amounts of the WC/FeCrCo shell-mimetic laminated structure decrease by 80.77%, 75.56%, and 73.68%, respectively, compared with those of the pure FeCrCo deposit. The enhanced wear resistance could be attributed to the synergistic effects of improved microhardness and the superior load-bearing and load-sharing capabilities of WC particles.