Experimental analysis of laser cladded Ni-WC coating on SS410

Purpose This study aims to estimate the effect of laser cladding process parameters on the clad geometry, microstructure, microhardness and wear characteristics of Ni-WC coatings deposited on SS410. Design/methodology/approach The clad powder is a combination of Ni-alloy and fused WC with corresponding ratio of 40 Wt.% and 60 Wt.% respectively. The process parameters are laser power (2400–3000 W), scanning speed (15–25 mm/s) and powder feed rate (40–50 g/min). A total of nine samples were prepared according to Taguchi L9 orthogonal array. The analysis of the coatings was performed using optical microscope, SEM, EDS, Vickers microhardness test and dry sliding wear tests, while statistical analysis was conducted using ANOVA, signal-to-noise ratios and multiple linear regression models. Findings Statistical analysis showed that laser power and powder feed rate have significant effect on the responses as compared to scanning speed, with laser power contributing up to 61.18% for clad width, 53.61% for dilution ratio and powder feed rate contributing up to 49.78% for wear volume, whereas scanning speed showed a comparatively smaller effect. The coating demonstrated superior microhardness compared to the substrate (259.2 HV0.5) with a maximum microhardness of 1150.6 HV0.5 obtained at 2400 W laser power, 15 mm/s scanning speed and 40 g/min powder feed rate. A minimum wear volume of 0.42 mm3 was obtained under the same condition, that relates to lower dilution (13.41%) and good WC retention. Abrasive wear was the main wear mechanism identified under optimal conditions. Originality/value The research work presents a detailed statistical and experimental analysis of laser-cladded Ni-WC coatings with a fixed 40/60 Wt.% composition on SS410 steel, giving quantitative relationships between process parameters and responses and an optimized range of process parameters for obtaining enhanced wear resistance. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2025-0266/