A1 Refereed original research article in a scientific journal
Advancing Wear Resistance of HVOF-Sprayed WC-NiCr Coatings Through Laser Remelting
Authors: Singh, Navneet K.; Siva Rao, S. V. V. N.; Kumar, Vijay; Vinay, Gidla; Singh, Harpreet; Bandyopadhyay, Partha Pratim
Publisher: Springer Nature
Publication year: 2026
Journal: Journal of Thermal Spray Technology
Volume: 35
First page : 1365
Last page: 1383
ISSN: 1059-9630
eISSN: 1544-1016
DOI: https://doi.org/10.1007/s11666-026-02190-w
Publication's open availability at the time of reporting: No Open Access
Publication channel's open availability : Partially Open Access publication channel
Web address : https://doi.org/10.1007/s11666-026-02190-w
Thermal-sprayed coatings frequently exhibit inherent defects, including porosity, microcracks, and weak mechanical bonding, which deteriorate their overall quality. Laser remelting offers an effective means to refine the microstructure of these coatings and results in limiting these defects. In this regard, the current study investigates the effect of laser remelting (LR) at 300 W and 500 W on the microstructure, mechanical properties, and tribological performance of HVOF-sprayed WC-NiCr coatings. Laser remelting significantly refined the coating microstructure, reducing porosity and enhancing phase stability. The microhardness increased by 8% (LM1, 300 W) and 19% (LM2, 500 W) due to improved WC precipitation and the formation of secondary oxides. Tribological tests demonstrated a 27% reduction in the coefficient of friction (COF) and a 19% decrease in wear rate for LM2, attributed to the formation of protective tribolayers, including WO3 and NiWO4. Additionally, surface roughness (Sa) was reduced by 39%, contributing to smoother wear tracks and lower material loss. These findings highlight laser remelting as an effective post-processing technique to enhance the wear resistance, surface integrity, and mechanical robustness of HVOF-sprayed WC-NiCr coatings. The improved tribological performance suggests that laser-remelted coatings can serve as a sustainable and high-performance alternative to cobalt-based coatings, particularly for applications in aerospace, mining, and energy sectors, where extreme wear conditions prevail.
Keywords:
laser remelting, microstructural characterization, tribolayer formation, wear resistance