Study on microstructure and abrasive behaviors of inconel 718-WC composite coating fabricated by laser directed energy deposition

Additive manufacturing enables the development of high-performance materials by in-situ alloying of multiple components. In this study, Inconel 718-based composite, reinforced with tungsten carbide (WC), was synthesized on a 316L stainless steel substrate using laser directed energy deposition (DED). The microstructural evolution, distribution density of WC particles, and strengthening mechanisms of the DED-processed metal matrix composite (MMC) with different WC particle sizes and ratios are systematically investigated. It illustrated that increasing laser power enables the microstructure transforming from equiaxed to dendritic, which is attributed to the different cooling rates and temperature gradients. In addition, the morphology of the 60% WC ratio of the particle composite shows macrocracks. The incorporation of different sized WC affects retained WC distribution density and tailors a gradient layer around the edge of the WC particle. The in-situ WC-W2C phases precipitated in the deposited layer and the evenly distributed high level of ex-situ retained WC particles induce solid solution strengthening and dispersion strengthening, respectively. As a result, the optimal size of the 90 μm WC/Inconel 718 shows the highest wear resistance. The underlying strengthening mechanisms are elucidated. Consequently, the wear mechanism of Inconel 718-based composite reveals the typical abrasive wear characteristics in the presence of WC particles.