WC-10Ni particle-reinforced stainless steel matrix composites have potential applications in aerospace, energy engineering, automotive manufacturing, and marine engineering equipment. However, there is currently insufficient research on the integrated manufacturing and comparative analysis of Ni-coated (WC-10Ni)1.5/316 and agglomerated-sintered (WC-10Ni)1.5/316 composites using Laser Melting Deposition (LMD) technology. In this work, the fabrication and examination of the LMDed specimens are conducted to determine the influence of the forming process of particle reinforcement on the microstructure and wear properties of WC-10Ni/316 composites. The microstructure, phase composition, composition distribution, microhardness, and wear resistance of the two composites were comparatively analyzed using confocal laser scanning microscopy (CLSM), scanning electron microscopy (SEM), microhardness tester, X-ray diffraction(XRD), energy-dispersive spectroscopy (EDS), and a reciprocating wear tester. The results indicate that the microstructure of Ni-coated (WC-10Ni)1.5/316 composite specimen contains a higher quantity of undecomposed Ni-coated WC-10Ni particles, with a lower proportion of precipitates, and dendrites predominantly exhibit an elongated dendrite morphology. In contrast, the agglomerated-sintered (WC-10Ni)1.5/316 composite specimen features a greater content of decomposed agglomerated-sintered WC-10Ni particles, a higher content of precipitates, and dendrites mainly present as slender dendrites. Both composites consist of phases such as γ-(Fe, Ni, Cr), WC, W2C, Fe6W6C, M6C, and Cr23C6. The undecomposed WC-10Ni particles and tungsten precipitates significantly enhance the microhardness and wear resistance of the specimen. Specifically, the Ni-coated (WC-10Ni)1.5/316 composite specimen displays a microhardness of 350.2±3.3 HV1.0, with a wear rate of 1.5797±0.0455mg/(N·km). Meanwhile, the Agglomerated-sintered (WC-10Ni)1.5/316 composite specimen reveals an average microhardness of 410.9±6.1 HV1.0 and a wear rate of 0.8057±0.0352mg/(N·km).
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