Laser Cladding Technology Research Articles

Tribological and Corrosion Properties of Al2O3@Y2O3-Reinforced Ni60A Composite Coatings Deposited Using Laser Cladding

Since rare earth oxides and hard ceramic particles improve coating quality, a novel Al2O3@Y2O3 core–shell structure was prepared. Then, Ni60A coatings with different amounts (2~6 wt.%) of Al2O3@Y2O3 core–shell structures were prepared using laser cladding technology on an H13 steel surface. To demonstrate the unique effect of the core–shell structure on the performance of the coatings, a set of controlled experiments was also conducted with different proportions of Al2O3-Y2O3 mechanically mixed powders. The effect of Al2O3@Y2O3 addition on the phase composition, element distribution, microstructure, wear, and corrosion resistance of the coatings was characterized and tested thoroughly. By comparing the forming quality, hardness, wear, and corrosion resistance of the different coatings, 2 wt.% was confirmed as the optimal concentration of Al2O3@Y2O3, and its corresponding friction coefficient was about 0.44. The wear rate was approximately 4.15 × 10−3 mm3·(N·m)−1, the self-corrosion potential was around −0.3659 V, and the self-corrosion current density was about 1.248 × 10−6 A·cm−2.

Study on the Microstructure and Performance of the Multi-Field Composite-Assisted Laser Cladding of Nickel-Based Tungsten Carbide Coatings

Improving the hardness and wear resistance of die cutting tools is an important issue in the study of the service life of die cutting equipment. Using laser cladding technology, nickel-based composite coatings with varying BiFeO3 contents were prepared on a 45 steel substrate, because BiFeO3 can have an effect on the dilution rate and microstructure of the sample; morover BiFeO3 is a new type of multiferroic material with certain magneto-electric coupling effects which can be prepared for the study of added magnetic fields. The microstructure and morphology were characterized to determine the optimal BiFeO3 content. Based on the optimal addition of BiFeO3, a comparative analysis was conducted to investigate the effect of different magnetic field strengths under a composite energy field on the microstructure, hardness, and wear resistance of Ni-based WC cladding layers. The results show that the optimal addition of BiFeO3 was 5 wt%. At this concentration, there were no significant porosity defects in the coating, and the dilution rate was appropriate (4.77%). Additionally, the interface bonding strength was also increased. With optimal BiFeO3 addition, stirring with different magnetic field strengths was applied to the cladding layer, and the results show that the aspect ratio of the cladding layer gradually increased with increasing the alternating magnetic field strength. When the magnetic field strength in the composite energy field was 40 mT, the microstructure was fine and uniform, the hardness of the cladding layer reached the highest level, about 925.2 HV1.0, the wear resistance was also the best, the friction coefficient of the cladding layer was about 0.54, and the width of the wear mark was about 0.53 mm.

Determination of the geometric parameters of the defects based on the tomographically obtained data and their influence on the fatigue behavior of the S960 with laser cladded protective layers

This article deals with identifying defects of layered high strength steel materials with the help of tomography measurement. Test samples were made of S960 High Strength Steel to which layers of either aluminium bronze, hardchrome, cobalt alloy or stainless steel were applied by a laser cladding technology. The experimental campaign included a study of morphometric parameters of internal defects in and near the bi-material interface region using X-ray micro-tomography and their potential influence on the fatigue behavior during a three-point bending test.

Effect of ultrasonic radiation on the organization and mechanical properties of laser-melted Ni-based WC coatings

In this paper, laser cladding technology and ultrasonic radiation technology are combined to eliminate defects such as cracks and porosity in the coating. Firstly, the influence of the ultrasonic amplitude parameter on the macroscopic morphology and microstructure of the coating was investigated, and the dissolution law of WC was analyzed. It was found that under ultrasonic radiation with an amplitude of 14 μm, the surface of the coating was smoother and the average grain size was 16.52 μm2, which was reduced by 66.47 % compared to that of the coating without applied ultrasonic. Secondly, the effect of the ultrasonic radiation process on the mechanical properties of the coating was analyzed by comparative experiments. The results showed that when the amplitude of ultrasound was 14 μm, the number of cracks in the coating was effectively reduced, the amount of wear was reduced by 96.49 %, and the average microhardness value was 510.92 HV0.025, which was a relative increase of 28.10 %. Finally, the longitudinal residual stress of the coating was measured and the residual stress at the bottom of the coating was reduced by 95.31 % at an amplitude of 14 μm.

Research on the laser melting coating process of an AlCoCrFeNi high‐entropy alloy

AbstractLaser cladding technology is an advanced surface modification technique that has gained significant attention in various fields due to its energy savings, efficiency, and environmental friendliness. This paper discusses the preparation of AlCoCrFeNi high‐entropy alloy (HEA) coatings on the surface of a 5083 aluminum alloy using laser cladding technology under the Ar gas conditions. An orthogonal test system was used to optimize the laser cladding process parameters. The microstructure, as well as the mechanical, frictional, and electrochemical properties of the HEA coatings, were comparatively analyzed under the two process conditions S4 and S10. The results indicate that, under S10, the HEA coatings exhibit optimal surface quality. The coatings contained a mixture of Face‐centered cubic (FCC) and Body‐centered cubic (BCC) phases. Microscopic examination revealed three distinct areas: dark, gray, and off‐white. The coatings can significantly improve the wear and corrosion resistance of the alloy substrate. For the best results, it is set the laser power to 200 W, the laser scanning distance to .05 mm, and the laser scanning rate to 1250 mm/s. This present study offers a novel technical foundation for the fabrication of HEA coatings.

Effect of coated graphene on friction and wear properties of nickel-based self-lubricating coatings prepared by laser cladding

Graphene is an ideal material for improving the self-lubricating properties of coatings, but the high-energy laser beam can damage graphene during the laser cladding process. Therefore, in this paper, amorphous silicon dioxide (SiO2) is used to surface coat graphene particles to obtain silica-coated graphene with core-shell structure (G@SiO2). By adding niobium carbide (NbC) as the ceramic reinforcing phase and G@SiO2 nanoparticles as the solid lubricant in Ni60, a self-lubricating composite coating was prepared on the surface of 45 steel matrix by laser cladding technology. It is shown that G@SiO2 can promote the grain refinement of NbC in the coating. On the other hand, the addition of G@SiO2 promotes the generation of hard phase of chromium carbide, which together with NbC improves the hardness of the material. The maximum microhardness of the composite coating was 946 HV, which was 302.7% higher than that of the 45 steel base material. The lowest coefficient of friction value of the coated material was 0.25, and the lowest wear amount was 2.45 × 106 μm3. Compared with the composite coating without added G@SiO2, the coefficient of friction of the coated material with the addition of G@SiO2 was reduced by 50% and wear amount was reduced by 62%.

Fabrication of a bimodal micro/nanoporous copper cladding layer by the high-speed laser cladding and dealloying

The Cu30Mn70 cladding layer was prepared by high-speed laser cladding technology and successfully combined with chemical dealloying method to prepare a bimodal micro/nanoporous copper coating. The 0.1 M HCl solution was experimentally determined as the dealloying solution. During the dealloying, the Mn-rich regions were preferentially corroded and formed micron pores in situ; the remaining regions served as a framework to form nanoporous structures on both sides. With increasing time, the transformation of the nanoporous structure led to micron ligaments thinning or fracture, resulting in the structural collapse of the bimodal microporous/nanoporous copper coating surface. Repeated oxidation-dissolution processes on the surface accelerate the structural collapse of the surface and inhibit the demanganization layer thickness growth. The same structure was formed in the cross-sectional direction, with no structural collapse due to continuous H+ consumption and low corrosivity in the micropores. The bimodal microporous/nanoporous copper coatings remained highly porosity and rapidly increased in thickness to 340 μm from 24 to 72 h. After 72 h, the surface structure started to collapse and the growth of the demanganization layer thickness slowed down.

Investigation of the microstructural characteristics of laser-cladded Ti6Al4V titanium alloy and its corrosion behavior in simulated body fluid

Laser cladding technology has a wide range of potential industrial applications in the surface strengthening, repair and reuse of orthopedic implants. By employing this technique to conduct same-material surface restoration and enhancement on titanium alloys, it demonstrates significant developmental potential. However, the microstructure of laser additively manufactured titanium alloy differs significantly from that of traditional titanium alloys, which affects its corrosion resistance in human body fluids. To compare the corrosion resistance differences between the cladding layer and the substrate, this study investigates the microstructure of multi-pass laser cladding Ti6Al4V (TC4) titanium alloy and analyzes the corrosion morphology and corrosion products of the cladding layer in simulated body fluids (SBF). By comparing the electrochemical corrosion behavior of laser cladding with that of traditionally manufactured TC4, this research reveals the differences in corrosion resistance between the two titanium alloys. The research demonstrates that the microstructure of cladding primarily consists of prior-β grains and continuous grain boundary α phase, along with a complex basketweave structure composed of fine acicular α phase and lamellar α phase. Additionally, due to the complex thermal cycling process, the acicular α' colonies within the prior-β grains. These features enhance the cladding layer’s resistance to plastic deformation and increase microhardness, though with some uneven distribution. Interestingly, the TC4 cladding layer forms a porous passivation layer after corrosion, primarily composed of a TiO2 passivation film and deposits of hydroxyapatite and other phosphates. Due to the lower β-phase content, finer grains with higher energy states, and a greater proportion of high-angle grain boundaries (HAGBs) in the cladding layer, it exhibits higher electrochemical activity. As a result of these microstructural differences, the corrosion resistance of the TC4 cladding layer in SBF is inferior to that of TC4 manufactured using traditional techniques.

Study on corrosion mechanism of laser-clad Ni-WxC coating by in-situ electrochemical method under high temperature and pressure environment

Corrosion protection of oil and gas equipment by laser cladding technology has emerged as a crucial method to reduce costs and increase efficiency. The in-situ electrochemical method was employed to investigate the microstructure evolution and corrosion mechanisms of laser-clad Ni1725-WxC coatings under high temperature and pressure environment. The coating is composed of cellular γ-Ni (W, Cr, Fe), block W2C, WC/W2C eutectic structure with a shell of WC, and small amount of CrxCy (Cr7C3/Cr23C6) in Ni1725 matrix. The corrosion resistance of the coating is worsened with increasing temperature under in-situ electrochemical method owing to reduced reaction activation energy and increased transfer rate. Furthermore, the surface potentials of the coating follow the order: E1 (WC shell) > E2 (Ni1725 matrix (oxide)) > E3 (WC/W2C eutectic phase) > E4 (block W2C). Therefore, galvanic corrosion occurs between WC shell and Ni1725 matrix. W2C with lower potential corrodes preferentially as well at WC/W2C eutectic structure in WxC particle, which expands with increasing temperature to form a loose internal structure.

Substantial enhancement of AlCoCrFeNiTiWC high-entropy alloy coating performance under water cooling and pulsed laser

AlCoCrFeNiTiWC high-entropy alloy (HEA) coatings were prepared using laser cladding technology with continuous laser and air cooling, as well as pulsed laser with water cooling. The phase structures of the coatings were BCC, (Ti,W)C, and μ phase. The carbides and μ phase in the pulsed laser with water-cooled coating were refined, and the proportion of the μ phase decreased. The wear resistance of the pulsed laser with water-cooled coating significantly increased, which can be attributed to the reduction in the proportion of μ phase, the refinement of carbides, and the formation of a wear lubrication layer. The pulsed laser with water cooling enhanced the thickness and uniformity of the passivation film on the coating surface, thereby improving corrosion resistance.

Effect of ZrO2 Particles on the Microstructure and Ultrasonic Cavitation Properties of CoCrFeMnNi High-Entropy Alloy Composite Coatings

CoCrFeMnNi-XZrO2 (X is a mass percentage, X = 1, 3, 5, and 10) high-entropy alloy composite coatings were successfully prepared on 0Cr13Ni5Mo martensitic stainless steel substrates using laser cladding technology. The phase composition, microstructure, mechanical properties, and cavitation erosion behavior of the composite coatings under different contents of ZrO2 were studied. The mechanism of ZrO2 particle-reinforced cavitation corrosion resistance was studied using ABAQUS2023 finite element software. The results show that the phase structure of the composite coating organization is composed of FCC phase reinforced by ZrO2 phase. The addition of ZrO2 causes lattice distortion. The coatings have typical branch crystals and an equiaxed crystal microstructure. With the increase in ZrO2 content, the microhardness of the composite coatings gradually increases. When X = 10%, the coating’s microhardness reached 348 HV, which was 95.53% higher than the high-entropy alloys without ZrO2 added. Adding ZrO2 can prolong the incubation period of high-entropy alloys; the high-entropy alloy composite coating with 5 wt.% ZrO2 exhibited the best cavitation resistance, with a cumulative volume loss rate of only 15.74% of the substrate after 10 h of ultrasonic cavitation erosion. The simulation results indicate that ZrO2 can withstand higher stress and deformation in cavitation erosion, reduce the degree of substrate damage, and generate higher compressive stress on the coating surface to cope with cavitation erosion.

Preparation of graphene/AlCoCrNiTiMox coatings by laser parameter optimization based on TRIZ theory and its application in extending the service life of surveying and mapping drones

During the use of surveying and mapping drones, their aluminum (Al) alloy body is prone to corrosion and has certain requirements for mechanical properties. In order to extend the service life of surveying and mapping drones, this study uses laser cladding technology to prepare graphene (Gr) reinforced AlCoCrNiTiMox high entropy alloys (HEAs) coatings on the Al alloy surface of the drone body. In order to optimize the laser preparation parameters, the Invention Problem Solving Theory (TRIZ) is introduced. By utilizing innovative tools such as physical contradictions, technical contradictions, and material field models of this theory, the preparation process parameters such as laser power, laser scanning speed, laser spot diameter were optimized. The microstructure of the coatings were analyzed using scanning electron microscope (SEM), transmission electron microscope (TEM), electron back scatter diffraction (EBSD), etc. The corrosion resistance, hardness and wear resistance of the coatings were tested. The experimental results show that the microstructure of Gr/AlCoCrNiTiMox alloy is mainly composed of equiaxed grains and molybdenum-chromium (Mo-Cr) precipitates. The Gr/AlCoCrNiTiMox HEAs exhibits excellent corrosion resistance in 0.5 mol/L H2SO4 solution. The corrosion resistance of alloys is related to their composition, the effects of Gr and Mo elements. Under the combined effects of solid solution strengthening, precipitation strengthening, Mo element and Gr, the mechanical properties of Gr/AlCoCrNiTiMox alloys are excellent. The hardness of Gr/AlCoCrNiTiMo0.1 and Gr/AlCoCrNiTiMo0.2 alloys are 685 HV and 736 HV, respectively, with average friction coefficients of 0.64 and 0.58, respectively. The effect of Mo element makes the grain size of Gr/AlCoCrNiTiMo0.2 alloy smaller than that of Gr/AlCoCrNiTiMo0.1 alloy, resulting in better mechanical properties and corrosion resistance. The research results indicate that laser cladding of Gr/AlCoCrNiTiMox coating on the Al alloy surface of drone fuselage provides assurance for extending its service life.

High-power fiber laser incident beam absorptivity variation of molten pool surfaces during their solid-liquid-gas state evolution

The thermal and ablation effects of lasers are widely used in laser additive manufacturing, laser welding, laser cleaning, and laser cladding technologies. Absorptivity is the core index of laser beam-thermal energy conversion efficiency. This paper analyzed the irradiated material's absorption behavior during the solid-liquid-gas evolution of laser-ablated metal surfaces by comparing the temperature fields and the corresponding weld cross-sections for different laser action periods, considering the fusion and vaporization latent heats. The solid-liquid-gas state evolution of high-power fiber laser-irradiated metal surfaces occurs during several milliseconds, with a short solid-phase existence period, since fusion or melting time is much shorter than the vaporization time. As the solid-liquid-gas state evolves, the average absorptivity and the share of thermal conduction energy loss decrease with the laser action time, while the fusion energy loss gradually increases. The solid-phase surface of the metal in laser processing absorbs significantly more incident laser energy than the liquid-phase one. The longer the solid-phase occurrence period of the metal surface during the laser action, the greater its average absorptivity of the incident laser. By increasing the laser spot area and scanning rate, the solid-phase period of the laser-irradiated metal surface can be increased, improving its incident laser absorptivity.

Effects of C content on the microstructure and properties of CoCrFeNiTi0.5Mo0.5Cx high-entropy alloy coatings by laser cladding

In order to deeply investigate the influence mechanism of different contents of non-metallic element C on the microstructure, microhardness, wear resistance and corrosion resistance of high-entropy alloy coatings. CoCrFeNiTi0.5Mo0.5Cx high-entropy alloy coating was prepared on the surface of AISI 1045 steel by laser cladding technology. The results show that the microstructure of CoCrFeNiTi0.5Mo0.5 without C addition consists of FCC phase, BCC phase, intermetallic compound phase and σ-phase structure, and the carbide phases (M7C3 and TiC) start to appear after the addition of C element. The microhardness of the coating increases and then decreases with the increase of C content, and the average hardness is the highest when x = 0.03, 495.3HV0.5, which is 27.6% higher than that of C0. The abrasion resistance of the CoCrFeNiTi0.5Mo0.5Cx high-entropy alloy coatings is gradually increased and then decreased with the increase of C content, and the wear amount decreases from 0.0813 mm3 to 0.0514 mm3, and the main frictional wear mechanisms are adhesive wear, abrasive wear and oxidative wear. With the increase of C content, the corrosion resistance of the coating is gradually improved and then reduced, when the C content is 0.03, the highest corrosion potential is −0.818V, the lowest corrosion current is 1.382E-4 A/cm2, at this time, the passivation film on the surface of the coating is the most stable and dense, with the best corrosion resistance. The results of this paper provide a theoretical reference for the effect of adding non-metallic elements on the microstructure and properties of high-entropy alloy coatings.

Review on hard particle reinforced laser cladding high-entropy alloy coatings

Since their advent in 2004, high-entropy alloys have allured the field of materials science and engineering. Laser cladding technology, with its advantages of a small heat-affected zone and rapid heating and cooling, has become a popular technique for preparing high-entropy alloy coatings. Traditional high-entropy alloys have the problem of strength-plasticity mismatch, which limits the further application of laser cladding high-entropy alloys in industry. As a method to solve these challenges, hard particle reinforced alloy coating technology can effectively control the comprehensive properties of high-entropy alloy coatings. This paper first explores and analyzes the five strengthening mechanisms and four main influencing factors of hard particle reinforced laser cladding alloy coatings. Then, from the perspective of introducing particle types, the research status of ceramic particles, rare earth particles and other types of hard particle reinforced laser cladding high entropy alloy coatings is introduced. Finally, the characteristics of hard particle reinforced laser cladding high-entropy alloy coatings are summarized, and future recommendations for hard particle reinforced alloy coatings technology and its application in laser cladding high-entropy alloys are proposed, which will be helpful for researchers and producers in this field.

High-speed laser cladding (Fe,Cu)-dopped Ni-Co protective coatings for SOFC MICs: From long-term oxidation behavior to mechanical stability

The long-term operation of intermediate temperature-solid oxide fuel cells (IT-SOFCs) could be significantly influenced by the stability of the interconnect itself, especially, its oxidation resistance under the cathode environment. To effectively prevent Cr-volatilization and improve the interconnector performance, application of highly dense and stable protective coatings over the interconnector is indispensable. In this work, Ni-Co-based alloy protective coatings doped with Fe and Cu were applied onto the 441 interconnector via a novel high-speed laser cladding technology. The microstructure evolution, phase composition, oxidation resistance, electrical conductivity and mechanical properties of the coated steels were investigated at different oxidation stages at 800 °C. It was found that the Ni33.8Co34Fe32.2-coated steel shows the best oxidation resistance and electrical properties. The oxidation rate (kp) and ASR of Ni33.8Co34Fe32.2-coated steel is respectively 4.44 × 10−13 g2 cm−4 s−1 and 25.55 mΩ cm2, significantly lower than the uncoated steel and Ni44.6Co44.7Cu10.7-coated steel at the end of 1000-h test cycle. The resultant conductivity of the Ni44.6Co44.7Cu10.7 and Ni33.8Co34Fe32.2-coated steels is approximately 7.8 and 4.1 S cm−1, respectively, which could meet the requirement for SOFC stacks. In addition, the nano-hardness of the Ni33.8Co34Fe32.2 and Ni44.6Co44.7Cu10.7-coated steels was found to be 8.3 GPa and 8.8 GPa, respectively, through nanoindentation testing. The improved surface hardness is attributed to grain refinement and increased oxide content on the coating surface. The results indicated that the Ni-Co-based alloy coatings effectively improved the long-term stability and mechanical property of the 441 interconnector under the SOFC cathode environment.

The effects of Ni and Al elements on microstructure and mechanical properties of low carbon CoCrMo alloy coatings

Low-carbon cobalt-based alloy coatings with high ductility and low thermal fatigue crack propagation rates were prepared using laser cladding (LC) technology. The microstructure of the coatings was characterized using SEM, EBSD, and TEM, while the mechanical properties were tested and analyzed. The CoCrMo alloy primarily consists of γ-Co and a minor amount of ε-Co. The addition of Ni increased the stacking fault energy (SFE), resulting in the retention of γ-Co in the alloy. However, the increase of Al content reduced the SFE, leading to the precipitation of Al3Ni intermetallic compound along with a eutectic region with Al3Ni, Cr23C6, and ε-Co. More ε-Co phase appeared after tensile deformation due to the stress-induced transformation induced plasticity (TRIP) effect. Ni addition increased the content of face-centered cubic (fcc) γ-Co, enhancing the coating's ductility by approximately 85 % compared to CoCrMo. With higher Al content, the ε-Co phase increased, and the dispersion of Al3Ni improved the coatings' strength. The jagged structure of the eutectic region increased the resistance to thermal fatigue crack propagation, causing the crack propagated along the grain boundary. Optimal mechanical properties were achieved with the addition of 13 wt% Ni and 7 wt% Al, which achieved a 53 % increase in ductility and a 40 % reduction in the thermal fatigue crack propagation rate compared to CoCrMo.

Effect of the Laser Cladding Parameters on Microstructure and Elevated Temperature Wear of FeCrNiTiZr Coatings.

In order to prepare coating with good friction and wear resistance at elevated temperature on the surface of hot-working tool steel, by using a CO2 laser, FeCrNiTiZr high-entropy alloy coating with different laser scanning speeds (360, 480 and 600 mm/min, respectively) was successfully fabricated by using laser cladding technology on the surface of H13 steel in this paper. Phase constitutions, microhardness, microstructure, and wear characteristics of FeCrNiTiZr coatings under different laser scanning speeds were analyzed. It was determined that 480 mm/min was the optimal laser scanning speed. The results showed that the coating at the scanning speed of 480 mm/min consists of a BCC phase with significant lattice distortion and high dislocation density; the crystal structure is cellular crystal and dendrite crystal. The coating demonstrates the highest microhardness (842 HV0.2), which is 4.2 times that of the substrate (200 HV0.2). Its average friction coefficients at room temperature and 823 K are approximately one-seventh and one-third of the substrate's, respectively, and its wear volume is reduced by about 98% and 81% under these conditions. Compared to the substrate, the coating underwent slight abrasive wear, adhesive wear, and oxidative wear at both room temperature and 823 K. In contrast, the substrate underwent severe abrasive wear, adhesive wear, oxidative wear, and even fatigue wear.

Electrical and current-carrying tribological properties of CoCrFeNi-(Mo, Ti, W) high-entropy alloy coatings on copper alloys by infrared-blue composite laser cladding

Infrared-blue composite laser cladding technology is used to prepare highly conductive and wear-resistant CoCrFeNi-(Mo, Ti, W) HEA coatings on the surface of the copper alloy to overcome the problem of high reflectivity of copper alloy aiming to enhance the surface performance of copper alloy current-carrying friction part. The microstructure and electrical properties of the high-entropy alloy coating were investigated. The wear resistance of the coatings was tested under high-speed and high-current conditions using a self-made current-carrying friction and wear testing machine. The results show that fine-grain and second-phase strengthening significantly enhances the hardness of the high-entropy alloy coating. The high-entropy alloy coating maintains the excellent electrical conductivity of the copper alloy, with an overall conductivity remaining above 60 % IACS. During the current-carrying friction process, the CoCrFeNi-(Mo, Ti, W) HEA coatings exhibited good wear resistance, with wear rates of 0.84 g/h, 1.08 g/h, and 1.32 g/h, respectively. The wear mechanisms observed included varying degrees of adhesive wear, abrasive wear, fatigue wear, and arc erosion.

Microstructure, wear and corrosion resistance of Ni-based composite coating by multi-layer laser cladding

Using laser cladding technology to prepare coatings on the gear ring of the main wheel made of ZG42CrMoA, the composite coatings consisting of γ-Ni, M23C6, Ni3B, WC, and W2C. As the amount of WC nanoparticles increased, a "pinning" effect on dislocations hindered dislocation movement during wear, Comparative analysis showed a reduction in wear rate by 76.94 % and 72.80 % compared to the untreated substrate and high-frequency quenched substrate, respectively. Further, finite-element analysis indicated maximum compressive stress values of 274.37 MPa and 262.20 MPa during the impact and friction phases, respectively. This was lower than the corresponding values of the high-frequency quenched layer, which were 288.63 MPa and 283.16 MPa. The corrosion current density of the composite coating reduced by 87.98 % and 92.71 % compared to the untreated substrate and the high-frequency quenched substrate, respectively. Additionally, the electrochemical impedance amplitude of the composite coating was 72,456 Ω, which was substantially higher than that of the high-frequency quenched substrate (1270 Ω) and the untreated substrate (1717 Ω) by 570.5 % and 422.0 %.