Nickel Matrix Research Articles

Iron Integration in Nickel Hydroxide Matrix vs Surface for Oxygen-Evolution Reaction: Where the Nernst Equation Does Not Work.

This study focuses on the oxygen-evolution reaction (OER) activity comparison between two forms of NiFe (hydr)oxides: compound 1, where Fe ions are applied on the surface of nickel (hydr)oxide, and compound 2, with Fe ions incorporated into the structural matrix of nickel (hydr)oxide. The observed exponential link between Coulombic energy and the total charge of the system points to a direct proportionality between the potential and the concentration of oxidized nickel ions (e.g., V ∝ [oxidized Ni]), diverging from the logarithmic relationship outlined in the Nernst equation or its modifications, which is not evident in this case. Initial visible spectroscopy indicates a notable trend toward oxidation. As, during the oxidation, more Ni is oxidized, a repulsion effect develops, diminishing the likelihood of further oxidation, and a distinct linear correlation emerges between the quantity of oxidized Ni(II) and the applied potentials.

Solution heat treatment of electron beam freeform fabricated in-situ TiC-γ'/ Ni–Fe–Cr composite: Strength-toughness synergy by regulating TiC and γ′ precipitates

Nickel matrix composites reinforced by ceramic particles typically exhibit elevated strength but diminished toughness. In this paper, a novel in-situ micron-size TiC and nano-size γ′ phases reinforced Ni–Fe–Cr matrix composite was successfully prepared using the electron beam freeform fabrication (EBF3). Subsequently, the as-built composite was subjected to solution heat treatment at different temperatures. At a solution temperature of 1150 °C, the composite demonstrates superior strength-toughness synergy (ultimate tensile strength = 1109.4 ± 25.4 MPa, elongation = 12.08 ± 0.62%), exhibiting an increase of 17.1% and 104.4%, respectively, compared to the as-built composite. A systematic analysis of the strengthening and toughening mechanisms revealed that the γ′ phase played a predominant role in enhancing strength, while the size, morphology, and content of TiC phase significantly influence fracture toughness. After being solution heat treated at 1150 °C for 2 h, the γ′ phase precipitated uniformly with its size coarsening to 93.85 nm, demonstrating an optimal strengthening effect by shearing mechanism. Meanwhile, the TiC phase partially dissolved into the matrix and transformed from a long-strip shape to a more stable spherical shape. This transformation significantly reduced the formation of microvoids along the TiC/matrix interface during tensile loading, enhancing the fracture toughness. The γ′ and TiC phases were regulated by solution heat treatment to reach a balance of optimising properties, achieving synergistic enhancements in strength and toughness.

Highly efficient Ni3Se2@sintering porous Ni catalytic electrode for durable hydrogen evolution reaction

The development of cheap, efficient, and long-term stable hydrogen evolution reaction (HER) electrocatalysts is indispensable but still challenging for large-scale industrialized water electrolysis. Recently, many studies have shown that in-situ selenization of metal matrixes is expected to improve the catalytic activity of the metal-based electrodes. In the present work, optimal nickel matrix with controlled polygonal morphology and pore size was obtained by adjusting the sintering process. A highly efficient Ni3Se2@sintered Ni electrode was acquired by in-situ growing nano-Ni3Se2 on sintered Ni matrix using one-step hydrothermal selenization. The metallurgical bonding between Ni particles accelerates electron transfer, and nano-Ni3Se2 provides more active sites. As a consequence, the prepared Ni3Se2@Ni500 electrode can operate stably at current density of 200 mA cm−2 over 260 h. The excellent hydrogen catalytic performance and long-term stability make such electrode promising in the hydrogen evolution reaction.

Short study on mechanism of morphology change of γ′ precipitates in IN718 Plus

γ′ Ni3Al phase (L12 structure) strengthened superalloy has become an important strengthening phase in Ni based superalloys because of its excellent high-temperature service performance, and has been widely used. The process of γ′ phase precipitation has also received a lot of attention and research. However, most studies focused on its growth rate. There were few studies on the morphology transformation of γ′ phase, and the morphology transformation process is complex. The mechanism of γ′ phase transformation process was systematically analyzed in this paper. Firstly, through molecular dynamics calculation, the most stable morphology of the γ′ phase in the nickel matrix was obtained under ideal conditions. The stability of spherical precipitates is higher than that of cubic precipitates. When the temperature is greater than 800 K, the stability is more obvious.Then through the micro EDS analysis of the γ′ phase in the morphology transformation process, it was shown that the soft impingement phenomenon exists in the nickel base alloy with high γ′ phase volume fraction. Further, by the derivation of the formula of solid-state phase transformation, it was found that the growth rate of precipitate is directly proportional to the concentration gradient of Al in the matrix at the interface, while increases with the rising of the Al concentration in the matrix at the interface. Finally, the way and mechanism of soft impingement affecting the morphology transformation were analyzed. The precipitates formed by soft impingement are nearly cubic precipitates with rounded edges and corners.

Fabrication and characterization of Ni-TiO2 and Ni-V2O5 single-layer and double-layer coatings with the approach of improving the wear and corrosion properties

The main purpose of this study is to investigate the metallurgical behavior of Ni-TiO2 and Ni-V2O5 single-layer coatings and compare them with Ni-TiO2/Ni-V2O5 and Ni-V2O5/Ni-TiO2 double-layer coatings. The general attitude is the optimal choice of coatings in terms of wear and corrosion properties. The dimensions of TiO2 and V2O5 ceramic powders were 20 nm and 500 nm, respectively, and their morphology was also different. The presence of the submicron V2O5 particles was more than the TiO2 nanoparticles in the nickel matrix deposit. Also, with double layering the coatings (Ni-TiO2/Ni-V2O5 and Ni-V2O5/Ni-TiO2), the presence of ceramic particles in the upper layer had increased compared to the same single-layer coatings. Therefore, the increase in the hardness of the deposits was directly related to the percentage of ceramic powders in the coating. The surface morphology of the Ni-TiO2 layers was formed as a cauliflower shape while the Ni-V2O5 deposits had a smooth morphology. Increasing participation of TiO2 particles in the Ni-TiO2 layer had made the morphology rougher. Also, by applying the Ni-TiO2 layer under the Ni-V2O5 deposit, the surface morphology of the Ni-V2O5 layer became smooth, which can be due to the increase in the V2O5 content in this layer. The lowest amount of fluctuation appeared in the roughness profiles related to the Ni-V2O5 layers, and the large fluctuation range in the Ni-TiO2 layers was due to the smooth and cauliflower structure, respectively. The crystallite size in double-layer coatings was smaller than the single-layer coatings due to the higher nucleation and growth rate of nickel deposition in the nickel matrix upper layers. According to the presented results, the Ni-V2O5 and Ni-V2O5/Ni-TiO2 coatings were the most wear resistant coatings. Also, the Ni-V2O5/Ni-TiO2 and Ni-TiO2/Ni-V2O5 double-layer coatings were suitable candidates for corrosion resistance and to consider both properties, Ni-V2O5/Ni-TiO2 was very suitable. Hardness, surface morphology, roughness, preferred planar texture, and ceramics powder participation were important parameters in determining the wear and corrosion properties of coatings. Also, it seems that the effect of the double layering of nickel matrix deposits on the metallurgical properties was greater than the dimensions of the ceramic particles participating in the coating.

Morphological and functional characterization of electroplated Ni-graphene composite coatings

Composite coatings (CECs) are providing a unique technological advantage for improving mechanical and tribological surface properties. Among different methods, electrodeposition is one of the most exploited to produce composite surface coatings on metal substrates. However, the process parameters affect graphene distribution, coating morphology and performance. This paper investigates how different deposition conditions influence the inclusion of large Graphene nanoplates (GnPs) in a Nickel matrix and the coating morphology and tribological performance. Set the process condition such as electrical parameters and the galvanic bath, the work focuses on the stirring rate effect. To this end, Ni-GnP coatings were obtained by a laboratory setup and evaluated through surface profilometry, SEM characterization and a dry-sliding linear reciprocating wear test. The results highlight the influence of stirring on coating uniformity. The low stirring rate allows larger particles to be embedded, which are not thoroughly covered; however, they act as a solid lubricant and reduce the friction coefficient.

Synergistic optimization of microstructures and properties of electrodeposited Ni–CeO2 composite coatings with CeO2 microparticles and CeO2 nanoparticles

The synergistic mechanism of microparticles and nanoparticles on optimizing microstructures homogeneity and enhancing microhardness and corrosion resistance of mixed coatings was deeply researched by co-electrodepositing CeO2 microparticles and CeO2 nanoparticles into nickel matrix. Microparticles contribute to enhancing the microhardness of the coating, while nanoparticles promote the homogeneity of the microstructure, thereby improving the corrosion resistance of the coating. Therefore, by co-electrodepositing microparticles and nanoparticles into the nickel matrix, microparticles and nanoparticles in the nickel matrix generate a synergistic optimization effect, combining the advantages of microparticles and nanoparticles. Microparticles are mainly responsible for enhancing the microhardness of the coating, while nanoparticles are responsible for promoting the homogeneity of the microstructure in the coating, maintaining a homogeneous distribution of microhardness, and improving the corrosion resistance of the coating. Ultimately, the mixed coating achieves both high microhardness and excellent corrosion resistance, along with homogeneous microhardness distribution.

Exploring elevated temperature fretting wear behaviour of wrought and laser powder bed fusion IN718 superalloy

The study examines the fretting wear of the Laser Powder Bed Fusion (L-PBF) processed IN718 alloy under gas turbine-like conditions. It involves a large (>106) test cycle investigation at 550 °C and ∼800 N. The heat-treated L-PBF IN718 material exhibited higher hardness compared to heat-treated wrought IN718 due to the formation of finer precipitation of γ' and γ'' in the FCC nickel matrix. A custom wear test setup simulates the harsh industrial environment, revealing a two-fold lower wear coefficient in the L-PBF alloy due to improved hardness and a finer microstructure. The friction coefficient remains marginally different, with the L-PBF alloy showing lower values during the initial phase. The wear mechanisms are similar, but the wrought IN718 HT exhibits severe oxidation-assisted galling.

The Tunable Rhenium Effect on the Creep Properties of a Nickel-Based Superalloy.

Atomistic simulations on the creep of a nickel-based single-crystal superalloy are performed for examining whether the so-called rhenium effect can be tuned by changing the spatial distribution of rhenium in the nickel matrix phase. Results show that Rhenium dopants at {100} phase interfaces facilitate mobile partial dislocations, which intensify the creep, leading to a larger creep strain than that of a pure Ni/Ni3Al system containing no alloying dopants. If all the Re dopants in the matrix phase are far away from phase interfaces, a conventional retarding effect of Re can be observed. The current study implies a tunable Re effect on creep via dislocation triggering at the phase interfaces.

The influence of spark plasma sintering on multiscale mechanical properties of nickel-based composite materials

The paper presents a comprehensive investigation of the influence of the main process parameters of spark plasma sintering on the mechanical and microstructural properties of nickel-silicon carbide composites at various scales. Microstructure analysis performed by scanning and transmission electron microscopy revealed a significant interfacial reaction between nickel and silicon carbide due to the decomposition of silicon carbide. The chemical interaction of the matrix and reinforcement results in the formation of a multicomponent interphase zone formed by silicides (Ni31Si12 or/and Ni3Si) and graphite precipitates. Furthermore, several types of structure defects were observed (mainly nano/micropores at the phase boundaries). These significantly influenced the mechanical response of nickel-silicon carbide composites at different levels. At the macroscopic scale, uniaxial tensile tests confirmed that applying a 1000 °C sintering temperature ensured that the manufactured composite was characterised by satisfactory tensile strength, however, with a considerable reduction of material elongation compared to pure nickel. Moreover, the fractography study allowed us to identify a significant difference in the damage mode for certain nickel-silicon carbide samples. Secondly, the interface of the nickel matrix and silicate interphase was tested by bending with microcantilevers to evaluate its deformation behaviour, strength, and fracture characteristics. It was confirmed that a diffusive kind of interface, such as Ni-NiSi, demonstrates unexpected bonding properties with a relatively large range of plastic deformation. Finally, the nanoindentation of three main components of the nickel-silicon carbide composite was executed to evaluate the evolution of nanohardness, Young's modulus, and elastic recovery due to the application of various spark plasma sintering conditions.

Postprocessing of tungsten carbide‐nickel preforms fabricated via binder jetting of sintered‐agglomerated powder

AbstractThis study binder jets a tungsten carbide‐nickel (WC‐Ni) sintered‐agglomerated composite powder, and postprocesses the preforms using an initial sintering step followed by a hot isostatic pressing (HIP) step. The effects of sintering temperatures, sintering durations, and HIP temperatures on notable properties (e.g., porosity, microstructure, hardness, and oxidation behavior) are quantified. The highest average relative density produced in this study was 96.8%, and volumetric shrinkage of these coupons was about 64%. Microstructural characterization shows that the WC grains are homogenously distributed throughout the nickel matrix and grow to an average diameter of 1.6 (a 60% increase) during processing. X‐ray diffraction patterns indicate that no unwanted products were formed. Processed coupons achieved a maximum hardness of 54 Rockwell C, limited by their internal porosity. Oxidation tests result in the production of WO3 and NiWO4 at temperatures above 600°C. Methodologies and results from this study can be leveraged to additively manufacture highly dense, geometrically complex WC‐Ni parts with small carbide grains, low nickel content, desirable microstructure, and suitable functional properties.

High-Temperature Friction and Wear Behavior of Nickel-Alloy Matrix Composites with the Addition of Molybdate

To improve the tribological characteristics of materials employed in spatial mechanisms, there is a significant requirement to develop solid lubricating composites with superior performance. This study investigates the tribological characteristics of composites consisting of a nickel matrix combined with silver molybdate and barium molybdate. The experimental analysis focuses on evaluating the tribological behaviors of these composites from 25 °C to 800 °C. The findings indicate that the combined application of silver molybdate and barium molybdate resulted in enhanced self-lubricating properties of the composites, particularly at temperatures over 400 °C. The inclusion of both silver molybdate and barium molybdate in the composite resulted in the achievement of a low friction coefficient (0.34–0.5), as well as a wear rate ranging from 0.47 to 1.25 × 10−4 mm3 N−1m−1, within the temperature range of 400 to 800 °C. Furthermore, an analysis was conducted to examine the wear processes of the composites at various sliding temperatures. This analysis was based on the evaluation of the chemical composition and morphologies of the sliding surfaces, which were verified by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and Raman spectroscopy.

Tribotechnical Characteristics of Nickel-Based Composite Coatings Obtained by Hybrid Technologies

As an object of this study, the coatings were used, which are composed of self-fluxing nickel-based alloys or compositions containing them, formed in a hybrid technological process with two main stages: spraying by the plasma method and subsequent remelting – by the gas-flame method or laser heating. An experimental measurement of their resistance to abrasive wear under conditions of boundary friction with the introduction of lubricants has been carried out for the coatings obtained in this process. At the same time, the influence of the coating composition and the remelting method on the wear value measured by the artificial base method has been investigated. To evaluate the dynamics of structure formation in the surface layer subjected to mechanical loads during the friction, X-ray diffraction analysis, metallographic method, and scanning electron microscopy in the electron diffraction mode have been used. After the laser remelting stage, it is possible to obtain coatings with wear resistance that is twice or more superior to the level for sprayed coatings of the same composition processed by the gas flame method. Wear of the coating surface has been found to occur through the mechanism of fatigue failure of the least hard component of the coating, i. e., the nickel-containing intermetallic phase, with the formation of an island-type film of hard crystallites of the carbide-boron phase weakly bound to the coating base, which ultimately leads to cracking of particles of this phase and their crumbling from the surface. The durability of layers obtained after the laser remelting stage can be increased, according to experimental data, by reducing the grain size of the phases in the coating and its texturing, as well as increasing the concentration of alloying elements in the composition of the metal-containing binder phase of the coating. The use of alloying additives leads to an additional increase in wear resistance by 2–4 times. This is due, depending on the type of additives, with an increase in the amount of the hardening phase while maintaining the plasticity of the matrix (coatings with chromium carbide additives), the degree of alloying of the nickel matrix (by the tungsten carbide and boron carbide additives), as well as the presence of a finely dispersed carbide-boride component, which reduces the processes of deformation and scratching.

Comprehensive anti-corrosion study of electrodeposited graphene oxide-alumina composite with nickel matrix in NaCl solution

In this work, a matrix of nickel composite coating is embedded with graphene oxide and alumina. This work developed a matrix of nickel composite coating embedded with graphene oxide and alumina (GO-Al2O3) at various concentrations using an electrodeposition process. Fourier transforms infrared spectroscopy (FTIR) and Energy-dispersive X-ray spectroscopy (EDAX) confirmed further incorporation of GO and GO-Al2O3 within nickel coating. The calculated crystal size of the nickel coating was 19.46 nm; however, it reduced to 11.58 nm in the Ni-GO-Al2O3 (1.5 g/L) coating. The surface morphology of Ni-GO-Al2O3 coating using Field emission Scanning electron microscopy (FE-SEM) showed fine grain size; however, nickel had cubic-shaped crystals and was significantly larger. Contact angle measurements reveal the hydrophobic characteristic of the Ni-GO-Al2O3 coating, which was 110.8° compared to nickel (71.4°). Tafel and electrochemical impedance showed maximum polarization resistance for Ni-GO-Al2O3 (1.5 g/L) coating. The developed Ni-GO-Al2O3 coating was put through short, long-term immersion tests and showed less weight loss than Ni and Ni-GO coating. pH change was the least for Ni-GO-Al2O3 coating due to its compact shape, which prevented the transport of corrosion-causing ions to the metal and consequently reduced metal oxidation. Ni-GO-Al2O3 coating shows the least blue spot, indicating negligible rupture after immersion. Atomic force microscopy study revealed that Ni-GO-Al2O3 has a smoother surface, which did not significantly change even after immersion. Nickel coating showed cracks, producing high corrosion products and more pits, showing its inability for long-term inhibition; however, Ni-GO-Al2O3 coating with the least cracks and pits showed negligible corrosion products on its surface even after one month of exposure. Fe and O are higher in Ni and Ni-GO after immersion and least in Ni-GO-Al2O3, making it more protective. Compared to pure Ni coatings, the composite coating electrode containing 1.5 g/L of GO-Al2O3 had the best corrosion resistance due to the abovementioned characteristics.

Atomic insights into the tensile behavior of carbon nanotube with different geometrical characteristics embedded in nickel matrix

Carbon nanotubes (CNTs) extensively serve as reinforcements in metal matrix nanocomposites because of their superior mechanical properties. In this paper, we have performed a qualitative analysis of carbon nanotubes with different geometrical properties embedded in a nickel matrix to predict tensile behavior and mechanical properties via molecular dynamics simulations. The effects of CNT rotate angle, long-short CNT and CNT number on the deformation mechanism, Young's modulus and ultimate tensile strength (UTS) were investigated. The different rotation angles of CNTs significantly affect the deformation mechanisms and mechanical properties of CNT/Ni nanocomposites. For the long CNT/Ni composites, when the rotate angle is 0°, the Young's modulus and UTS are the smallest, which are 233.03 GPa and 10.68 GPa, respectively. When the rotate angle is 15°, the elastic modulus and UTS are the largest, which are 252.9 GPa and 15.63 GPa, which increase by 8.5 % and 46.3 %, respectively. For the short CNT/Ni composites, when the rotate angle is increased from 0°to 90°, its mechanical properties first decrease and then increase. The distribution of long and short CNTs significantly modifies the deformation pattern of the nickel matrix. Increasing number of CNTs improves Young's modulus and UTS of CNT/Ni nanocomposites.

Development of a laser preheating concept for directed energy deposition

In today’s manufacturing, additive manufacturing processes enable the production of complicated three-dimensional structures that are hard to be manufactured with traditional manufacturing processes. Due to its high build rate, the laser-based directed energy deposition (DED-LB) process is an attractive and versatile process to manufacture these kinds of components. In addition to the production of components, DED-LB is used for repair or coating applications. The DED-LB process consists of a multitude of complex thermal mechanisms with high heating and cooling rates of 5 × 102 up to 5 × 105 K/s. For materials with high hardness or low thermal conductivity like tool steels, cast iron, or tungsten carbide, these high cooling rates can lead to defects in the microstructure like cracks, pores, or delamination between the substrate and the deposited structures. By preheating the substrate, the cooling rates can be reduced and defects can be eliminated. In this paper, a preheating cycle was developed, which uses the laser of a DMG MORI LT 65 DED hybrid machine as a moving heat source for the substrate preheating. For this cycle, process parameters, a tool path strategy, and a temperature control system were developed. The impact of the elaborated concept was shown by depositing tungsten carbide in a nickel matrix on an S235 steel substrate.

Influence of polymer content on in-situ polymer-derived particles reinforced nickel matrix composites

The influence of polycarbosilane (PCS) content on the macroscopic appearance, microstructures and tensile properties of particles reinforced nickel matrix composites (PRNMCs) fabricated via in-situ polymer-derived particles (PDPs) method was studied. The method to decide suitable addition of polymer was proposed. It is revealed that the suitable content of PCS to obtain an intact PRNMCs is 1.24– 8.31 wt%, which is decided by the density of raw materials, volume elastic aftereffect of green compact and the volume fraction of interparticle gaps in green compact under pressing. The formation and evolution of amorphous SiO2 and lamellar graphite particles in PRNMCs with different PCS contents have been clarified. With increasing PCS content, the content of amorphous SiO2 particles beneficial to improve the strength and ductility of Ni-PCS composites keeps stable. However, the number and size of lamellar graphite particles harmful to tensile properties are acceleratedly increased. These results provide guide to designing high performance PRNMCs by in-situ PDPs method.

Electrodeposition and Properties of Composite Ni Coatings Modified with Multilayer Graphene Oxide.

Within the framework of this study, Ni-based composite electrochemical coatings (CECs) modified with multilayer graphene oxide (GO) processed using microwave radiation have been deposited. The process of these coatings' electrodeposition in the potentiodynamic mode has been studied. The structure of Ni-GO and Ni-GO (MW) CECs has been studied using X-ray phase analysis (XPA) and scanning electron microscopy (SEM).It has been shown that the addition of GO into a nickel deposit contributes to the formation of uniform fine-grained coatings. As a result, the microhardness of the Ni-GO (MW) CECs increases by 1.40 times compared to Ni without GO. The corrosion-electrochemical behavior of nickel CECs in 0.5 M H2SO4 solution was researched. It was established that the corrosion rate of the nickel-GO (MW) CEC in 3.5% NaCl decreases by about 1.70 times in contrast to unmodified nickel coatings. This effect is due to the absence of agglomeration of the graphene oxide in the volume of the nickel matrix and the impermeability of GO particles to the corrosive environment.

Spark plasma sintering of ceramic-reinforced binary/ternary nickel and titanium metal matrix composites: Mechanical properties, microstructure, and densification – A review

Spark Plasma sintering is an excellent technique for developing ceramic-reinforced binary/ternary nickel and titanium metal matrix composites (MMCs). This review analyzes the mechanical properties, microstructure, and densification characteristics of SPS-produced composites. Introducing ceramic reinforcement such as carbides, oxides, nitrides, or borides enhances the mechanical characteristics and functionality of MMCs. The SPS method has advantages such as high heating rates, low processing durations, and relatively low sintering temperatures, all of which assist in reducing reactivity concerns and retaining the desirable properties of the matrix and reinforcing materials. The impact of different process parameters such as temperature, pressure, heating rate, and holding time on the final microstructure and densification of the composites was discussed in this review. Additionally, it examined how different types, contents, and particle sizes of reinforcement affected the mechanical qualities, including hardness, tensile strength, fracture toughness, and wear resistance. Furthermore, the production of secondary phases and the interfacial bonding between the matrix and reinforcements are explored because they significantly affect the mechanical performance and behavior of the composites. This work contributes to an extensive understanding of the SPS procedure for ceramic-reinforced nickel and titanium MMCs, offering insightful information on processing parameters that enhance production and modify the characteristics of these technologically advanced materials for many applications in the aerospace, automotive, and structural industries.

A comparative study on characteristics of composite (Cr3C2-NiCr) clad developed through diode laser and microwave energy

A typical ferrite/martensitic heat-resistant steel (T91) is widely used in reheaters, superheaters and power stations. Cr3C2-NiCr-based composite coatings are known for wear-resistant coatings at elevated temperature applications. The current work compares the microstructural studies of 75 wt% Cr3C2- 25 wt% NiCr-based composite clads developed through laser and microwave energy on a T91 steel substrate. The developed clads of both processes were characterized through a field emission scanning electron microscope (FE-SEM) attached with energy-dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD) and assessment of Vickers microhardness. The Cr3C2-NiCr based clads of both processes revealed better metallurgical bonding with the chosen substrate. The microstructure of the developed laser clad shows a distinctive dense solidified structure, with a rich Ni phase occupying interdendritic spaces. In the case of microwave clad, the hard chromium carbide particles consistently dispersed within the soft nickel matrix. EDS study evidenced that the cell boundaries are lined with chromium where Fe and Ni were found inside the cells. The X-ray phase analysis of both the processes evidenced the common presence of phases like chromium carbides (Cr7C3, Cr3C2, Cr23C6), Iron Nickel (FeNi3) and chromium-nickel (Cr3Ni2, CrNi), despite these phases iron carbides (Fe7C3) are observed in the developed microwave clads. The homogeneous distributions of such carbides in the developed clad structure of both processes indicated higher hardness. The typical microhardness of the laser-clad (1142 ± 65HV) was about 22% higher than the microwave clad (940 ± 42 HV). Using a ball-on-plate test, the study analyzed microwave and laser-clad samples' wear behavior. Laser-cladding samples showed superior wear resistance due to hard carbide elements. At the same time, microwave-clad samples experienced more surface damage and material loss due to micro-cutting, loosening, and fatigue-induced fracture.