Measuring Dilution and Wear for Laser Cladding of Stellite 6 Produced on a P91 Steel Substrate using Two Different Heat Inputs

Stellite 6 was deposited by laser cladding on a P91 substrate with energy inputs of 1 kW (P91-1) and 1.8 kW (P91-1.8). The chemical compositions, microstructures and surface roughnesses of these coatings were characterized by atomic absorption spectroscopy, scanning electron microscopy and atomic force microscopy. The microhardness of the coatings was measured and the wear mechanism of the coatings was evaluated using a pin-on-plate (reciprocating) wear testing machine. The results showed less cracking and pore development for Stellite 6 coatings applied to the P91 steel substrate with the lower heat input (P91-1). Further, the Stellite coating for P91-1 was significantly harder than that obtained for P91-1.8. The wear test results indicated that the weight loss for P91-1 was much lower than for P91-1.8. The surface topography data indicated that the surface roughness for P91-1 was much lower than for P91-1.8. The measurements of dilution and carbon content showed that P91-1 has lower dilution and higher concentration of carbon than P91-1.8. It is concluded that the lower hardness of the coating for P91-1.8, together with the softer underlying substrate structure, markedly reduced the wear resistance of the Stellite 6 coating and the lower hardness of the coating for P91-1.8 was due to higher level of dilution and lower concentration of carbon.