WC-Co coating, which is a subcategory of Tungsten Carbide-based coatings, is prominent among a variety of industries. However, because of its expense, poisoning, and low corrosion resistance of Cobalt in acidic environments, alternative compositions have been designed. One of these alternatives is the Iron Aluminide intermetallic compound which can replace Cobalt. This study investigates laser cladding of WC-FeAl powder on a 321 Stainless-Steel substrate. WC-FeAl powders were synthesized by mechanical alloying of initial Aluminum and Iron powders, milled for 20 h, followed by an hour of annealing at 800 degrees Celsius. Then, the annealed particles were mechanically alloyed with WC powders for 50 h. The result of the X-ray diffraction (XRD) analysis showed that no brittle and destructive phase was formed during synthesis. Subsequently, powders were coated on the stainless-steel substrate by laser cladding method. Effect of the main parameters of the laser cladding, including laser power, laser probe velocity, and powder spray rate, on the coating properties, such as porosity, geometry, thickness and, dilution were studied. Results indicate that with a higher power of the laser, the penetration depth and the width of the coating increased. Besides, with a higher velocity of the laser probe, dilution and penetration depth decreased. Furthermore, the Higher rate of powder spray led to a thicker coating. The optimum parameters of different samples were 250 W power, 4 mm/s probe velocity, and 400 mg/s powder spray rate. Evaluation of the mechanical properties indicated that the 1600 Vickers hardness, 5.7 MPa.m1/2 fracture toughness, and 355 GPa Young's modulus were obtained. Besides, The evaluation of the mechanical properties of the coating showed that the hardness, fracture toughness, and elasticity modulus are 1600 V, 5.7 MPa.m1/2, and 355 GPa respectively. Obtained results revealed that in comparison with the WC-FeAl composite coating with 500 ppm additional Boron and WC-Co coating both fabricated by thermal spray coating, for the WC-FeAl coating studied in this investigation, respectively the hardness is 1.16 and 1.21 times higher and the fracture toughness is 2.5 and 2.8 times higher. As well, Young's modulus of the coating was 1.56 times higher than the WC-Co coating made by the laser cladding method.

WC-Co涂层是基于碳化钨的涂层的一个子类别，在许多行业中都很重要。然而，由于钴的昂贵，中毒以及在酸性环境中钴的低耐腐蚀性，已经设计了替代组合物。这些替代品之一是可以代替钴的铝化铁金属间化合物。这项研究研究了在321不锈钢基底上激光熔覆WC-FeAl粉末的情况。WC-FeAl粉末是通过将初始的铝粉和铁粉进行机械合金化而合成的，然后研磨20小时，然后在800摄氏度下退火一小时。然后，将退火后的颗粒与WC粉机械合金化50小时。X射线衍射（XRD）分析的结果表明，在合成过程中没有形成脆性和破坏相。后来，通过激光熔覆法将粉末涂覆在不锈钢基底上。研究了激光熔覆的主要参数，包括激光功率，激光探针速度和粉末喷涂速率，对涂层性能的影响，例如孔隙率，几何形状，厚度和稀释度。结果表明，随着激光功率的提高，涂层的穿透深度和宽度增加。此外，随着激光探针速度的提高，稀释度和穿透深度降低。此外，较高的粉末喷涂速率导致涂层更厚。不同样品的最佳参数是250 W功率，4 mm / s探针速度和400 mg / s粉末喷涂速率。力学性能的评价表明，获得了1600维氏硬度，5.7MPa.m1 / 2断裂韧性和355GPa杨氏模量。此外，对涂层的机械性能的评价表明，硬度，断裂韧性和弹性模量分别为1600V，5.7MPa.m1 / 2和355GPa。所得结果表明，与通过热喷涂制备的额外500 ppm硼和WC-Co涂层的WC-FeAl复合涂层相比，本研究中研究的WC-FeAl涂层的硬度分别高1.16倍和1.21倍断裂韧性分别是其2.5和2.8倍。同样，涂层的杨氏模量比通过激光熔覆法制成的WC-Co涂层高1.56倍。所得结果表明，与通过热喷涂制备的额外500 ppm硼和WC-Co涂层的WC-FeAl复合涂层相比，本研究中研究的WC-FeAl涂层的硬度分别高1.16倍和1.21倍断裂韧性分别是其2.5和2.8倍。同样，涂层的杨氏模量比通过激光熔覆法制成的WC-Co涂层高1.56倍。所得结果表明，与通过热喷涂制备的额外500 ppm硼和WC-Co涂层的WC-FeAl复合涂层相比，本研究中研究的WC-FeAl涂层的硬度分别高1.16倍和1.21倍断裂韧性分别是其2.5和2.8倍。同样，涂层的杨氏模量比通过激光熔覆法制成的WC-Co涂层高1.56倍。