Influence of tantalum addition on the microstructure and wear resistance properties of NiCuBSi/65WC composite coatings

Nickel-based tungsten carbide composite coatings are extensively utilized on various wear-resistant workpiece surfaces due to their exceptional properties, including high hardness and wear resistance. However, as the WC content increases, uneven structure and susceptibility to cracking of the coating during the forming process are enhanced, thereby impacting its service performance. To address these issues, NiCuBSi/65WC composite coatings with varying tantalum (Ta) contents were fabricated on 42CrMo steel substrates by laser cladding. The influence mechanism of Ta content on the microstructure and wear resistance of the coatings was investigated. The results demonstrate that the addition of tantalum promotes the formation of reinforcement phases such as TaC and W2C in the coating. Moreover, with increased Ta content, the edge of WC particle reaction layers in the coating gradually transforms from sawtooth to shorter rod-shaped morphology. Additionally, as the Ta content increases, the dissolution degree of WC particles rises, thereby facilitating the formation of TaC and W2C compound carbide. This leads to an enhancement in both the quantity and uniform distribution of carbide reinforced phases within the coating, resulting in an increase in average coating hardness from 482.4 HV0.2 to 580.1 HV0.2. When the Ta content reaches 7 wt% in particular, no cracks are observed on the coating surface, and a uniform distribution of carbides is achieved. The relative wear resistance of NiCuBSi/65WC coating with 7 wt% Ta is approximately 2.36 times higher than that without Ta.