Study on the Microstructure, Wear, and Corrosion Resistance of GH3536 Coatings Prepared by Laser‐Assisted Cold Spraying

During the cold spray deposition of nickel‐based superalloy powders, particles with insufficient deformation and weak bonding inevitably form, which significantly degrades the coating performance. To enhance the coating's performance, a laser‐assisted cold spraying process is employed to prepare the GH3536 coating. The laser assistance softens the substrate and particles by heating, and during deposition, the powder particles undergo recrystallization and “weld” the pores, improving the coating's density. Compared to the cold‐sprayed (CS‐GH3536) coating, the laser‐assisted cold‐sprayed (LACS‐GH3536) coating exhibits a remarkable 96.2% reduction in porosity and a 63.4% decrease in wear rate. The wear mechanisms of all coatings include oxidative wear, abrasive wear, and adhesive wear. In a 3.5 wt% NaCl solution, the LACS‐GH3536 coating shows outstanding corrosion resistance, with a low Icorr of only 10.321 μA cm − 2 . Laser heating facilitates recrystallization within the coating, improving grain uniformity and significantly enhancing both passivation and corrosion resistance.