Effect of Overlap Rate on Microstructure and Corrosion Behavior of Laser-Clad Ni60-WC Composite Coatings on E690 Steel

To investigate the influence of laser cladding overlap rate on the microstructure and corrosion resistance of cladded layers, Ni60-WC composite coatings with different overlap rates (30%, 50%, and 70%) were prepared on E690 offshore steel in this study. The relationship between the corrosion resistance and microstructure of the cladded layers fabricated at different overlap rates was analyzed using an electrochemical workstation, scanning electron microscope, X-ray diffractometer, and energy dispersive spectrometer. The results demonstrate that the overlap rate exerts a significant impact on the corrosion resistance of the cladded layers, and the corrosion resistance of the cladded layers gradually improves with the increase in overlap rate. The cladded layer prepared with a 70% overlap rate exhibits excellent corrosion resistance, featuring the highest open-circuit potential (−0.31 V vs. SCE), the lowest corrosion current density (3.35 μA/cm2), the largest capacitive arc radius in the electrochemical impedance spectroscopy (EIS), and a relatively flat surface after corrosion tests. Microstructural characterization results indicate that the increase in overlap rate promotes grain refinement and the formation of reinforcing phases (e.g., M23C6). The coating with a 70% overlap rate possesses the densest microstructure and abundant flocculent carbides, which act as an effective barrier against the penetration of corrosive media, thereby endowing it with optimal performance.