Crack Arrest Effect of FeMnNiSi-Inconel625-Ni60 Laminated Structure Prepared by Laser Cladding Additive Manufacturing

This study addresses the technical challenges of cracking and surface crack initiation in Ni60 alloy cladding layers fabricated by laser cladding additive manufacturing on FeMnNiSi alloys. An innovative FeMnNiSi-Inconel625-Ni60 laminate design was proposed, achieving metallurgical bonding of the dissimilar materials through an Inconel625 transition layer. This effectively addresses the interfacial stress concentration issue caused by differences in thermal expansion coefficients in conventional processes. The results demonstrate that the interfacial microstructure is regulated by synergistic Nb-Mo element segregation, promoting the precipitation of γ″ phase and the formation of a nanoscale Laves phase. This phase not only inhibits carbide aggregation and growth, refining grain size, but also deflects crack propagation paths by pinning dislocations, achieving a dual mechanism of stress reduction and crack arrest. The Ni60 cladding layer in the laminated structure exhibits an average surface microhardness of 641.31 HV_0.3, 3.88 times that of the substrate (165.22 HV_0.3), while the Inconel625 base layer shows 340.71 HV_0.3, 2.06 times the substrate's value. Wear testing reveals the laminated cladding layer has a wear volume of 0.086 mm³ (0.243 mm³ less than the substrate's 0.329 mm³) and a wear rate of 0.86 × 10^-2 mm³/(N·m), 73.86% lower than the substrate's 3.29 × 10^-2 mm³/(N·m), indicating superior wear resistance. The electrochemical test results show that under the same corrosion conditions, the self-corrosion potential and polarization resistance of the FeMnNiSi-Inconel625-Ni60 cladding layer are significantly higher than those of the substrate, while the corrosion current density is significantly lower than that of the substrate. The frequency stability region at the highest impedance modulus |Z| is wider than that of the substrate, and the corrosion rate is 71.86% slower than that of the substrate, demonstrating excellent wear resistance. This study not only reveals the mechanism by which Laves phases improve interfacial properties through microstructural regulation but also provides a scalable interface design strategy for heterogeneous material additive manufacturing, which has important engineering value in promoting the application of laser cladding technology in the field of high-end equipment repair.