A novel method based on the pre-texturing approach to fabricate SiC reinforced metal matrix composites via wire laser cladding

This work presents a novel pre-texturing method to fabricate SiC-reinforced 316L metal matrix composite coatings using wire laser cladding without composite feedstock wires. Sixteen surface textures were produced by wire EDM, enabling controlled embedding of SiC particles. Depending on groove geometry, SiC embedding efficiency ranged from 35–73%, yielding final clad reinforcement levels of 2.8–12.2 vol.%. Macro/microstructural analyses confirmed defect-free clads, refined cellular–dendritic structures, and SiC dissolution forming Si-rich hard phases. EDX analysis showed Si enrichment up to 1–4 wt% across the clad area. Microhardness increased from 170 HV in the unreinforced clad to >330 HV in optimized textures. Tribological testing (15–45 N) showed the friction coefficient reduced from 0.60 (S17) to 0.45–0.50 for reinforced samples, while wear volume decreased by 40–55% and wear rate by 50–60%. Samples with the highest SiC uptake exhibited the best performance across all loads. This method enables tunable incorporation of ceramic reinforcement in WLC and significantly enhances mechanical and tribological properties using standard metallic wire. • Successful SiC incorporation into 316L wire laser cladding without cored wire. • Texture design controlled SiC uptake achieving up to 12.2 vol.% reinforcement. • Reaching three-fold grain refinement by SiC residues and dissolution phases. • 100% increase in microhardness values during surface composite fabrication. • Friction coefficient and wear rate improved by 40–60% across all loads.