In Situ Synthesized NbC-Reinforced Laser Clad Composite Coating on 17-4PH Stainless Steel: Microstructure Evolution and Wear Resistance Enhancement

This study presents a novel in situ reinforcement strategy for 17-4PH stainless steel by using Nb and Cr3C2 powders as precursors, addressing the challenge of poor particle dispersion and interfacial bonding in conventional ex situ ceramic additions. The coatings were systematically compared with 17-4PH coatings without the addition of a reinforcing phase. The results show that the coating without Nb addition is dominated by α-Fe martensite, exhibiting a coarse columnar/dendritic microstructure. After adding Nb and Cr3C2, the coating successfully forms in situ face-centered cubic NbC, with a significantly refined and uniformly distributed microstructure. The 10 wt.% Nb+Cr3C2 coating exhibits a refined microstructure with an average grain size reduced from 1.12 μm to 0.85 μm and a microhardness of 495.5 HV, representing an 86% increase over the substrate and a 34% improvement compared to the unreinforced coating. Friction–wear tests demonstrate that the composite coating reduces wear track width and depth by approximately 50% and 45%, respectively, compared to the substrate, with the wear mechanism transitioning from severe adhesive and fatigue wear to mild abrasive wear and localized micro-delamination. In situ synthesized NbC effectively optimizes the coating microstructure, enhances interfacial bonding, and markedly improves the hardness and wear resistance of 17-4PH coatings, providing theoretical and technical support for their engineering application under severe service conditions.