Corrosion and wear resistance characteristics of NiCr coating by laser alloying with powder feeding on grey iron liner

To reduce the mixed fuel induced excessive wear of the cast iron engine cylinder liners, research on laser alloying of NiCr alloy with powder feeding was performed to locally change both the composition and the microstructure of the liner. The research indicated that laser alloying of 75Ni25Cr on grey cast iron liner demonstrates sound alloying layers free of cracks and porosities. The microstructure of the alloyed layer is composed of pre-eutectic austenite and ledeburite. The alloying element Ni is mainly located in the austenite, while Cr is mainly in cementite. The average hardness is HV_0.2500. The corrosion resistance of the alloyed layers in diluted H₂SO₄ solution and NaOH solution is dramatically improved compared to the grey cast iron. The relative wear resistance of the laser-alloyed 75Ni25Cr layer is 4.34 times of that of the grey cast iron. The improvements on the corrosion and wear resistance of the cast iron are attributed to the composition and microstructure change by laser alloying of 75Ni25Cr. Laser alloying can be a good solution to improve wear and corrosion resistance of the grey iron liners in mixed fuel environment.