Comparison of erosion performance of uncladded and


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J. Electrochem. Sci. Eng. 12(5) (2022) 911-922; http://dx.doi.org/10.5599/jese.1333 

 
Open Access : : ISSN 1847-9286 

www.jESE-online.org 

Original scientific paper 

Comparison of erosion performance of uncladded and  
WC-based laser cladded SS304 and SS410 steels 
Sarpreet Singh1,, Parlad Kumar1and Deepak Kumar Goyal2 
1Punjabi University, Patiala, Punjab, India 
2I. K. Gujral Punjab Technical University Jalandhar, Kapurthala, Punjab, India 

Corresponding author: singh.sarpreet9976@gmail.com 

Received: March 28, 2021; Accepted: June 3, 2022; Published: August 19, 2022 
 

Abstract 
Myriad hydro materials have been encountered with the severe attacks of eroded particles 
during the operation, leading to degradation of target material and economic loss. In this 
study, Colmonoy-6+WC powders were deposited with the help of the laser cladding 
method on the bare SS304 and SS410 steel surfaces. Distinct properties of cladded 
surfaces, such as mechanical as well as metallurgical properties, were investigated. The 
influence of slurry erosion parameters like angle of impact and impact velocity of eroded 
particles on the cladded as well as uncladded steel specimen was analysed. Under all 
slurry erosion conditions, there was an escalation in slurry erosion resistance in the case 
of cladded steel as that of as-received steel specimens. In slurry erosion, the influence of 
the impact velocity of erodent particles is more against the impact angle. The scanning 
electron microscopy images of eroded uncoated steel specimens represent ductile 
behaviour along with the formation lip, ploughing etc., while eroded cladded steels exhibit 
brittle behaviour. 

Keywords 
Ni+WC based coatings; erosive wear; laser cladding 

 

Introduction 

In this contemporary era, there is a plethora of manufacturing units that are facing the problem 

of erosive wear. Owing to the influence of abrasive along with hard particles employed in the 

components, which are utilised in hydro machinery causing erosion, the reduction of the efficiency 

of turbine frequently occurs, which ultimately halts whole working operations [1-2]. There are 

myriad factors, for instance, the size and hardness of erodent particles, level of slurry concentration, 

the impact velocity of abrasive particles as well as the target surface characteristics that influence 

the erosive wear of elements utilised in hydro machinery [3-7]. Turbines, propellers, pumps, and 

valves are the most commonly used components in fluid machinery. The equipment utilised in this 

machinery is generally made of cast iron, mild steel and stainless steel. These materials, on the other 

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hand, are much less resistant to erosive wear [8-9]. The development of novel erosion-resistant 

materials is important. Various techniques, including heat treatment and surface coatings, have 

been explored to make the surface hard to the impact of erodent particles in order to reduce erosion 

wear. The laser cladding technique has numerous advantages over traditional approaches, including 

strong adhesion between the deposition powder and the substrate, reduced heat involvement, and 

surface deformation, which need to be cladded. Due to significant advancements in technology 

along with science involved in lasers, material processing techniques using lasers [10,11] have been 

considered a favoured technique for the treatment of the surface. In comparison to conventional 

approaches, surface treatments done by laser processing techniques have shown improved surface 

hardening of the material, fatigue, reduction in the erosion and corrosion rate, as well as reduction 

of stress corrosion along with the elimination of cracks, which are most common during other 

surface treatments, of distinct alloys and metals [10,11]. Savanth et al. [12] deposited the 

Colmonoy-5 coatings on medium carbon steel by the laser cladding technique by varying the laser 

cladding parameters such as laser beam power and scanning speed. With the help of laser cladding, 

there was a strong metallurgical bond between the substrate and coating. The hardness of the 

coating has been increased with an increase in the laser cladding as that of the scanning speed. The 

sound cladding has been obtained and laser power had more influence on the hardness than of 

scanning speed. Moskal et al. [13] analysed the characterization of the primary microstructure of 

laser-cladded NiCrAlY coatings deposited on Inconel 625 Ni-based superalloy and 316L stainless 

steel. It was found that the dendritic microstructure was the result of rapid solidification due to 

differences in the chemical composition of dendritic and inter-dendritic areas. Paul et al. [14] used 

the laser cladding approach and deposited two powders, namely, Metco-41C and NiCrSiBC and 

coatings produced by this technique were found to be crack-free. Yao et al. [15] produced TiN/Al 

composite coating and after the deposition of coating powders, there was a significant improvement 

in wear as well as the micro-hardness. The reason was an increase in the count of narrow and 

elongated dendrites in the cladded surfaces. Thus, the laser cladding method as a surface treatment 

should be investigated to improve the erosion problem in hydro machinery components. 

On the paradoxical side, in the last few decades, plenty of researchers used distinct powders such 

as nickel-based, iron-based, tungsten carbide-based and cobalt-based powders in many industrial 

applications to enhance the characteristics of different materials [16]. Nickel-based and WC 

powders have received the most interest as wear-resistant coatings [16]. Nickel-based powders 

exhibit a number of desired features that make them feasible to use in a variety of prospective 

engineering purposes [17], including strong bonding strength, improved corrosion behaviour, and 

great resistance to wear owing to adhesive and abrasive mode of failure. In addition, WC-cladded 

coating offers a lot of potential by virtue of qualities such as high hardness, enhanced resistance to 

wear, coefficient of thermal expansion is low, and good plasticity [18-21]. In order to attain sound 

carbide composite coating, Fishman et al. [22] used a laser cladding approach to manufacture WC 

coating on high-speed steel. The coatings, single layers produced with 40-50 percent WC, had 

hardness in the range of 1100–1200 HV9.81N. Yang et al. [23] created laser clads on the target 

surface of AISI 1010 steel using a blend of WC/Co powders and reported that the wear resistance 

was improved over the base material. Hence, in the current study, Colomonoy-6+WC coatings have 

been deposited on SS304 and SS410 steels using the technique of laser cladding. Further, cladded 

steels are used for the analysis of micro-hardness, porosity, microstructure and slurry erosion. A 

comparison of the mass loss owing to the slurry of Colmonoy-6+WC coated as well as uncladded 



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SS304 and SS410 steels was also conducted. Furthermore, the mechanism behind the wear of 

eroded surfaces has been investigated. 

Experimental  

Materials 

The aim of the present study is to produce Ni-based and WC coatings on the SS304 and SS410 

steels and evaluate their performance against slurry erosion. Samples of both above-mentioned 

steels were made. Specimens of 25 mm diameter and 7 mm width were made from the steel rod of 

25 mm. Before the deposition of coatings, the surface of the target specimens was finished to 

remove the contaminants with the assistance of a surface grinder. Table 1 and Table 2 show the 

chemical composition of SS304 and SS410 steels as determined by spectroscopic analysis, as well as 

the ASTM standard composition [24,25]. The chemical composition of SS304 and SS410 steels, as 

determined by spectroscopy, is consistent with the ASTM standard. Owing to the presence of 

chromium and nickel, steel provides resistance to wear and corrosion. 

Table 1. The chemical composition of SS410 steel  

Component 
Content, wt.% 

Cr C S Mn P Si Fe 

ASTM 11.5 to 13.5 <0.15 <0.03 <1 <0.04 <1 Balance 

Untreated 11.857 0.1307 0.0249 0.9401 0.0319 0.9881 Balance 

Table 2. The chemical composition of SS304 steel 

 Content, wt.% 

Components Cr C S Mn P Si Ni N Fe 

ASTM 17.5 to 19.50 <0.03 <0.015 <0.045 <0.045 <1.0 8.00 to 10.50 .10 Balance 

Untreated 17.928 0.028 0.012 1.469 0.0319 0.9814 8.91 .095 Balance 

Laser cladding set up 

The process of deposition of coatings was done at M/S Magod Laser Technologies, situated in 

Pune, India, with the diode laser cladding setup. A diode laser (LASERLINE, LDF 4.000, Germany) 

system has a special feedings system, which is coaxial in function, a beam delivery system, and a 

five-axis workstation provides more flexibility. The cladding material on the substrate was 

Colmonoy-6 +WC powder, and the properties of its elements [26,27] are listed in Table 2. As 

illustrated in Figure 1, a scanning electron microscope (SEM) JEOL, JSM6510LV has been utilized in 

order to investigate the structure and shape of the coating powder particles. The Colmonoy-6 

particles had a spherical shape, as shown in SEM images, but the shape of WC particles was found 

to be elongated. Prior to laser cladding, Colmonoy-6 and WC powder were combined in an 

equivalent amount (50 wt.%) utilising a blending method. A double cone blender (ILDCB001, 

Innovative Engineering Work, India) was employed for optimum blending. Powders were then put 

into the powder feeding mechanism. A diode laser with a coaxial powder feeding system was used 

to clad the steel specimens with a laser beam. The powders created from the double cone blender, 

which blended the Colmonoy-6+WC powders, were fed into the powder feeding system's bin. The 

powder feed system allows for a consistent flow of powder in a stream with a diameter of 2 mm 

and a flow rate of powder ranging from 10-40 g min-1. The purpose of shielding and carrier gas is 

done by argon. Earlier, the aim of removing all contaminants from the substrate's surface was done 

by sandblasting, which involved grit blasting the substrate with alumina (Al2O3), and after the 

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sandblasting, the surface was washed with de-ionized water along with acetone. There is a need for 

required surface roughness (7-9 µm) for producing the sound coating adhesion and this process was 

done through sandblasting [28]. As indicated in Table 3, steels were cladded using the laser cladding 

technique at optimal levels of several process parameters, namely: scanning speed, laser power, 

and powder feed rate. It was discovered that the above-mentioned laser cladding process 

parameters (scanning speed to be 1700 mm min-1, laser power to be 2000 W, powder feed rate to 

be 30 g min-1) were optimal for producing sound coating and illustrated in Table 4 [29]. 

Table 3. Properties of powders (tungsten carbide and Colmonoy-6) 

Name of Powder Density, g/cm3 Melting point, °C Hardness, Rockwell C scale 

Colmonoy-6 8.10  1030 56-61 

Tungsten carbide 10.0  2785-2830 88+ 

Table 4. Process parameters used during laser cladding 

Process parameters Range 

Laser power, kW 2 

Scanning speed, mm min-1 1700 

Powder feed rate, g min-1 30 

 
Figure 1. SEM micrograph of Colmonoy-6+WC powder 

Mechanical and material characterization of treated and untreated specimens 

For micro-hardness testing, the grit size of emery paper was from P100 to P1500 and used to 

polish the laser-clad and uncoated specimens. A Vickers microhardness tester (RMHT- 201, Radical 

Scientific Equipment Pvt. Ltd., India) has been used to assess the changes in cross-sectional micro-

hardness of the Colmonoy-6+WC coatings under a 1 kg load and a 25-seconds dwell period. In 

addition, the space between two consecutive indentations was maintained at 0.1 mm. Micro-

hardness measurements were calculated as the average of twelve readings made in similar areas. 

SEM analysis was utilised to study the splat distribution and porosity of the polished coated samples 

in cross-section. Surface SEM micrographs were utilized to analyse the vivid porosity of cladded 

materials surface using Envision 3.0 Series image analyser software (Chennai Metco Private Limited, 

India). Furthermore, SEM has been utilized to analyse the slurry erosion performance of laser 

cladded and uncoated specimens. 



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Slurry preparation 

Natural sand has been employed as striking material in the experimental investigation of slurry 

erosion, and its morphology is depicted in Figure 2. The shape of sand particles is uneven, with sharp 

edges, as shown in the SEM image. Larger silt particle sizes over 800 are unable to access the hydraulic 

components due to the existence of sedimentation chambers and sand filters and are thus excluded 

for erosion testing. Therefore, an average particle size of 350 µm is used for the current study. 

 
Figure 2. SEM image of erodent sand particles 

Slurry erosion analysis 

Slurry erosion experimentation was conducted at various variables using a specifically manufac-

tured test rig, as depicted in Figure 3 and the same had been utilized in previous work [29].  

 
Figure 3. Schematic diagram of the slurry erosion test rig 

The influence of two factors, impact velocity of erodent particle and impact angle, were 

investigated. Clad specimens were kept within the testing chamber in the specimen holder and had 

the capacity to adjust the orientation of the target surface in order to study the impact angle effect. A 

nozzle directs the combination of erodent particles and water in the testing chamber. A rotating vane 

pump is installed at the bottom, and one end of the pump is used to carry the slurry from the mixing 

chamber and directs the flow to the nozzle. There are valves built in the delivery pipe in order to 

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control the amount and pressure of the slurry. The slurry concentration is prepared in the mixing 

chamber with a predefined sand particle size, as required by the test and for present experimentation, 

the slurry concentration is 35,000 ppm. In order to avoid the settlement of erodent particles at the 

bottom, a stirrer is used in the mixing chamber. The mass loss was calculated at regular intervals by a 

precision microelectronic balance (ME36S, Cubis Laboratory Balances) and the accuracy of this 

machine is 0.1 mg. The diameter of the nozzle and the distance between the nozzle and target surface 

were set at 5 mm and 2.8 cm, correspondingly. 

As per ASTM standard G-73 [30], erosive wear analysis has been done on uncladded and cladded 

steel specimens. Moreover, the levels of the parameters mentioned above have been considered are 

illustrated in Table 3. Impact angles can be adjusted by moving the specimen holder around to 

examine the influence of impact angles of erodent particles. Myriad investigations have determined 

that ductile materials exhibit the most erosion at 20-40o impact angles, while materials that are brittle 

in nature exhibit the most erosive wear at 90° [31-34]. As a result, impact angles of 30 and 90° were 

chosen for slurry erosion experimentation. Most of the time, the relative velocity between the slurry 

and impeller varied between 10 and 35 m s-1 [35,36]. As a response, two levels of impact velocity (15 

and 30 m s-1) were considered in the slurry erosion testing to imitate real-world conditions. In order 

to analyse the impact of both variables, full factorial was used, as represented in Table 5. Slurry erosion 

testing was done for one hour. Table 6 represents slurry erosion testing using a full factorial array and 

these combinations have been used for the slurry erosion testing. According to the slurry erosion tests, 

the cladded specimens had a lower rate of erosion than uncladded specimens. After each hour of 

testing, the mass loss was computed, and in order to measure accurate measurement, the process of 

cleaning the specimens with acetone was done before the measurement of mass loss. SEM images 

were used to examine the eroded specimens in order to understand the actual mechanisms that cause 

slurry erosion. 

Table 5. Different levels of slurry erosion parameters 

S. No. Velocity, m s-1 Impact angle, o 

1 15 30 

2 30 90 

Table 6. Slurry erosion testing using a full factorial array 

 Velocity, m s-1 Impact angle, o 

Test 1 15 30 

Test 2 15 90 

Test 3 30 30 

Test 4 30 90 

Results and discussion 

Characteristics of coating deposition 

Figure 4 represents SEM images of the cross-section surface of laser-clad SS304 and SS410 steels, 

respectively. From the cross-sectional SEM images, the coating had a metallurgical connection 

between the coating and substrate. Though there were fewer microvoids owing to the porosity of 

cladding materials, the coating seemed to have fewer defects. The value of porosity obtained for the 

coatings was in the range between 1.3 and 1.6 % (in both steels), and the same values were reported 

by different researchers with the deposition of the same cladded materials [21]. According to the 



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cross-section SEM images, the thickness, which was higher than 1 mm, was observed for the coating. 

From the SEM images, it was witnessed that carbides were evenly dispersed in Colmonoy-6 pool. 

Although most of the carbides were spherical in shape, on the surface, a few unevenly shaped carbides 

were detected. 

 a b 

 
Figure 4. (a) Cross-sectional SEM image of laser cladded SS410 steel and (b) cross-sectional SEM image of 

laser cladded SS304 steel 

The hardness of the uncoated SS304, SS410 steel, and cladded steels was represented in Figure 5. 

The value of hardness was measured at a distinct position on the cladding top surface with the 

application of 1 kg. The hardness of cladded surface was much higher than the substrate materials. 

The average hardness of SS304 and SS410 steel was noticed to be 152 and 178 HV9.81N, respectively. 

An increase in microhardness was seen after the cladding of Ni+WC-based coatings on both steels, 

which could be related to the presence of dispersed carbides on the cladded surfaces [37]. The 

coating's micro-hardness ranged from 1009 to 1113 HV9.81N, with a mean value of 1074 HV9.81N in 

the case of SS304 steel and 1079 HV9.81N for SS410 steel. This represents that after the coating 

deposition, there is no remarkable impact on the base material and hardness, found to be almost 

the same in both cladded surfaces.  

 
Steel specimen 

Figure 5. Micro-hardness of coated and uncoated steel specimens 

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Mechanism of slurry erosion 

Experimental investigations of slurry erosion were carried out on the above-mentioned cladded 

material and uncladded steel specimens under various operating circumstances. As indicated in Figure 

6, the bar graph elucidates the information regarding the change in mass loss of cladded and 

uncladded specimens. When comparing uncoated SS410 and SS304 steels to Colmonoy-6 + WC-

cladded steel, it was discovered that the latter had stronger resistance to erosion. This could be due 

to the higher clad surface's hardness compared to uncladded steels. The maximum erosion was at the 

maximum impact velocity (30 m s-1). The reason for this, when the impact velocity increases then, 

there is also an increase in the kinetic energy of sand particles. Consequently, maximum mass loss was 

noticed in all experiments. Goyal et al. [38] carried out the research work on slurry erosion analysis of 

steel and it has been observed that impact velocity was the major contributor to slurry erosion and 

similar results have been reported by Lopez et al. [39]. Further, utmost erosion was observed at an 

angle of 30° and this represents the ductile failure and as the impact angle increases, this exhibits 

more resistance to erosion owing to the brittle mode of failure [40-42].  

 
Steel specimen 

Figure 6. Loss of mass after erosion of laser-cladded and uncoated SS304 and SS410 steel using 4 mm jet 

Eroded surface analysis 

Most of the time, the mechanism of removal of material under slurry erosion is affected by the 

properties of encountered surfaces of the material and working parameters in general [38]. Plastic 

deformation, along with cutting, is used to erode the material from the target surface in the case of the 

ductile mode of wear [43]. Fatigue failure occurs in brittle materials when energy is transferred to the 

target surface of the material by the repetitive influence of erodent particles [38]. Furthermore, distinct 

erosion mechanisms exist for different operating situations, such as low plus high impact angles, and for 

the lower impact angles, ploughing, chip formation, and cutting are the mechanisms which are generally 

occurred on eroded surfaces [44]. Cracks and craters formed by material erosion as platelets, on the 

other hand, are plausible erosion mechanisms for normal impact [45]. The subsequent paragraphs 

illustrate the erosion mechanisms of cladded and uncladded steel specimens.  

Uncoated SS304 and SS410 steel 

After the polishing of as received steels before erosion causes some scratches on the surface. 

SEM images of uncoated steels after the erosive wear occurred at using impact angle of 30° and 

M
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ss
, 

H
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impact velocity of 30 m s-1, are shown in Figure 7. Maximum erosion has been witnessed in the case 

SS304 steel as that of SS410 steel. This is because of the higher hardness of SS410 steel against the 

SS304 steel. At this operating condition, slurry erosion was found to be highest as with a higher 

impact angle, the more mass removal rate was noticed, and the mode of failure in both cases was 

ductile. Steel surface had some cracks and the same was represented in Figure 7, which paved the 

way to the continuous and normal impact of erodent particles, while on the eroded surfaces of steel 

specimens, lip formation was seen, which could be related to the ductile mode of failure of the 

material under higher erodent particle velocity (30 m s-1) and low impact angle (30o) [45]. Signatures 

of the ploughing and micro-cutting have been observed on the eroded surface of steel, as illustrated 

in SEM pictures, may be caused by the same mechanism. Further, it also has been witnessed that 

the wear resistance of SS410 is more owing to the higher hardness, and that is the reason there is 

less plastic deformation in comparison with SS304. 

 a b 

 
Figure 7. SEM images of (a) uncoated SS304 steel and (b) uncoated SS410 steel after erosion 

Coated SS304 and SS410 steel 

Figure 8 shows SEM images of cladded SS304 and SS410 steel after the maximal rate of wear at 

the velocity of 30 m s-1 and 90o impact angle.  

 a b 

 
Figure 8. SEM images of (a) coated SS304 steel and (b) coated SS410 steel after erosion 

A significant number of cracks were created on the eroded cladded surface by dint of the 

continuous impact of erodent particles at 90°. After the deposition of cladded powder, a significant 

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increase in wear resistance was noticed and the mode of failure was brittle because there was no 

formation of lip, ploughing and crater. The reason behind this mode of failure is owed to the impact 

angle of 90°. T. Savanth et al. [12] evaluated the slurry erosion performance of Colomonoy-5; it was 

found that under the same operating conditions, the mode failure was brittle, which was in 

accordance with the present research work. Further, research work carried out by Paul et al. [14] 

was on the slurry erosion performance of laser cladded 316 L steel and it was found that the mode 

of failure was brittle. Moreover, the mode of failure was almost the same in the case of coated 

SS304 and SS410 steels and no significant effect of the base material was observed.  

Conclusions 

• The laser cladding technique was used to successfully create Colmonoy-6+ WC coatings on SS304 

and SS410 steels under specified laser cladding process parameters: scanning speed, laser 

power and powder feed at 1700 mm/s, 2 kW and 30 g/min, respectively. 

• There was a significant improvement in hardness after the deposition of coating materials. The 

hardness of the cladded steels was found to be more than six times of the uncladded steel 

specimens. 

• Mass loss was found to be less in the coated specimens than in the uncladded specimens. The 

reason behind this was the higher hardness of the deposited coating. The most significant factor 

for mass loss of coated and uncladded steel was found to be impact velocity. 

• Signs of lip formation, craters, ploughing were observed in the case of eroded uncoated steel 

specimens and the mode of failure was ductile, while the eroded cladded specimens had no 

signs of lip formation and ploughing. Owing to the brittle mode of failure, there were some 

cracks on deposited coatings. 

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