**Comparison Between Laser Cladding and Plasma Spray Welding** Laser cladding and plasma spray welding are two distinct surface enhancement techniques, with the main difference lying in their heat sources. Laser cladding uses a highly concentrated laser beam that provides rapid heating, high temperature, and short exposure time. This allows the molten layer to reach temperatures of up to 10âµâ€“10ⶠ°C/s, resulting in a very fast cooling rate. The laser melts the powder layer while slightly melting the substrate’s surface, creating a strong metallurgical bond between the two. Due to the quick heating and cooling process, the heat-affected zone is small, and the dilution ratio of the clad layer is minimized. In contrast, plasma spray welding employs a lower power density and longer thermal exposure time. This leads to more extensive diffusion between the coating and the base material, increasing the heat-affected zone and causing greater composition contamination. As a result, the microstructure of the plasma-sprayed layer tends to be coarser compared to the fine structure achieved through laser cladding. The finer grain size in laser-clad layers—typically 2–4 grades higher—contributes to improved mechanical properties such as micro-hardness, corrosion resistance, and wear resistance. Laser cladding also ensures that the original properties of the cladding material, such as high hardness, wear resistance, and oxidation resistance, are preserved. It achieves a strong metallurgical bond without significant degradation of the base material. This results in a dense, low-dilution interface with minimal interdiffusion, making it ideal for applying high-performance alloy coatings on cost-effective steel substrates. Compared to other surface treatment methods, laser cladding offers superior adhesion strength and performance. The ability to tailor the properties of the clad layer while maintaining a strong bond with the substrate makes laser cladding an attractive choice for advanced engineering applications. Whether for improving wear resistance or enhancing corrosion protection, laser cladding provides a reliable and efficient solution that outperforms traditional techniques like plasma spray welding.
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