The mould foot roller is a key component of a continuous casting machine. In order to investigate the possibility of using laser cladding to repair mould foot roller, Fe-based powders and 42CrMo steel are used in this work. The laser cladding process parameters were optimized by orthogonal experiments. The chemical compositions, microstructure, properties of the cladding layer under the optimum process parameters, and substrate were systematically investigated by using optical microscopy (OM), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray diffraction (XRD), microhardness test, wear test, and salt spray corrosion test. The results indicate that the primary factor affecting the width and depth of the cladding layer is laser power. The scanning speed also has a significant effect on the height of the cladding layer. The optimum process parameters for repairing the mould foot roller are 2 kW laser power, 4 mm/s scanning speed, and 15 g/min feeding rate of powder. Along the depth direction of the cladding layer, the microstructure of the coating gradually transforms from plane crystal, cell grains, or dendrites to equiaxed grains. The matrix is mainly martensite with retained austenite; the eutectic phase is composed of netlike M₂B, particulate M₂₃(C,B)₆, and M₇(C,B)₃ phase. The hardness of the cladding layer is significantly improved, about three times that of the substrate. The weight loss of the cladding layer is just half that of the substrate. Its wear resistance and corrosion resistance have been significantly improved. The work period of the laser cladding-repaired foot roller is much longer than for the surfacing welding-repaired one. In summary, laser cladding technology can increase the life of mould foot rollers.

We propose a novel technique for the large-scale synthesis of aligned-plate nanostructures that are self-assembled and self-supporting. The synthesis technique involves developing nanoscale two-phase microstructures through discontinuous precipitation followed by selective etching to remove one of the phases. The method may be applied to any alloy system in which the discontinuous precipitation transformation goes to completion. The resulting structure may have many applications in catalysis, filtering and thermal management depending on the phase selection and added functionality through chemical reaction with the retained phase. The synthesis technique is demonstrated using the discontinuous precipitation of a γ′ phase, (Ni, Co)₃Al, followed by selective dissolution of the γ matrix phase. The production of the nanostructure requires heat treatments on the order of minutes and can be performed on a large scale making this synthesis technique of great economic potential.