This study systematically investigates the influence of laser power (1000 W, 1400 W, 1800 W) on the microstructure and properties of Ni25 alloy coatings prepared by laser cladding to optimize process parameters for enhanced comprehensive performance. Through the analysis of multi-dimensional characterization, it is found that the laser power significantly changes the thermal cycle, thus determining the evolution of microstructure. At 1000 W, a fine dendritic structure with dispersed hard phases (BNi₃, BFe₃Ni₃, CrB₂, Cr₇C₃) yielded the highest hardness (442.52 HV) but poor wear (volume loss: 0.3346 mm³) and corrosion resistance (Icorr: 2.75 × 10⁻⁴ A·cm⁻²) due to microstructural inhomogeneity. The 1400 W coating, featuring a uniform γ-Ni dendrite/eutectic network and increased B solid solubility, achieved an optimal balance with the lowest wear rate (0.0685 mm³), superior corrosion resistance (Icorr: 2.34 × 10⁻⁵; A·cm⁻²), and a stable friction coefficient (0.816), despite lower hardness (342.00 HV). At 1800 W, grain coarseness and Cr₇C₃ decomposition led to blocky hard phases, recovering hardness (415.36 HV) and reducing the friction coefficient (0.757), but resulting in intermediate wear and corrosion resistance. This study demonstrates that the uniformity and continuity of the microstructure are the key determinants governing the comprehensive service properties of the laser cladding layer, with their importance outweighing a single hardness index. 1400 W is identified as the optimal laser power, providing critical insights for fabricating high-performance Ni25 coatings in demanding service environments.

Under the conditions of laser power of 1500 W, scanning speed of 5 mm/s, spot diameter of 3.5 mm, and powder feeding rate of 10 r/min, this study systematically investigated the influence of different tempering temperatures (200 °C and 600 °C) on the microstructure, friction and wear properties, and corrosion resistance of laser cladding Ni25 coatings, as well as the underlying mechanisms. The phase composition, microstructure, chemical composition, wear resistance, and corrosion resistance of the coatings were characterized and analyzed using X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), pin-on-disk friction and wear tests, and electrochemical workstations. The results showed that the as-clad coating was composed of γ-Ni supersaturated solid solution and various metastable borides/carbides (such as Cr₃B₄), presenting fine-grained and non-equilibrium features. Tempering at 200 °C mainly achieved stress relaxation, enhancing and shifting the diffraction peaks to the left without changing the phase composition, while tempering at 600 °C drove significant diffusion-type phase transformation, leading to the decomposition of metastable Cr₃B₄ and the precipitation of stable phases such as Ni₂Si, accompanied by grain growth and microstructure coarsening. Friction tests indicated that the coating tempered at 600 °C exhibited the lowest average friction coefficient (0.679) and wear volume (0.0582 mm³) due to stable microstructure and hard phase strengthening, demonstrating the best wear resistance. However, electrochemical tests revealed a “trade-off” effect: the fine-grained microstructure of the as-clad coating, with its uniform composition, had the lowest corrosion current density (8.10 × 10⁻⁵ A/cm²) in 3.5% NaCl solution, showing the best resistance to uniform corrosion, while tempering, especially at 600 °C, caused grain growth, coarsening of the second phase, and micro-galvanic effects, slightly reducing the anodic dissolution resistance and increasing the corrosion current. This study clarified that heat treatment can significantly enhance the mechanical and tribological properties of Ni25 coatings by regulating their transformation from metastable to stable states, but at the potential cost of some corrosion resistance, providing a theoretical basis for optimizing post-treatment processes for different service conditions (wear resistance or corrosion resistance).