OBRABOTKAMETALLOV Vol. 28 No. 3 2026 56 TECHNOLOGY References 1. Zhong M., Liu W. Laser surface cladding: the state of the art and challenges. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 2010, vol. 224 (5), pp. 1041–1060. DOI: 10.1243/09544062JMES1782. 2. Wang K., Zhang Z., Xiang D., Ju J. Research and progress of laser cladding: process, materials and applications. Coatings, 2022, vol. 12 (10), p. 1382. DOI: 10.3390/coatings12101382. The infl uence of laser cladding modes on the defectiveness of Ni-Al coatings Natalya Kozhukhova a, Vyacheslav Sirota b, *, Anton Churikov c, Sergey Zaitsev d, Dmitry Prokhorenkov e Belgorod State Technological University named after V.G. Shukhov, 46 Kostyukova st., Belgorod, 308012, Russian Federation a https://orcid.org/0000-0002-9380-0968, kozhuhovanata@yandex.ru; b https://orcid.org/0000-0003-4634-7109, zmas36@mail.ru; c https://orcid.org/0000-0002-1829-2676, churikov.toni@mail.ru; d https://orcid.org/0000-0003-0122-1908, sergey-za@mail.ru; e https://orcid.org/0000-0002-6455-8172, bstu-cvt-sem@yandex.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2026 vol. 28 no. 3 pp. 44–57 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2026-28.3-44-57 ART I CLE I NFO Article history: Received: 16 June 2026 Revised: 29 June 2026 Accepted: 11 July 2026 Available online: 15 September 2026 Keywords: Laser cladding Ni-Al Coating Funding This research was carried out within the framework of the state assignment of the Ministry of Science and Higher Education of the Russian Federation No. FZWN2026-0007, titled “Structural and Physical Principles of the Formation of Functional Topocomposite Protective Coatings Based on Multicomponent Alloys for Elements of Tunnel Boring Complexes with a High Degree of Abrasive Wear”, for the period 2026–2028. The work was also supported by the Center for High Technologies of Belgorod State Technological University named after V. G. Shukhov. Acknowledgements The research was carried out using the equipment of the Center for High Technologies of BSTU named after V. G. Shukhov. ABSTRACT Introduction. Laser cladding of powder composites is a promising method for producing heat-resistant coatings. The Ni–Al system, capable of forming the strengthening Ni3Al phase, is of interest for protecting components operating under high-temperature oxidation conditions. However, the process is complicated by the high reactivity of aluminum and the tendency to form oxides and embrittle the structure. The literature lacks systematic recommendations for selecting parameters that ensure a dense, defect-free coating for the Ni–15% Al composition. The purpose of this work is to optimize the laser cladding parameters of the Ni–Al powder composite according to the criteria of continuity, geometric accuracy, and minimal defectiveness of the deposited bead. Materials and methods. Cladding was performed using a fi ber laser with a power of 1,500–3,900 W, scanning speed of 20–100 mm/min, and powder feed rate of 24–69 g/min. A total of 40 single-track beads were produced. Quality was assessed by visual inspection, metallography of crosssections, microhardness testing, energy-dispersive X-ray spectroscopy (EDS), and X-ray diff raction (XRD) phase analysis. The energy input E and specifi c energy input G were calculated for each mode. Results and discussion. The minimum energy input required to form a continuous bead is found to be E ≥ 54 kJ. The optimal parameter window corresponds to E = 54–81 kJ at a scanning speed of 20–30 mm/min and a laser power of 1,860–2,700 W. At higher specifi c energy input, the iron content diff using from the substrate increases, and the heat-aff ected zone expands. The microhardness of the coatings reaches 260–290 HV, signifi cantly exceeding that of the initial steel substrate (≈150 HV). At lower G values, the structure contains the strengthening Ni3Al phase, while at higher G values, taenite (Fe0.64Fe0.36) becomes the dominant phase. Aluminum oxides are not detected in either case. Conclusions. Modes with E = 54–81 kJ and G = 3.3–5.0 kJ/g are recommended, as they provide a dense, defect-free coating with high hardness and the desired phase composition. Further increase in energy input is inadvisable due to excessive dilution with the substrate material. The obtained results can serve as a basis for developing technological regulations for the application of Ni–Al coatings. For citation: Kozhukhova N.I., Sirota V.V., Churikov A.S., Zaitsev S.V., Prokhorenkov D.S. The infl uence of laser cladding modes on the defectiveness of Ni-Al coatings. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2026, vol. 28, no. 3, pp. 44–57. DOI: 10.17212/1994-6309-2026-28.3-44-57. (In Russian). ______ Sirota Vyacheslav V., Ph.D. (Physics and Mathematics) Belgorod State Technological University named after V.G. Shukhov, 46 Kostyukova st., 308012, Belgorod, Russian Federation Tel.: +7 904 539-14-08, e-mail: zmas36@mail.ru
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