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Laser Processing of Fe-Cr-B Alloys: Microstructure Evolution, Non-Equilibrium Solidification and Wear-Corrosion

Lei He^1,2,3, Changle Zhang², Jiang Ju¹

¹School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China.

Materials (Basel, Switzerland)

|July 15, 2026

Summary

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Laser processing refines iron-chromium-boron (Fe-Cr-B) alloys, significantly enhancing wear and corrosion resistance compared to casting. Rapid solidification techniques like laser cladding and DED produce finer borides and denser microstructures for improved performance.

Area of Science:

Materials Science and Engineering
Metallurgy
Additive Manufacturing

Background:

Fe-Cr-B alloys offer excellent wear and corrosion resistance due to hard boride phases.
Conventional casting leads to coarse borides and segregation, causing brittleness and limiting reliability.
Laser processing techniques (cladding, LPBF/DED) enable rapid solidification, altering microstructure and properties.

Purpose of the Study:

To review and systematically analyze the effects of laser processing on Fe-Cr-B alloys.
To compare microstructural evolution and performance across different laser processing methods and casting.
To identify limitations and propose future research directions for optimizing laser-processed Fe-Cr-B alloys.

Main Methods:

Classification of evidence based on processing methods: laser cladding, LPBF/DED, casting.

Keywords:

Fe-Cr-B alloy casting corrosion resistance directed energy deposition (DED)laser additive manufacturing (LAM)laser cladding laser powder bed fusion (LPBF)microstructure control wear resistance

Related Experiment Videos

Quantitative comparison of boride refinement, grain size, and relative density.

Analysis of non-equilibrium solidification mechanisms (solute trapping, CET) and their control via G/R ratio.

Systematic review of existing literature, distinguishing direct evidence from indirect inference.

Main Results:

Laser cladding refines borides from 150-300 μm to 10.8-20 μm; DED achieves 1-5 μm equiaxed grains with >98% density.
Laser-clad Fe-Cr-B coatings exhibit ~1052 HV0.5 hardness, 18% better wear resistance, and 70% less cavitation mass loss than cast counterparts.
Non-equilibrium mechanisms significantly influence phase evolution and microstructure under rapid cooling.

Conclusions:

Laser processing, particularly DED, offers superior microstructural control and performance enhancement for Fe-Cr-B alloys over conventional casting.
Understanding non-equilibrium solidification mechanisms is crucial for designing advanced Fe-Cr-B materials.
Further research is needed in thermodynamic databases, standardization, post-processing, and unified performance datasets for laser-processed Fe-Cr-B alloys.