A Review of High Temperature Durability and Laser Cladding Crack Suppression Techniques for Nickel‐Based Alloys: Mechanisms and Strategies

This review comprehensively examines the durability issues and technological advancements of nickel‐based alloys in high‐temperature service conditions, focusing on oxidation, creep, thermal shock, and corrosion performance, as well as the underlying mechanisms of crack formation and suppression in laser cladding. It first explores the roles and limitations of alloy composition, microstructure control, and surface modification in enhancing high‐temperature oxidation and creep resistance. Then, it thoroughly analyzes the impacts of thermal stress, solidification shrinkage, and elemental segregation during laser cladding on crack formation, and summarizes crack‐suppression strategies like reducing dilution, adjusting laser energy density, altering scanning speed, and adding small amounts of Mo. The review notes that while nickel‐based alloys show significant mechanical and chemical stability in high‐temperature environments, they still face challenges in balancing microstructure and macro‐properties, co‐optimizing multiple properties, and controlling processing costs. Future research should focus on developing multi‐scale, multi‐physical, field‐coupled theoretical models, finely tuning process parameters, and establishing unified evaluation standards to promote the widespread use of nickel‐based alloys in key sectors like aviation and energy.