Laser Surface Cladding as a Sustainable Alternative to Hard‐Chrome Plating—A Mechanical and Tribological Assessment

This study investigates the potential of laser surface cladding (LSC) using two stainless steel alloys, austenitic (M1) and martensitic (M2), as a sustainable alternative to hard‐chrome plating (HCP). Comprehensive evaluations, including microstructure, phase aggregate, hardness, bending, and wear tests (sliding, abrasive, and erosive), conducted as per ASTM standards, followed by post‐wear damage analysis, reveal distinct performance advantages for each alloy clad. The M2 clad exhibits higher flexural strength and modulus, along with the lowest specific damage rate in both sliding and abrasive wear tests, attributes to its higher hardness and strength. The M1 clad, in contrast, shows the lowest coefficient of friction and superior erosive wear resistance, owing to its relatively ductile nature and the formation of stable oxide films. Overall, the results demonstrate that iron‐based laser‐clad coatings offer a technically effective and environmentally benign substitute for HCP, with application potential in hydraulic and mining components. While clad M1 is more erosive‐wear resistant, clad M2 is more suitable to withstand sliding and abrasive wear damage.