Dry and grease-lubricated reciprocating wear resistance of laser-clad FeCrMoCB amorphous coating on AISI 52100 steel

Purpose This paper aims to investigate the reciprocating wear resistance of laser-cladded FeCrMoCB amorphous coatings on AISI 52100 steel under both dry and grease-lubricated conditions. It aims to explore the effects of microstructural refinement and lubrication regimes on the tribological performance of the coatings. Design/methodology/approach This paper opted for an exploratory study of nine Fe-based amorphous coatings were deposited on AISI 52100 substrates using a fiber laser cladding system, with variable process parameters guided by the Taguchi method optimization. The samples underwent tribological testing using a High-Frequency Reciprocating Rig under dry and NLGI 3 grease-lubricated conditions. Characterization techniques included Scanning Electron Microscopy, X-ray Diffraction, Energy Dispersive X-ray spectroscopy and Vickers microhardness testing. Findings This paper provides empirical insights about nine optimized coatings samples, particularly samples S6 and S7, exhibited significantly enhanced wear resistance. Under dry conditions, these coatings reduced the coefficient of friction (COF) by up to 30% and wear volume loss by up to 75% compared to uncoated steel. Grease lubrication further lowered COF by 24.5%–35.6% and improved wear rates by 30%–40%. The results highlight a strong correlation between refined microstructure, high amorphous content and tribological performance. Research limitations/implications Because of the chosen research approach, the findings are limited to controlled laboratory conditions and specific loading scenarios. Therefore, further studies are needed to assess long-term durability under cyclic or thermal loads. Practical implications This paper includes implications for the developed coatings are suitable for industrial components subjected to varying lubrication regimes, such as in bearings or gears, offering enhanced durability and reduced maintenance needs. Social implications The development of high-performance, wear-resistant coatings such as laser-cladded Fe-based amorphous materials contributes to longer-lasting mechanical components, which can reduce industrial waste, lower energy consumption and support more sustainable manufacturing practices. By improving the efficiency of components in transportation and heavy machinery sectors, this research aligns with global efforts toward greener technologies and resource conservation. Originality/value This study provides novel comparative insights into the performance of laser-cladded Fe-based amorphous coatings under different lubrication regimes, showcasing their potential for industrial wear protection applications. Peer review The peer review history for this article is available at: Link to the cited website