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The ZrO2 particle reinforced Fe60 alloy coatings were deposited on the surface of steel by laser using Fe60 self-fluxing spherical alloy powder adding mass fraction of 0.1%, 0.3%, 0.5%, 0.7%, 0.9% content ZrO2 powder. The structure and hardness of the samples were analyzed by the means of OM、SEM、XRD、micro-hardness tester. Experimental results show that: ZrO2 powder in Fe60 alloy powder can alleviate the generation of cracks effectively in the process of laser direct deposition, Fe60 alloy coating with high Cr content was prepared successfully on the steel substrate, and the coating formed good metallurgical bonding with the Q235 steel, and the thickness of the coating is up to 6mm. The phases of the deposited coating composed of Cr7C3, αFe, {Fe, Cr} solid solution, ZrO2, and Fe3C. ZrO2 particle play an important role in phase transformation toughening and dispersion toughening, the cracks in the sample has been eliminated due to addition of ZrO2 ceramic powder. The coating with 0.5% ZrO2 particle had fine crystal structure without cracks, and the hardness is up to 817HV. Therefore, the adding ZrO2 ceramic particles to Fe60 alloy powder is an effective way to eliminate cracks and improve the hardness in the laser direct deposition Fe60 alloy coating with high wear-resistant..

Laser direct deposition ZrO2 particle reinforced Fe60 alloy coating