Controlling microstructure of FeCrMoBC amorphous metal matrix composites via laser directed energy deposition

Abstract Fe-based amorphous coatings are typically known for their high hardness and wear resistance and are often applied using thermal spraying techniques. When cladding these materials, using laser directed energy deposition (DED), it becomes possible to vary the cooling rate to create unique microstructures. Herein, it is demonstrated that a common FeCrMoBC coating alloy, typically known for its high hardness, can be fabricated into a variety of microstructures using DED, including an amorphous metal matrix composite with a soft dendritic phase and intrinsic toughening mechanism. The work offers the promise of using DED to fabricate custom claddings with high toughness as well as providing a potential route for creating ductile-phase-reinforced metallic glass composites using additive manufacturing.