A synergistic strategy combining ultrafast lasers and laser-cladded WC-Ni composite coating to form structurally stable textures for enhanced wear resistance

Surface texturing is a key method for reducing friction and enhancing wear resistance, and its performance largely depends on the quality and characteristics of the texture structure. This study proposes a synergistic strategy combining ultrafast lasers and laser cladding, using picosecond lasers to directly ablate the surface of the WC-Ni composite coating to prepare micro-pit textures of different diameters. The synergistic mechanism between the ultrafast laser and the WC-Ni composite coating was investigated, and the structural evolution resulting from changes in texture diameter along with its regulatory mechanism on wear behavior were systematically examined. The resulting textured coating exhibits a high-precision circular pit structure with minimal thermal damage and oxidation. Notably, ultrafast laser ablation does not disrupt the hard phase of the WC-Ni composite coating and induce phase transformations or structural defects. Further studies indicate that the presence of the hard phase within the texture and the reinforced coherent interfaces are key to ensuring structural stability. Compared to the original coating (D0), all textured coatings exhibited lower wear rates. This superior performance is attributed to the synergistic effects of wear debris capture and isolation, which suppress three-body wear, reduced strain concentration, and improved hydrodynamic lubrication. Among them, the 150μm-diameter textured coating (D150) demonstrates the most outstanding wear resistance, achieving a 69.88% reduction in wear rate. The D150 achieves an optimal balance between structural stability, debris control capability, and lubrication conditions. The synergistic effect between ultrafast laser-induced high-precision surface texturing and the wear resistance of laser-clad composite coatings offers a promising strategy for enhancing material performance under complex operating conditions. © 2026 Elsevier Ltd.