Aprameya, C.R.Joladarashi, S.Ramesh, M.R.2026-02-032025Surface and Coatings Technology, 2025, 513, , pp. -2578972https://doi.org/10.1016/j.surfcoat.2025.132457https://idr.nitk.ac.in/handle/123456789/20049Severe wear often limits the high-temperature durability of SS304 components, necessitating the development of surface-engineered solutions. In this investigation, Mo-reinforced Stellite 6 claddings were developed using Laser Directed Energy Deposition (L-DED) to provide enhanced surface protection. Claddings with (3, 6, and 9 wt%) Mo reinforcement enhanced hardness by 2.9, 3.1, and 3.3 times, respectively, compared to the SS304 substrate. This improvement is attributed to Mo-induced solid solution strengthening and the formation of hard intermetallic phases. Dry sliding wear tests were conducted at RT and 600 °C under (10 and 20 N) loads. Wear characterisation of the clads was performed using OM, XRD, FE-SEM, EDX, and Raman spectroscopy. At RT, claddings primarily exhibited abrasive wear with minor plastic deformation. However, at 600 °C, the wear mechanism evolved into a combination of severe adhesive, oxidative, abrasive, and plastic deformation modes, with oxidative wear governing the tribological behavior. Stellite 6 with 9 wt% Mo clads exhibited better tribological performance than the other two variants, owing to the development of oxide glaze layers of Cr<inf>2</inf>O<inf>3</inf>, NiO, CoO<inf>2</inf>, and Co<inf>3</inf>O<inf>4</inf>. Enhanced performance of the claddings is attributed to solid solution strengthening, Cr-rich carbide formation, increased dislocation density, and the L-DED technology enabling refined microstructure and strong metallurgical bonding. These findings highlight the potential for further advancements in Mo-reinforced Stellite 6 L-DED claddings for high-temperature wear applications. © 2025 Elsevier B.V.AbrasionAbrasivesAdhesivesChromium compoundsCladding (coating)Cobalt compoundsHigh temperature applicationsMolybdenum alloysMolybdenum oxidePlastic deformationReinforcementSolid solutionsStelliteStrengthening (metal)Surface resistanceTribologyWear resistanceDirected energyEnergy depositionsHigh temperature wear resistanceMo reinforced laser directed energy deposition cladsOxide phasisSliding wearSolid solution strengtheningSs304Stellite 6Surface enhancementCarbides