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A functionally gradient TiC/Ni alloy composite coating was produced by one step laser cladding with pre-placed mixture powder on 1045 steel substrate. The clad layer consists of TiC particles, γ-Ni primary dendrites and interdendritic eutectics. From the bottom to the top of the clad layer, TiC particles exhibit a continuous increase both in size (from 0.8 μm to 4.5 μm) and in volume fraction (from 4% to 33%), and their morphology changes correspondingly from small globe to coarse flower-like cluster. The rapid coarsening of TiC clusters during the solidification of laser pool results from the collision and sintering of particles. The preferential engulfing to a small cluster moving at slower speed by liquid/solid front leads to in-situ formation of the gradient structure of the coating.
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