Microstructure and tribological properties of Y2O3-doped Fe-based alloy coatings by laser cladding

• Y2O3 doping up to 0.3 wt.% transforms the Fe45 coating microstructure from columnar to fine cellular/equiaxed grains, enhancing hardness by 14.06% and reducing wear volume by 51.16%. • Excessive Y2O3 (0.9 wt.%) leads to coarser feather-like structures, degrading hardness and wear resistance, yet still outperforming undoped coatings. • Rare-earth oxide modification offers a cost-effective alternative to process optimization for improving laser-clad Fe-based coatings. • The study provides quantitative evidence for optimal Y2O3 content, guiding industrial application for wear-resistant coatings on carbon steel components.