Laser re-melting of HVOF coating with WC blend: Thermal stress analysis

► Laser treated coating surface is free from asperities such as voids, cracks, and cavities. ► Cellular structures are observed in different sizes and orientations due to non-uniform cooling. ► Laser treatment enhances residual stress levels in coating as compared to as-sprayed coating. ► Microhardness of the laser treated coating increases significantly in the surface region.