The in-flight temperature variation and dissolution of WC powder particles producing an Fe-Cr-W-C system by direct laser deposition

► A mathematical description of the temperature rise of powder particles is investigated. ► Calculated temperature rise plots are correlated with experimental results. ► In-situ reactions from carbide and alloy precursors to form new surface alloys are viable. ► Highly undercooled microstructures require further heat treatment for stabilisation.