Inconel 625 coatings were synthesised on AISI 4130 steel substrates by tungsten inert gas welding. Optimisation of process parameters was conducted through a combination of numerical simulations and technological experiments. The welding speed has a significant effect on the width and height of the cladding layer and the welding current mainly affected the penetration. A proper decrease of welding speed with raising heat input was conductive to the decrease of coating residual stress levels and dilution rates, which promoted the solid solution of corrosion resistant elements (Mo and Nb) and favoured the improvement of coating corrosion resistance. The cladding quality and efficiency could be improved by parameter optimisations through the combination of numerical and technological methods.
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