A three-dimensional finite element model taking into account interfacial topography, porosity of plasma sprayed coatings, temperature dependent thermophysical parameters and phase change has been developed to simulate multipass laser remelting process. Temperature evolution, temperature gradient, melting pool shape and dimensions are simulated. The laser remelting experiments are carried out on the plasma sprayed WC–12Co coatings. The simulated results are in good agreement with the experimental measurements. After laser remelting, a denser and more homogenous coating is obtained. The microhardness of the coating is significantly enhanced owing to the dispersion strengthening, the fine grain strengthening and the solution strengthening, which is increased by three times compared with that of the plasma sprayed coatings.
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