In the present experimental study, the application of microwave heating is used to develop the composite clads of Ni-based metallic powder (matrix) and Al2O3 powder (reinforcement) on the surface of AISI 304 stainless steel substrate. A domestic microwave oven working at 2.45 GHz frequency and 900 W was used to conduct the experimental trials. The Ni + 10% Al2O3 composite clads were characterized through X-ray diffractometer (XRD), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and microhardness tests. The pin-on-disk type tribometer was used for analyzing the sliding wear behavior of Ni + 10% Al2O3 clads. The microstructural results revealed the presence of randomly dispersed Al2O3 particles inside Ni matrix. The average microhardness (Vicker's) of composite clad was enhanced by 3.5 times that of the substrate. The clad exhibited 156 times more wear resistance than AISI 304 substrate. Craters and groove formation were responsible for wear loss in the clad material while plastic deformation caused the failure of AISI 304 substrate.

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