Surface modification of low carbon steel substrate by Al-rich clad layer applied by GTAW

► Preheating at 500 ± 50 °C accompaniment with post weld heat treatment could significantly reduce crack susceptibility of overlayer. ► The microstructure of overlayer consists of Fe3Al and FeAl3 needle-like intermetallics in the FeAl matrix. ► Al-Fe clad increases the surface hardness and oxidation resistance of the cladded samples.