Laser surface modification using Inconel 617 machining swarf as coating material

► Inconel 617 machining swarf was laser clad onto mild steel. ► Low cost clad material produced consistent corrosion resistant layers. ► The microstructure of layers was columnar-dendritic with patches of cellular arrays. ► Significant gradients in elemental composition were found in the clad. ► Higher specific energy produced large dendrite arm spacing and low corrosion rate.