Laser surface alloying of aluminium with WC + Co + NiCr for improved wear resistance

In the present study, laser surface alloying of aluminium with WC + Co + NiCr (in the ratio of 70:15:15) has been conducted using a 5 kW continuous wave (CW) Nd:YAG laser (at a beam diameter of 0.003 m), with the output power ranging from 3 to 3.5 kW and scan speed from 0.012 m/s to 0.04 m/s by simultaneous feeding of precursor powder (at a flow rate of 1 × 10− 5 kg/s) and using He shroud at a gas flow rate of 3 × 10− 6 m3/s. The effect of laser power and scan speed on the characteristics (microstructures, phases and composition) and properties (wear and corrosion resistance) of the surface alloyed layer have been investigated in details. Laser surface alloying leads to development of fine grained aluminium with the dispersion of WC, W2C, Al4C3, Al9Co2, Al3Ni, Cr23C6, and Co6W6C. The microhardness of the alloyed zone is significantly improved to a maximum value of 650 VHN as compared to 22 VHN of the as-received aluminium substrate. The mechanism of microhardness enhancement has been established. The fretting wear behavior of the alloyed zone was evaluated against WC by Ball-on-disc wear testing unit and the mechanism of wear was established.

► Optimization of process parameters for the development of defect free microstructure.
► Detailed mechanism of microstructural evolution under laser processing conditions.
► To understand the role of process parameters on the distribution of carbides.
► Improved hardness of the alloyed zone (650 VHN) as compared to substrate (22 VHN).
► Improved wear resistance (4 times as compared to substrate) of the alloyed zone.