Mitigation of abrasive wear damage of Ti–6Al–4V by laser surface alloying

• Intermetallic composite was formed on the surface of Ti–6Al–4V by laser alloying.
• The laser coatings consisted of hard titanium aluminides.
• The hardness and abrasive wear resistance of composite coatings improved.
• The material removal was dominated by abrasive and adhesive mechanisms.

Ti–6Al–4V alloy is lightweight, heat treatable and machinable with excellent strength characteristics. These properties favor its extensive applications in the automobile, aerospace and aeronautical industry. However, low hardenability, poor wear resistance and the tendency to gall and smear have reduced the use of Ti–6Al–4V. This study was designed to investigate the enhancement in the abrasive wear resistance of Ti–6Al–4V laser alloyed with three different premixed composition of Mo + Zr + Stellite 6 using a 4.4 kW continuous wave (CW) Rofin Sinar Nd:YAG laser processing system. Microstructural evolution in the samples was studied by optical and scanning electron microscopes. The phase evolution was studied by X-ray diffractometer. There exists metallurgical reaction and bonding between the Ti–6Al–4V substrate and the laser coatings. Scanning electron micrographs and X-ray diffraction spectra of the coatings revealed the formation of various titanium aluminides among other complex phases. The β-phase of Ti was retained owning to the presence of Mo – a β-phase stabilizer, in the powder mixture. Three-body abrasive wear resistance test indicates that the wear of the coatings was dominated by adhesive mechanism which is characterized by fine scratches. A twenty-four fold improvement in wear resistance was obtained in the coatings when compared with the native alloy.