Laser cladding of Al‐Sn alloy on a mild steel

Direct laser cladding of Al alloy on mild steel produces continuous brittle intermetallic FexAly layers at the interface resulting in weak bonding of the clad and the substrate. To overcome this problem, both Ni and Al were investigated as intermediate coatings. Although a Ni coating with a thickness of 70 μm was successful in eliminating the formation of continuous Al‐Fe intermetallics, the bonding at the Al alloy/Ni interface was not strong enough to survive a bending test. A pure Al coating was found to be a better barrier layer. In both cases the optimization of processing parameters for Al alloy cladding was realized via microstructural screening and mechanical property testing including hardness, preliminary wearing and bending tests. Operating windows were established in terms of low dilution, freedom from cracks and porosity, coating-substrate bonding and chemical homogeneity. The results of a comparative study indicated that the laser clad layers showed superior wear resistance to the conventiona...