Processing,microstructure, and properties of laser-clad Ni alloy FP-5 on Al alloy AA333

This article describes the results of laser cladding Ni alloy FP-5 on Al alloy AA333, microstructure and crystal structure characterization, and properties of the clad evaluated by Vickers hardness measurement and wear testing. Direct cladding of Ni alloy on Al alloy creates brittle Ni _x Al _y compounds in the interface, which make the interface very brittle, and result in cracking at the interface. The compound formation is avoided by introducing an intermediate layer of Cu or bronze. The cracking tendency of the clad is prevented by preheating the substrate to 673 K. The microstructure and crystal structure of the clad and interface are investigated by scanning electron microscopy (SEM) and transmission electron microscopy (TEM). Five phases in the clad layer (including three new phases) and two phases in the interface are identified by convergent beam electron diffraction (CBED) and selected area diffraction (SAD) studies. The mechanical properties of the laser-clad Ni alloy are evaluated by Vickers hardness measurements and wear testing, which show superior results over Cu- and Fe-based alloys.