Titanium aluminide coating on titanium surface using three-dimensional microwelder

Feasibility of a new method of titanium aluminide coating on titanium surface based on a reaction between aluminum liquid beads and the surface of titanium substrate has been studied using a computer-aided three-dimensional microwelder (3DMW) designed by the present authors. A predetermined length of thin aluminum wire was fed onto the substrate surface, and a spark was stricken from a thin electrode of a W-Ce₂O₃ alloy to make a small aluminum liquid bead on the substrate surface and to simultaneously melt a small area of the substrate surface beneath the bead. All conditions including the length of the wire feeding, the position of the electrode, electric power, etc. had been programmed beforehand. The liquid bead containing aluminum and titanium rapidly solidified on the titanium substrate surface producing titanium aluminides on it. Repetition of the aluminum wire feeding, the electrode positioning and the spark striking produced a coating layer consisting of sub-layers of TiAl₃, TiAl and Ti₃Al from the surface side to the substrate side. Vickers hardness and wear resistance of the coated sample were remarkably improved.