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Abstract <p>Alloying or cladding ferrous alloys on an Al substrate, or <i>vice versa</i>, is difficult due to the tendency to form brittle aluminides. In this study, we demonstrate that Fe-based Rockit<sup>®</sup>401 alloy can be deposited layer by layer on an Al 1100 substrate using laser surface cladding to obtain uniform and homogeneous clads without cracking or delamination. X-ray diffraction confirms that clad layers consist of Fe-rich <i>α</i>, Cr-rich <i>α</i>′, and prior-austenitic phases to a varying degree, without having large-scale formation of those brittle Fe-Al phases/compounds. Microstructural studies inside the clad and across the clad–substrate interface reveal directionally solidified dendrites and a multi-phase aggregate in between. The Cr-rich <i>α</i>′ in the inter-dendritic regions records higher hardness (<i>H</i>). 3-layer clads exhibit the highest <i>H</i> and elastic modulus (<i>E</i>) values. Microhardness of clad samples (426–485 HV<sub>0.1</sub>) is significantly higher than that of base Al 1100 (26.5 HV<sub>0.1</sub>). The <i>H</i>/<i>E</i><sub>r</sub> and <i>H</i><sup>3</sup>/<i>E</i><sup>2</sup> values of the 3-layer clads are 5.5–8.5 and 436–1628 times higher than those of the Al 1100 substrate, respectively. Wear volume loss and specific wear rate for the topmost clads are remarkably reduced (around 1/10th) than that of Al 1100. Three-point bending tests of clad layers reveal better flexural extension and strength with only vertical but no horizontal cracks.</p> Graphical Abstract <p></p>

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Structure–Property Correlation in Multi-layer Laser Surface Cladding of Ferrous Alloy on Al 1100 for Enhanced Surface Mechanical Properties

  • 期刊论文

  • 发表日期：

    2026年3月26日

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  • Bidipta Dam,
  • Jyotsna Dutta Majumdar,
  • Indranil Manna

摘要

Abstract

Alloying or cladding ferrous alloys on an Al substrate, or vice versa, is difficult due to the tendency to form brittle aluminides. In this study, we demonstrate that Fe-based Rockit®401 alloy can be deposited layer by layer on an Al 1100 substrate using laser surface cladding to obtain uniform and homogeneous clads without cracking or delamination. X-ray diffraction confirms that clad layers consist of Fe-rich α, Cr-rich α′, and prior-austenitic phases to a varying degree, without having large-scale formation of those brittle Fe-Al phases/compounds. Microstructural studies inside the clad and across the clad–substrate interface reveal directionally solidified dendrites and a multi-phase aggregate in between. The Cr-rich α′ in the inter-dendritic regions records higher hardness (H). 3-layer clads exhibit the highest H and elastic modulus (E) values. Microhardness of clad samples (426–485 HV0.1) is significantly higher than that of base Al 1100 (26.5 HV0.1). The H/Er and H3/E2 values of the 3-layer clads are 5.5–8.5 and 436–1628 times higher than those of the Al 1100 substrate, respectively. Wear volume loss and specific wear rate for the topmost clads are remarkably reduced (around 1/10th) than that of Al 1100. Three-point bending tests of clad layers reveal better flexural extension and strength with only vertical but no horizontal cracks.

Graphical Abstract