Effect of processing parameters on the cohesive strength of laser surface engineered ceramic coatings on aluminum alloys

The mechanical performance of laser surface engineered ceramic composite (TiC/Al) coating on 2024 and 6061 Al alloy substrates has been evaluated using four-point bend test. The performance of the coating is expressed in terms of the cohesive strength of the coating. Load-displacement measurements carried out during the bend test helps to determine the load corresponding to crack initiation. This load required to initiate fracture in the coating provides a measure of the strength of the coating. A simplistic approach based on elementary beam theory and strength of material in conjunction with rule of mixture was adopted to calculate the cohesive strength of the composite coating. This approach is also further extended for attempts to evaluate apparent residual stress within the coating. Since process parameters exert a significant influence in controlling the end properties of the component, the effect of laser power and laser scan speed on the cohesive strength has also been investigated. It is observed that coatings with lower scan speeds have much higher cohesive strengths and they also seem to have good metallurgical bond with the substrate thus showing better mechanical behavior than the other high scan speeds used in this present study. The apparent residual stress in the coating appears to transform from compressive to tensile in nature with increasing laser scan speed eventually contributing to delamination of the coating. (Author)