Laser surface remelting of plasma sprayed nanostructured Al2O3–13wt%TiO2 coatings on titanium alloy

Plasma sprayed nanostructured coatings were successfully fabricated on a titanium alloy (Ti–6Al–4V) substrate using the as-prepared nanostructured Al2O3–13wt%TiO2 feedstock. A CO2 laser was used to remelt the plasma sprayed coatings. The effects of laser remelting on the phase constituents, microstructure and properties of the ceramic coatings were investigated. The laser remelted coatings (LRmC) possessed a much denser and more homogenous structure and excellent metallurgical bonding to the substrate. The average porosity of the LRmC was reduced to 0.9%, compared with 6.2% of the as-sprayed coatings. The net-like structure in the as-prepared feedstock remained in the coatings before and after laser remelting. The metastable γ-Al2O3 phase in the as-sprayed coatings transformed to stable α-Al2O3 during laser remelting. The LRmC could remain nanostructure. The microhardness of the coatings was enhanced to 1000–1400 HV0.3 after laser remelting, which was much higher than that of the plasma sprayed coatings and 2–3 times higher that of the substrate. Significant decreases in surface roughness were also found in the LRmC.