Formation of thick hardened layers of an order of millimeter by the laser surface alloying process has been investigated to improve the wear resistance of commercial Al–Mg alloy, 5083 plate. Laser surface alloying was carried out by melting the precoated plasma-sprayed layer with Al coated Ni powders (80 and 95 mass% Ni) together with the substrate plate by using the continuous wave CO
2 laser irradiation. The thickness of the laser alloyed layer was about 1 to 4 mm depending on the plate traveling speed at constant laser power 2100 W. The microstructures of the laser alloyed layer consisted of α(Al)+Al
3Ni lameller eutectic, the needle like primary Al
3Ni, the dendritic Al
3Ni
2 surrounding by Al
3Ni and the lump like AINi surrounding by Al
3Ni
2, and volume fraction of the compound with higher Ni content increased with increasing Ni content in laser alloyed layer. The relation between the microstructures and Ni content of the laser alloyed layer corresponded with the Al–Ni phase diagram. The hardness of laser alloyed layer increased with the increase in Ni content and reached about 700 HV in maximum. The wear resistance of the laser alloyed layer increased with the increase in hardness up to about 250 HV and showed almost saturated value even at higher hardness. Moreover, the wear resistance of the laser alloyed layer was much higher than that of the plasma-sprayed layer and was same as that of carbon steel, S50C.
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