Purpose: To improve the wear resistance of Al-Cu sintered parts by the use of a coating layer of hypereutectic Al-Si alloy deposited by laser cladding. Design/methodology/approach: Coaxial laser cladding was used to deposit a coating layer of hypereutectic Al-Si alloy on sintered Al-Cu alloy to improve its wear resistance. The laser cladding parameters were varied; firstly obtaining single laser cladding tracks and finally obtaining a larger area of coating by overlapping tracks. Findings: The Al-Si coating layer presented good metallurgical bonding with the sintered Al alloy and was composed mostly of eutectic Al-Si in the upper zone and alpha Al dendrites plus eutectic Al-Si in the lower zone. Laser also generates a melted layer in the base-sintered material, mainly composed of a columnar dendritic structure with copper segregated in the interdendritic region, which assured a gradual transition to the clad structure. Pin-on-disc tests showed that the wear resistance of the part was improved with the Al-Si coating. Practical implications: The wear resistance of sintered Al-Cu alloy was improved more than 70% using a coating layer of hypereutectic Al-Si alloy deposited by laser cladding. Originality/value: Single tracks and a continuous layer of Al-Si were successfully deposited by laser cladding on Al-Cu sintered parts. Pin-on-disk comparative tests showed an increase of more than 70% in wear resistance due to the Al-Si coating.
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