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Abstract
Ni–20Cr alloy was deposited on stainless steel using air plasma spray. Inherent defects in coating like porosity, oxides and splat boundaries are considered as potential sources for oxygen ingress during high-temperature application. In order to minimize such flaws, the plasma-sprayed coating was remelted and solidified, using continuous wave CO2 laser. Microstructural optimization was achieved by optimizing process parameters such as laser power and defocus distance. The laser-treated surfaces were characterized using optical and scanning electron microscopy as well as by XRD. At 500 W power, a 60 mm defocus distance was found to be optimum to avoid outward diffusion of iron. However, stresses were observed to be present in the plasma-sprayed coating before and after laser remelting and solidification, as determined by XRD of the treated samples.
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