Process optimization of Ti–Nb alloy coatings on a Ti–6Al–4V plate using a fiber laser and blended elemental powders

A fiber laser was used to modify the surface composition of a Ti–6Al–4V plate through deposition of the blown powder mixture of Ti–45 wt.%Nb. Scanning electron microscopy and energy dispersive spectroscopy (EDS) were employed to examine the clad sections microstructure and chemical composition. The optimized set of laser processing parameters, including the laser power of 1100 W, the laser scan speed of 350 mm/min (or ∼5.83 mm/s), the laser spot diameter of 2 mm and the powder feed rate of 0.1 g/s was found with the identification of combined parameters, the laser specific energy, the powder density and the newly defined laser supplied energy (i.e. representing the amount of energy given to the unit mass of the blown powder). It is shown that, with these parameters, continuous beads can be formed with pore-free sections and a homogeneous composition corresponding to that of β (Ti, Nb) solid solution phase. Furthermore, Al and V elements are thoroughly replaced with a more biocompatible element, Nb, in the second layer of a Ti–Nb cladding build-up on the surface of the Ti–6Al–4V plate (i.e. after ∼1 mm in clad thickness from the clad/substrate interface).