Laser-Surface-Remelted Powder Metallurgy TiAl Alloys: Microstructure and Mechanical Properties

Laser processing has been widely investigated as an effective approach for improving surface properties and consolidating advanced materials, particularly complex alloys such as titanium aluminides (TiAl). In this study, laser surface remelting was applied to binary (Ti-45Al) and ternary (Ti-45Al-2Co and Ti-45Al-2Ni) alloys produced by powder metallurgy via blended elemental (BE) and pre-alloyed (PA) powder routes. Laser powers of 50 and 100 W were employed, resulting in a high-energy-density surface remelting regime applied to both green compacts and sintered samples with relatively high initial porosity, under an argon-controlled atmosphere. Microstructural and phase analyses were performed using scanning electron microscopy (SEM) and X-ray diffraction (XRD), while mechanical behavior was assessed by instrumented microindentation. Laser processing promoted the formation of a dense and homogeneous surface layer, approximately 150 μm thick, accompanied by significant microstructural refinement and enhanced hardness and elastic modulus. While rapid solidification led to crack formation in laser-treated sintered samples, the green compacts exhibited defect-free modified layers. Overall, the results demonstrate that laser surface remelting is an effective strategy for enhancing the surface integrity and mechanical performance of TiAl alloys processed by powder metallurgy.